Low Pressure Two-Component Handheld Spray Gun
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Solution Overview
Problem
Existing spray systems for two-component adhesives face issues with overspray, uneven distribution, component mixing, equipment complexity, and safety concerns, particularly in handheld applications, due to high pressures and inadequate control over the spray pattern.
Innovation Solution
A low-pressure 2-K handheld spray gun design where the first fluid is airless and the second fluid is sprayed using reduced air pressure, with separate fluid passage ways and a mechanism for simultaneous control, along with a third fluid passage for air, and a removable nozzle tip to optimize mixing and pattern control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If airless spray equipment is used to spray adhesive at high pressure, then the adhesive can be forced through a small orifice and applied to the surface, but the operating pressure becomes too high (up to 50,000 kPa) causing safety concerns and equipment complexity
Solution Approach 1:
The adhesive stream is segmented into two separate fluid streams (first fluid and second fluid) that are sprayed through separate fluid passages. This segmentation allows each stream to be controlled at lower pressures individually, avoiding the need for extremely high pressures while still achieving effective adhesive application through the combined streams.
Solution Approach 2:
A mixing chamber acts as an intermediary where the two fluid streams combine after being sprayed separately. This intermediary structure allows the adhesive components to mix in a controlled environment at lower pressures, eliminating the safety risks associated with forcing a single stream through a small orifice at extremely high pressures.
2Object-affected harmful factors
If air-spray equipment is used to spray adhesive, then the adhesive can be sprayed at lower pressure (up to 1,600 kPa), but the adhesive is not homogeneously distributed over the surface with much more adhesive at the center compared to edges
Solution Approach 1:
The adhesive application is segmented into two separate fluid streams that are sprayed simultaneously from different angles. This segmentation allows the adhesive to be deposited more evenly across the surface, preventing the concentration of adhesive at the center that occurs with conventional air-spray methods.
Solution Approach 2:
Different regions of the spray pattern are targeted with different fluid streams. The first fluid stream targets one area while the second fluid stream targets another area, ensuring that adhesive is distributed more uniformly across the entire surface including edges, rather than concentrating at the center.
3Ease of operation
If handheld spray gun is used for adhesive application, then the equipment is portable and easy to operate, but the amount of overspray increases to more than 30-40% of the total amount applied
Solution Approach 1:
The adhesive is divided into two separate fluid streams that are sprayed simultaneously from the handheld gun. This segmentation allows for better control of the spray pattern and reduces overspray by ensuring that adhesive is deposited more precisely on the target surface rather than dispersing widely into the air.
Solution Approach 2:
The two-component adhesive system ensures continuous and complete deposition of adhesive material on the target surface. By spraying two streams simultaneously that mix upon contact with the surface, the system minimizes airborne adhesive particles and ensures that nearly all adhesive material applied is useful, reducing waste to less than 10%.
4Quantity of substance
If two-component adhesive is sprayed, then complete adhesive coverage can be achieved, but good mixing of the two components becomes difficult to secure, especially when one component is provided in relatively large amount and the other in relatively small amount
Solution Approach 1:
The two-component adhesive system segments the adhesive into two separate fluid streams that are sprayed through separate fluid passages. This segmentation allows each component to be delivered in the correct proportion and mixed upon contact with the target surface, ensuring both complete coverage and proper mixing ratio.
Solution Approach 2:
The target surface acts as an intermediary where the two fluid streams combine and mix. This intermediary approach ensures that the components mix in the correct ratio upon contact with the surface, maintaining stable composition while achieving complete adhesive coverage.
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
The solution significantly reduces overspray, improves mixing and homogeneity, and simplifies equipment handling, achieving over 90% efficient adhesive application with minimal airborne particles and reduced material waste.
Implementation Method 1
The first fluid and second fluid are provided through separate fluid passage ways and mixed when airborne
Implementation Method 2
Airless spraying involves using pressure to force a fluid to be sprayed through a small orifice
Data Source
Figure 1
Figure 2a~2c
AI summary
The present invention is in the field of low pressure limited overspray handheld aerosol spray gun for spraying a two-component adhesive, a method for spraying a two-component adhesive and a two-component adhesive obtainable by said method. In manufacturing of larger objects, such as matrasses and furniture, adhesives are often applied to fix parts of the large object together. Most adhesives are applied using either air-spray equipment or air-assisted spray equipment.