Internal Mixing Spray Gun Counter-Flow Impingement
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Solution Overview
Problem
Existing systems fail to adequately mix materials with significantly different viscosities and flow rates, leading to reduced quality of final products, such as fiberglass reinforced plastic (FRP) parts, due to inadequate mixing of resins and catalysts.
Innovation Solution
A spray gun design with a first liquid passage flowing downstream and a second liquid passage flowing upstream, impinging on the first liquid, combined with multiple mixing baffles featuring converging passages, creates a turbulent flow to effectively mix materials with varying viscosities and flow rates within a compact space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing systems are used, then device complexity is reduced, but mixing effectiveness deteriorates when materials have significantly different viscosities and flow rates
Solution Approach 1:
The mixing system is segmented into multiple liquid passages (first liquid passage for resin, second liquid passage for catalyst) with separate flow paths that converge at the spray tip. This segmentation allows independent control of materials with different viscosities while ensuring thorough mixing at the point of application, resolving the contradiction between mixing effectiveness and device complexity.
Solution Approach 2:
The patent implements local quality by creating a specialized mixing zone at the spray tip where counter-flowing liquids interact. The second liquid passage is positioned to impinge upon the first liquid at the outlet, creating a localized turbulent mixing region that effectively combines materials with different properties without requiring complex mixing mechanisms throughout the entire device.
2Manufacturing precision
If mixing length is increased, then mixing effectiveness improves, but device length increases
Solution Approach 1:
The patent employs periodic action through the counter-flow impingement mechanism where liquids alternately dominate the flow dynamics as they exit their respective passages. This periodic interaction creates intense turbulent mixing in a compact space, achieving effective mixing without requiring a long mixing channel, thus resolving the contradiction between mixing effectiveness and device length.
Solution Approach 2:
The invention utilizes hydraulic principles by designing the second liquid passage to flow upstream and impinge upon the first liquid at the outlet. This hydraulic counter-flow arrangement creates a compact mixing zone where pressure-driven flow patterns generate turbulent mixing, achieving effective mixing in a short device length without requiring mechanical mixing components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures a homogeneous mixture of materials with significant differences in viscosity and flow rate, reducing waste and increasing the strength and quality of FRP parts by enhancing mixing efficiency within a shorter device length.
Implementation Method 1
creates a turbulent flow to effectively mix materials with varying viscosities and flow rates
Data Source
AI summary
A system, in certain embodiments, includes a spray device including a first liquid passage configured to flow a first liquid in a generally downstream direction toward a spray tip. The spray device also includes a second liquid passage configured to flow a second liquid in a generally upstream direction such that the second liquid impinges upon the first liquid at an outlet to the second liquid passage. The upstream direction is substantially opposite from the downstream direction.