Removable Nozzle Tip Assembly for Continuous Thermal Spraying
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Solution Overview
Problem
Current thermal spray coating systems require manual disassembly or the use of multiple guns to change nozzles for different operating regimes, leading to inefficiencies and increased capital expenses, especially when applying multi-layer coatings.
Innovation Solution
A thermo spray gun system with interchangeable nozzle tips, mechanically and electrically coupled to the anode section, allowing for automatic or programmed changes using a robot-mounted gun and a station storing multiple nozzle tips, enabling seamless switching between different nozzle configurations without interrupting the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual disassembly or multiple guns are used to change nozzles for different operating regimes, then the ability to apply different coating layers is achieved, but production time increases and capital expenses increase
Solution Approach 1:
The nozzle assembly is divided into separate components: a reusable nozzle body and interchangeable nozzle tips. This segmentation allows the tips to be quickly swapped while retaining the main nozzle structure, enabling rapid transitions between different coating regimes without complete disassembly or replacement of the entire nozzle assembly.
Solution Approach 2:
A single nozzle body is designed to accommodate multiple types of nozzle tips through a universal mounting interface. This multi-functionality allows the same gun assembly to perform different coating operations (bonding layer application and thermal barrier application) by simply changing the tip, eliminating the need for multiple specialized guns or complex manual disassembly procedures.
2Adaptability or versatility
If manual disassembly is used to change the nozzle, then the operating regime can be changed, but the coating process is interrupted
Solution Approach 1:
Multiple nozzle tips are pre-configured and ready for immediate interchange. The quick-change mechanism allows operators to swap between pre-prepared tips without interrupting the coating process, as the transition can be performed rapidly during natural process transitions or between coating passes.
Solution Approach 2:
The nozzle tip mounting system incorporates dynamic elements such as quick-release latches, bayonet-style connections, or tool-less adjustment mechanisms that enable rapid reconfiguration. This dynamic design allows the nozzle assembly to be easily adapted between different operating regimes without requiring time-consuming manual disassembly and reassembly procedures.
3Adaptability or versatility
If two separate guns or spray cells are used, then complete coating systems can be produced, but capital expense increases
Solution Approach 1:
A single plasma spray gun assembly is designed with a universal mounting interface that accommodates multiple types of nozzle tips, each optimized for different coating applications. This allows one gun to perform the functions of multiple specialized guns by simply changing the tip, thereby reducing capital equipment requirements while maintaining complete coating system capability.
Solution Approach 2:
The invention merges the functionality of multiple specialized nozzles into a single multi-functional nozzle assembly. By combining various nozzle tip designs and mounting mechanisms into one integrated system, the invention consolidates what would traditionally require separate guns or spray cells into a single versatile unit, reducing both device complexity and capital expense.
Data Source
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AI summary
A thermo spray gun system comprising: a thermal spray gun; at least one mechanism comprising at least first and second nozzle tips and being movable between: a first position wherein the first nozzle tip is utilized to spray a coating material; and a second position wherein the second nozzle tip is utilized to spray a coating material.