Nozzle Body Angular Gas Flow for Liquid Spray Guns
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Solution Overview
Problem
Existing liquid spray guns face challenges in achieving efficient paint application and finish quality when using lower gas pressures, particularly with water-based paints of higher viscosity, as they result in reduced paint flow rates and increased noise levels, leading to higher operational costs.
Innovation Solution
A nozzle body design that directs pressurized atomizing gas angularly away from the spray axis, creating a larger volume of reduced pressure to enhance liquid flow rate and atomization efficiency while reducing gas consumption and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If lower gas pressures are used to save energy and reduce noise, then energy consumption and noise levels decrease, but liquid flow rate and atomization quality deteriorate
Solution Approach 1:
The patent changes the geometric parameters of the nozzle tube outlet, specifically creating a ramped axial section with a defined ramp angle (α) between 0.5° and 45°. This geometric parameter change modifies the flow dynamics of atomizing gas, enabling it to draw out liquid more effectively at lower gas pressures, thus resolving the contradiction between energy saving and maintaining liquid flow rate
Solution Approach 2:
The patent introduces a new dimensional aspect by adding the ramp angle (α) dimension to the traditional nozzle geometry. This additional angular dimension allows the atomizing gas to interact with the liquid in a new way, creating a low-pressure zone that enhances liquid draw-out without requiring higher gas pressure, thereby maintaining productivity while reducing energy consumption
2Manufacturing precision
If higher gas pressures are used to improve atomization quality, then atomization quality improves, but noise levels and gas consumption increase
Solution Approach 1:
The patent modifies the geometric parameters of the nozzle tube outlet with a specific ramp angle configuration that optimizes atomization quality at lower gas pressures. This parameter change allows achieving fine atomization without the need for high gas pressure, thereby reducing noise levels while maintaining manufacturing precision
Solution Approach 2:
The patent replaces the traditional mechanical approach of using high gas pressure to achieve atomization with a geometrically-engineered low-pressure zone creation mechanism. The ramped outlet geometry substitutes the need for high-pressure mechanical force with a pressure-differential mechanism, reducing noise while maintaining atomization quality
3Productivity
If higher gas pressures are used to increase liquid flow rate, then liquid flow rate increases, but transfer efficiency decreases
Solution Approach 1:
The patent changes the geometric parameters of the nozzle tube outlet to create an optimized flow pattern that improves transfer efficiency. The ramp angle (α) configuration ensures that liquid is drawn out more effectively by the atomizing gas, reducing overspray and improving transfer efficiency while maintaining liquid flow rate at lower gas pressures
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 design increases liquid flow rate and transfer efficiency, reduces noise exposure, and lowers operational costs by effectively utilizing lower gas pressures without compromising paint application speed or quality.
Implementation Method 1
the pressure at the nozzle tube outlet is lower than it is in traditional geometries in which atomizing gas flows in directions along the spray axis or towards the spray axis. The lower pressure at the nozzle tube draws more liquid from the nozzle passage
Data Source
Figure 1
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AI summary
Nozzle body (1) for a liquid spray gun comprising a tubular nozzle tube (66), comprising a) a nozzle tube passage (58), extending between a nozzle tube inlet and a nozzle tube outlet (52), through which the liquid exits the nozzle tube passage (58), and b) a nozzle tube wall (71) having a radially outer surface (75). The outer surface (75) of the nozzle tube wall (71) is operable to form, in conjunction with a surface of an air cap, an atomizing gas outlet arranged circumferentially around the nozzle tube outlet (52), such that the pressurized atomizing gas (110) exits into outside air (93) through the atomizing gas outlet and atomizes the liquid. The outer surface (75) of the nozzle tube wall (71) is oriented or shaped to direct at least a portion of the pressurized atomizing gas (110) exiting the atomizing gas outlet angularly away from the spray axis (200).