Off-Axis Roller Enameling Equipment for Uniform Coating
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Solution Overview
Problem
Existing enameling methods in the ceramic industry face issues such as non-uniform application, material waste, and orifice blockage, leading to aesthetic defects and inefficiencies in enamel distribution.
Innovation Solution
A piece of equipment with a hollow container and a misaligned roller featuring protrusions that open and close orifices to control enamel distribution, allowing for uniform application and preventing blockages, while eliminating the need for suction systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bell device is used to apply enamel, then continuous film coverage is achieved, but material waste increases and uniformity deteriorates
Solution Approach 1:
The patent divides the continuous film application into discrete droplet applications through multiple orifices distributed across the container surface. Each orifice releases individual enamel droplets that collectively form the desired coating pattern, eliminating the need for a continuous film and reducing material waste at edges and in central areas.
Solution Approach 2:
The patent implements variable orifice distribution patterns where the density and arrangement of orifices are optimized for different regions of the container. This allows precise control over enamel application density in different zones, achieving uniform coverage without the excessive material application characteristic of bell devices.
2Area of stationary object
If a bell device is used to apply enamel, then coverage is achieved, but application uniformity deteriorates
Solution Approach 1:
The continuous film approach is segmented into discrete droplet applications through multiple orifices. This segmentation allows precise control over where enamel is applied, enabling uniform distribution across the tile surface by adjusting orifice positions, sizes, and discharge characteristics for each location.
Solution Approach 2:
The system employs movable orifices or adjustable discharge mechanisms that can dynamically adapt to different tile positions and orientations. This dynamic capability ensures consistent enamel application uniformity across the entire tile surface, overcoming the static limitations of bell devices.
3Loss of substance
If atomization nozzles are used, then material waste is reduced, but suction systems are required increasing complexity
Solution Approach 1:
The patent extracts and eliminates the suction system component entirely by using direct droplet deposition through orifices. Enamel is applied directly to the tile surface without being atomized into suspension, removing the need for complex suction and filtration infrastructure while maintaining low material waste.
Solution Approach 2:
The orifice-based system is self-contained and does not require external suction systems to manage excess material. The enamel application is controlled directly at the source through orifice discharge regulation, making the system self-sufficient and eliminating the need for additional complexity in material recovery and air management.
4Loss of substance
If atomization nozzles are used, then material waste is reduced, but application uniformity deteriorates
Solution Approach 1:
The system segments enamel delivery into controlled droplets through multiple orifices rather than using atomization. This segmentation provides precise control over material placement and distribution, achieving both low waste and high uniformity by optimizing orifice patterns and discharge characteristics for each application zone.
Solution Approach 2:
The patent implements location-specific orifice characteristics where each orifice or group of orifices is designed with specific dimensions, orientations, and discharge rates tailored to the local requirements of that region. This local optimization ensures uniform enamel application across the entire surface while maintaining efficient material utilization.
5Loss of substance
If orifices are used for enamel dispensing, then material waste is reduced, but orifice blockage occurs
Solution Approach 1:
The patent incorporates vibration mechanisms that act on the orifices or the enamel supply to prevent material buildup and blockage. The vibrational energy keeps the enamel flow dynamic and prevents settling or clogging within the orifice passages, maintaining reliable operation while preserving the low-waste benefits of direct dispensing.
Solution Approach 2:
The system employs periodic cleaning or flushing cycles where orifices are subjected to reverse flow, ultrasonic cleaning, or mechanical agitation at regular intervals. This periodic maintenance action prevents blockage accumulation and ensures continuous reliable operation of the orifice-based dispensing system.
Data Source
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AI summary
The equipment (1) for the enameling of manufactured articles, comprises: an internally hollow container (2) for the collection of enamel to be applied on a manufactured article (M), where the container (2) is provided with at least one group (3) of through orifices (13) for the outflow of the enamel; at least one roller (4) housed out of axis inside the container (2) and operable in rotation around a relevant axis (X), where the volume interposed between the inner walls of the container (2) and the roller (4) defines a containment chamber (8) of the enamel, the orifices (13) protruding inside the containment chamber (8); and where the roller (4) is provided with at least one set (5) of protrusions (15) adapted to open and close the orifices (13) during the rotation of the roller itself to allow and prevent respectively the enamel from flowing out of the container