Overspray-Free Print Head Coating for Motor Vehicle Bodies
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Solution Overview
Problem
Conventional painting installations for car body components require paint separation systems, which consume resources and necessitate a steel structure to support the paint booth, leading to inefficiencies and increased costs.
Innovation Solution
Implementing overspray-free print heads as application devices in at least one paint booth, allowing for the elimination of paint separation systems and reducing the need for a steel structure, while still utilizing conventional atomizers in other booths for areas difficult to paint with print heads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional atomizers are used for paint application, then paint can be applied to components, but significant overspray occurs requiring paint separation systems
Solution Approach 1:
The patent extracts and eliminates the paint separation system by replacing conventional atomizers with print heads that do not generate overspray. The print heads deposit paint directly onto the component surface without the spray mist that would otherwise require separation and filtration systems.
Solution Approach 2:
The patent replaces the mechanical spray-based atomizer system with a print head system that uses controlled deposition. This substitution eliminates the need for complex mechanical paint separation systems including water sprays, chemicals, stone flour, and cardboard filters.
2Reliability
If paint separation systems are installed, then overspray can be removed, but water, chemicals, stone flour and cardboard filters are required increasing operational complexity
Solution Approach 1:
The patent removes the entire paint separation system including water sprays, chemicals, stone flour, and cardboard filters by using print heads that deposit paint without generating overspray. This eliminates the need for these additional operational elements.
Solution Approach 2:
The print head system is self-sufficient, depositing paint directly onto the component without requiring external paint separation mechanisms. The system serves its own function of clean deposition without needing auxiliary systems for overspray management.
3Stability of the object's composition
If steel structure is used to support paint booth, then paint booth can be positioned above paint separation, but construction complexity and costs increase
Solution Approach 1:
The patent eliminates the steel construction requirement by removing the paint separation system. Without the need to position a paint booth above a paint separation system, the complex steel structure supporting such positioning becomes unnecessary.
Solution Approach 2:
The patent segments the painting installation into independent paint booths that can be positioned at floor level without requiring support structures. Each paint booth operates independently without needing to be suspended above a paint separation system.
4Loss of substance
If print heads are used instead of atomizers, then overspray is eliminated, but areas difficult to paint with print heads may not be effectively coated
Solution Approach 1:
The patent applies different application methods to different areas of the component. Print heads are used for areas requiring precise, overspray-free deposition, while conventional atomizers are used for areas that are difficult to access or require broader coverage, ensuring optimal paint application throughout.
Solution Approach 2:
The painting process is segmented into different zones: areas coated with print heads for precise deposition and areas coated with atomizers for comprehensive coverage. This segmentation allows each method to be applied where it provides the greatest benefit.
Data Source
AI summary
The disclosure relates to a painting installation for painting components with a paint, in particular for painting motor vehicle body components, with a paint booth and an application device, in particular a print head, arranged in the paint booth, for applying the paint to the component located inside the paint booth, the application device operating essentially without overspray, so that the paint applied by the application device essentially completely on the component to be coated without overspray deposits. The disclosure provides that no paint separation is arranged below the first paint booth.