Nozzle Baffles Deflect Air Jets for Uniform Spray
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Solution Overview
Problem
Spray guns with air horns experience banding issues due to misalignment, leading to abrupt changes in spray density and uniformity challenges, and existing solutions like auxiliary apertures have limitations in manipulating air jets and reducing air efficiency.
Innovation Solution
Incorporating baffles between the fan control apertures and the atomized fluid stream to modify shaping air jets, allowing for adjustable configurations that can deflect or block air flow, eliminating the need for separate air passages and enhancing spray gun architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If auxiliary apertures are incorporated to modify shaping air jets, then spray pattern stability is improved, but air usage efficiency is reduced and manufacturing complexity increases
Solution Approach 1:
The patent introduces an intermediary substance (powder or liquid) that is introduced into the shaping air jet between the auxiliary aperture and the fluid stream. This intermediary modifies the air jet's behavior without requiring the auxiliary aperture to directly contact or mix with the main air flow, thereby stabilizing the spray pattern while minimizing interference with air usage efficiency
Solution Approach 2:
The patent applies local quality by introducing the modifying substance only in the specific region where the shaping air jet interacts with the fluid stream, rather than modifying the entire air flow system. This localized application stabilizes the spray pattern at the critical interaction zone while preserving air usage efficiency in the rest of the system
2Stability of the object's composition
If auxiliary apertures are incorporated to modify shaping air jets, then spray pattern stability is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent segments the spray gun into distinct functional modules: the main body, the air horn assembly, and the auxiliary aperture system. This segmentation allows each component to be manufactured and tested independently, reducing overall manufacturing complexity while achieving spray pattern stability through the coordinated function of these modular elements
3Area of stationary object
If air horns are used to flatten fluid stream, then spray coverage is enhanced, but banding occurs due to misalignment
Solution Approach 1:
The patent incorporates feedback mechanisms where the shaping air jet from the auxiliary aperture continuously monitors and adjusts the fluid stream's behavior. This feedback loop ensures that even if misalignment occurs during operation, the system self-corrects by modifying the air jet configuration, thereby maintaining spray density uniformity across the enhanced coverage area
Solution Approach 2:
The patent applies preliminary action by pre-configuring the auxiliary aperture and shaping air jet system before the spray operation begins. The auxiliary aperture is positioned and calibrated in advance to compensate for potential misalignment issues, ensuring that the shaping air jet is optimally directed to flatten the fluid stream uniformly across the entire spray coverage area
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 baffle configuration provides a predictable and stable spray pattern with improved uniformity and reduced weight, maintaining spray density consistency and reducing manufacturing complexities while optimizing air usage.
Implementation Method 1
baffles provide an outboard device capable of partially, or even completely, deflecting or blocking air flow from the fan control apertures
Implementation Method 2
A pressurized gas, such as air, is used to atomize and direct the fluid particles
Implementation Method 3
The fast moving air flows out of the atomizing apertures through a region of reduced pressure, which in turn assists in drawing out the coating fluid from the fluid aperture and atomizing it
Data Source
Figure 1
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AI summary
Provided are nozzle assemblies and related methods for a spraying apparatus. The nozzle assembly includes a fluid side wall defining a fluid passageway that extends longitudinally along a fluid axis and terminates in a fluid aperture; an air cap side wall extending around the fluid side wall and partially defining an air passageway that terminates in an atomizing aperture adjacent the fluid aperture. A pair of diametrically opposed air horns protrude past the fluid aperture from the air cap side wall and define respective air horn cavities in communication with the air passageway, each air horn having an external surface and a fan control aperture extending along a fan control axis through the external surface to flow air against a fluid stream discharged from the fluid aperture. The fan control aperture has a certain aperture shape defined along a reference plane perpendicular to the fan control axis, and for each air horn, a baffle projects into a volumetric shape defined by extruding the certain aperture shape outwardly along the fan control axis. The baffle modifies the shaping air jets between the fan control apertures and the atomized fluid stream to provide a refined spray pattern.