Interchangeable Nozzle Modules for Consistent Spray Jet Dimensions
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Solution Overview
Problem
State-of-the-art spray guns experience changes in spray jet size with increasing material throughput, leading to inconsistent layer thickness and requiring users to adjust their working methods with each nozzle change.
Innovation Solution
A nozzle set with interchangeable nozzle modules, each designed to have a different material throughput while maintaining the same spray jet cross-sectional height and width, allowing for consistent spray patterns across varying nozzle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the material throughput is increased by using a larger nozzle size, then the material throughput is improved, but the spray jet cross-sectional dimensions change leading to inconsistent layer thickness
Solution Approach 1:
The patent applies parameter changes by systematically varying the nozzle internal geometry parameters (conical section length, cylindrical section length, outlet diameter ratios) while maintaining the outlet diameter constant. This allows different nozzle designs to produce the same spray jet cross-section despite different material throughput capacities, resolving the contradiction between productivity and manufacturing precision
Solution Approach 2:
The nozzle is segmented into distinct functional sections (conical section and cylindrical section) with independently optimized lengths and diameter ratios. This segmentation allows precise control over flow characteristics and spray jet formation, enabling consistent spray patterns across different material throughput configurations
2Productivity
If the nozzle size is changed to achieve different material throughput, then the material throughput is improved, but the spray jet cross-section changes requiring users to adjust working methods
Solution Approach 1:
The patent creates a universal nozzle system where multiple nozzles with different material throughput capacities all produce the same spray jet cross-sectional dimensions. This universality allows users to change nozzles for different productivity requirements without changing their working methods, distance from substrate, or spray technique
Solution Approach 2:
By changing internal nozzle parameters (section lengths, diameter ratios) while keeping outlet diameter constant, the patent enables different nozzles to be functionally equivalent in terms of spray jet dimensions, making the system adaptable to different throughput needs without affecting operation consistency
3Productivity
If the nozzle internal geometry is optimized for higher material throughput, then the productivity is improved, but the spray jet cross-sectional height and width become inconsistent
Solution Approach 1:
The patent systematically changes internal geometry parameters (conical section length L1, cylindrical section length L2, diameter ratios d1/d2 and d2/d3) to decouple material throughput from spray jet cross-sectional dimensions. This allows throughput optimization without compromising spray jet shape consistency
Solution Approach 2:
Different sections of the nozzle internal geometry are optimized for different functions: the conical section for flow acceleration and the cylindrical section for flow stabilization. This local optimization ensures that each section contributes to maintaining consistent spray jet cross-section while enabling varied throughput capacities
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
Enables users to maintain consistent spray jet dimensions and layer thickness without altering their working methods, even when switching between different nozzle modules, thereby improving efficiency and reducing the complexity of nozzle changes.
Implementation Method 1
The atomizing air emerges from this annular gap. In the nozzle arrangement described above, this creates a vacuum on the front face of the material nozzle, whereby the material to be sprayed is sucked out of the material nozzle.
Implementation Method 2
creates a vacuum on the front face of the material nozzle, whereby the material to be sprayed is sucked out of the material nozzle
Implementation Method 3
Due to their hydrodynamic instability, the interaction between the fast-flowing compressed air and the ambient air, and aerodynamic disturbances, these threads and ribbons break up into droplets
Implementation Method 4
Due to their hydrodynamic instability, the interaction between the fast-flowing compressed air and the ambient air, and aerodynamic disturbances, these threads and ribbons break up into droplets
Implementation Method 5
This compresses the paint jet, or spray jet, with its originally circular cross-section (round jet), on the sides facing the horns and extends it in a perpendicular direction
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a set of nozzles for a spray gun (1), especially for a compressed-air paint spray gun, comprising at least one nozzle module group (10, 20, 30, 40) with at least two, preferably at least four different nozzle modules (15) for the optional mounting in or on one and the same base module (11) of a spray gun (1). The nozzle modules (15) are designed such that they have different medium flow rates under the same spray conditions, the spray jets which can be generated by means of the nozzle modules (15) having substantially the same spray jet section height (h) and the same spray jet section width (b), the spray jet sections of the different nozzle modules (15) in particular being congruent. The invention further relates to a spray gun system, a method for embodying a nozzle module, a method for selecting a nozzle module from a set of nozzles for a paint job, a selection system, in particular a "slide gate system", and a computer program product. The present invention enables the user to select the nozzle module which is ideal for the paint job and mode of operation in question.