Overspray Separation Unit With Immersed Inlet Collar
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Solution Overview
Problem
Existing overspray separation systems in painting booths face challenges such as high energy consumption, complex construction, and difficulty in automated exchange due to overspray deposition on external surfaces, leading to sticking issues and increased maintenance.
Innovation Solution
The device features a design with angled guide channels and connecting pieces that immerse into the inlet opening of each separation unit, minimizing overspray contact with external surfaces and allowing for horizontal movement and sealing, enabling efficient flow guidance and easy exchange of filter modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separation units are arranged side by side forming a filter wall exposed to booth air laden with overspray, then overspray separation is achieved, but overspray deposits on external surfaces causing separation units to stick together and complicating replacement
Solution Approach 1:
The harmful function of overspray deposition on external surfaces is extracted and eliminated by introducing an inlet collar that completely surrounds the inlet opening. This collar acts as a protective barrier that prevents overspray-laden air from contacting the external surfaces of the separation unit, thereby preventing deposition and sticking while maintaining separation effectiveness.
Solution Approach 2:
The inlet collar serves as an intermediary element between the overspray-laden air flow and the separation unit's external surfaces. It mediates the interaction by creating a sealed interface that directs air flow through the inlet opening while blocking direct contact with external surfaces, thus preventing deposition without compromising the separation function.
2Reliability
If conventional wet separators are used to capture overspray, then separation effectiveness is improved, but energy consumption increases due to high water circulation requirements
Solution Approach 1:
The patent employs disposable filter modules that are replaced periodically rather than continuously circulating and cleaning water. This approach eliminates the high energy consumption associated with wet separator water circulation while maintaining effective overspray capture through the disposable filtration medium.
Solution Approach 2:
The patent replaces the mechanical water circulation system of wet separators with a simpler disposable filter module system. This substitution eliminates the need for continuous water pumping and circulation, thereby dramatically reducing energy consumption while maintaining overspray separation effectiveness.
3Reliability
If electrostatically operating dry separators are used to remove overspray, then separation is achieved without water, but energy consumption remains high and construction becomes complex
Solution Approach 1:
The patent uses simple disposable filter modules instead of complex electrostatic separation systems. These filter modules require minimal energy compared to electrostatic separators while achieving effective overspray removal, thereby reducing energy consumption and simplifying the overall system construction.
4Ease of manufacture
If filter modules are replaced manually, then replacement is possible, but productivity decreases due to manual intervention requirements
Solution Approach 1:
The separation system is segmented into modular, interchangeable filter modules that can be independently replaced. This segmentation enables standardized replacement procedures that can be automated, thereby increasing productivity while maintaining ease of manufacture and installation.
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
This design reduces energy consumption, simplifies maintenance, and prevents sticking of separation units, facilitating automated and efficient overspray separation with reduced resource and energy requirements.
Implementation Method 1
a filter unit (60) in which the air is filtered
Implementation Method 2
the air guiding device comprises a guide channel formed by baffles extending downwardly
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device for separating overspray from the booth air of coating booths, in particular painting systems, charged with overspray. Said device comprises a separation unit (50) through which booth air charged with overspray can be guided and in which overspray is separated. Said separating unit (50) is designed as an exchangeable structural unit comprising a filter housing (56), an inlet opening (58) and a filter unit (60). The air flow charged with overspray can be guided via the air guiding device (38) to the separation unit (50). Said separating unit (50) comprises an inlet collar (82) which defines the inlet (58) at least in sections and the air guiding device (38) comprises a connecting sleeve (46), which immerses in such a manner into the inlet opening (58) when the separating device (50) is in operation in such a manner that said connecting sleeve (46) is surrounded by the inlet collar (82) of the separation unit (50).