Perforated Nozzle Plate Layout for Uniform Coating Overlap
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Solution Overview
Problem
Existing perforated plates for applying coating materials to motor vehicle bodies suffer from issues such as unsuitable overlap of coating material webs due to rectangular cross-sectional profiles, leading to imperfections like dents or overcoating, and high coating material flow rates that cause splashing.
Innovation Solution
A perforated plate with a nozzle configuration featuring a trapezoidal cross-sectional profile, achieved by varying through-hole diameters in edge and central regions, allowing for precise fluid application without splashing, and enabling uniform layer thickness distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If through-holes are arranged in a two-dimensional matrix configuration to create sharply defined coating material webs, then manufacturing precision of coating edges is improved, but coating material flow rate increases causing splashing
Solution Approach 1:
The coating application is segmented into sequential passes rather than attempting to cover the entire width in a single pass. The nozzle row applies coating to a limited width, and subsequent passes overlap to complete the coverage, reducing the flow rate requirement per nozzle while maintaining edge definition
Solution Approach 2:
The coating application is divided into periodic passes along the vehicle body, with each pass applying coating to a specific section. This allows the system to maintain precision while reducing the instantaneous flow rate demand by spreading the total coating quantity across multiple application cycles
2Ease of operation
If through-holes are arranged in a two-dimensional matrix configuration to generate trapezoidal cross-sectional profile, then ease of operation for overlapping coating webs is improved, but device complexity increases due to multiple through-holes with different diameters
Solution Approach 1:
Different sections of the nozzle row have different through-hole diameters optimized for their specific function: larger diameter holes in the central region for main coating flow, and smaller diameter holes in edge regions for controlled overlap areas. This local differentiation achieves the desired trapezoidal profile and overlapping capability without requiring complex variable geometry mechanisms
Solution Approach 2:
The through-hole diameters are varied as a discrete parameter across the nozzle row to generate the trapezoidal cross-sectional profile. By changing the hole diameter parameter from center to edge, the system achieves the desired coating web shape and overlapping characteristics while maintaining a relatively simple fixed-geometry nozzle structure
3Ease of manufacture
If through-holes have uniform diameter to simplify manufacturing, then ease of manufacture is improved, but manufacturing precision of coating thickness distribution deteriorates
Solution Approach 1:
Different sections of the nozzle row have different through-hole diameters optimized for their specific function: larger diameter holes in the central region for main coating flow, and smaller diameter holes in edge regions for controlled overlap areas. This local differentiation achieves the desired trapezoidal profile and overlapping capability without requiring complex variable geometry mechanisms
Solution Approach 2:
The through-hole diameters are varied as a discrete parameter across the nozzle row to generate the trapezoidal cross-sectional profile. By changing the hole diameter parameter from center to edge, the system achieves the desired coating web shape and overlapping characteristics while maintaining a relatively simple fixed-geometry nozzle structure
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The invention relates to a perforated plate (1) for an application device for applying a fluid to a component, preferably to a motor vehicle body and/or to an add-on part for the latter. The perforated plate (1) comprises at least three through-holes (2.1, 3.1, 3.2, 3.3) for the passage of the fluid, wherein the through-holes (2.1, 3.1, 3.2, 3.3) of a row of nozzles are assigned to a central region (2) and to two edge regions (3a, 3b), wherein the at least one outermost through-hole (3.1) has, in at least one edge region (3a), at least one reference through-diameter (d, dl, d2) which is smaller than at least one reference through-diameter (d3) of at least one through-hole (2.1) in the central region (2). The invention also comprises an application device and an application method using such a perforated plate (1).