Rotary Atomizing Electrostatic Applicator with Shaping Air Ring
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Solution Overview
Problem
Conventional rotary atomizing electrostatic applicators face a trade-off between increasing paint discharge rate and maintaining painting quality, leading to issues such as reduced coating efficiency, double patterns, and overspray due to the need for high rotational speeds and large bell cup diameters, which result in uneven paint film thickness and increased paint waste.
Innovation Solution
A rotary atomizing electrostatic applicator with a bell cup hit by atomization air at an angle of 90 degrees or less, featuring first air holes arranged at equal intervals on the circumference, oriented opposite to the rotation direction, and atomization air twisted in the opposite direction at an angle of 50 to 60 degrees, optimizing the twist angle of the shaping air to enhance atomization without increasing rotational speed or bell cup diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rotational speed of the bell cup is increased to decrease paint particle size, then atomization is improved, but coating efficiency decreases and paint waste increases
Solution Approach 1:
The patent changes the parameter of shaping air twist angle to a specific range (50-60 degrees) to achieve optimal atomization效果。By adjusting this angular parameter, the paint particles are properly atomized without requiring excessive rotational speed, thereby reducing paint waste while maintaining particle size control.
Solution Approach 2:
The patent utilizes shaping air (pneumatic force) to assist in atomizing paint particles. The shaped air flow, with its specific twist angle, works together with the bell cup rotation to break up paint into fine particles, reducing the need for high rotational speeds and minimizing paint loss through overspray.
2Productivity
If the paint discharge rate is increased to improve productivity, then output increases, but paint particle diameter increases and painting quality deteriorates
Solution Approach 1:
The patent optimizes the shaping air twist angle parameter to enable effective atomization at higher paint discharge rates. This parameter adjustment allows the system to handle increased paint flow while maintaining fine particle diameter, thus improving productivity without sacrificing painting quality.
Solution Approach 2:
The shaped air acts as an intermediary that facilitates the atomization process at higher discharge rates. By introducing this pneumatic mediator with controlled twist angle, the system can process more paint volume while still achieving fine particle atomization, bridging the gap between high productivity and high quality requirements.
3Manufacturing precision
If strong shaping air is used to improve metallic painting quality, then collision velocity increases, but coating efficiency decreases
Solution Approach 1:
The patent optimizes the twist angle parameter of shaping air to a moderate range (50-60 degrees) rather than using extremely strong or highly twisted air flows. This optimized parameter achieves sufficient collision velocity for quality metallic painting while avoiding excessive air force that would reduce coating efficiency and increase paint waste.
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 configuration achieves improved coating efficiency and uniform paint distribution, allowing for higher paint discharge rates without compromising painting quality, as demonstrated by the reduction in paint particle diameter and increased coating efficiency even at twice the conventional paint discharge rate.
Implementation Method 1
the atomization air discharged through the first air holes is twisted in the direction opposite to the rotation direction of the bell cup at an angle of 50 degrees or more and less than 60 degrees
Implementation Method 2
rotary atomizing electrostatic applicator
Data Source
AI summary
The present invention solves a problem of a trade-off between increases in paint discharge rate and maintenance of painting quality. A rotary atomizing electrostatic applicator includes a bell cup 10 whose back 10a is hit by atomization air SA-IN at an angle of 90 degrees or less; and first air holes 30 adapted to discharge the atomization air SA-IN directed at the back 10a of the bell cup, wherein the first air holes 30 are arranged at equal intervals on a circumference centered around a rotation axis of the bell cup 10, the first air holes 30 are oriented in a direction opposite to a rotation direction of the bell cup 10; and the atomization air SA-IN discharged through the first air holes 30 is twisted in the direction opposite to the rotation direction of the bell cup 10 at an angle of 50 degrees or more and less than 60 degrees.