Rotary Atomizer Coating Method for Glitter Paint Color Control
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Solution Overview
Problem
The existing rotary atomizer coating methods face challenges in achieving consistent color shades with various spray widths, leading to uneven appearance quality and increased paint loss due to overspray, especially when transitioning to new paint colors, as the orientation of glitter pigments is affected by changing spray pattern sizes and flying velocities.
Innovation Solution
A coating method that adjusts the particle size of paint particles based on the spray width using a rotary atomizer with controlled rotational speed, discharge rate, and airflow rates to maintain consistent color shades across different spray patterns, reducing overspray and enabling efficient paint application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the spray pattern size is changed to reduce overspray and paint loss, then the flying velocity of paint particles changes, but this causes uneven orientation of glitter pigment and inconsistent color shade
Solution Approach 1:
The invention changes the particle size parameter of paint particles based on the spray pattern size. When spray pattern size changes, the particle size is adjusted accordingly to maintain consistent impact energy and glitter pigment orientation, thereby achieving consistent color shade while allowing spray pattern variation for paint loss reduction
Solution Approach 2:
The invention establishes a control relationship where particle size is adjusted in response to spray pattern size changes. This feedback mechanism ensures that the impact energy of paint particles remains appropriate for achieving the desired color shade, compensating for changes in flying velocity caused by spray pattern variations
2Manufacturing precision
If the spray pattern size is kept within a narrow range to maintain color shade consistency, then glitter pigment orientation remains uniform, but the amount of overspray increases
Solution Approach 1:
The invention allows spray pattern size to vary for paint loss reduction while compensating for the resulting changes in particle flight characteristics by adjusting particle size. This enables broader spray pattern usage without sacrificing color shade consistency
Solution Approach 2:
The invention introduces dynamic adjustment of particle size based on spray pattern size, transforming a static coating process into a dynamic one where parameters are adjusted in real-time to maintain optimal performance across varying operating conditions
3Adaptability or versatility
If a new paint color is employed with various spray patterns, then coating versatility is improved, but a large amount of time is required to study coating conditions for each spray pattern
Solution Approach 1:
The invention establishes a universal control relationship between spray pattern size and particle size that applies across different paint colors. This universal principle reduces the time required to study coating conditions for new paint colors, as the fundamental relationship remains consistent even though specific parameter values may differ
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 method allows for the attainment of desired color shades with various spray widths, minimizing paint loss and enabling rapid determination of new coating conditions, thereby improving appearance quality and reducing waste.
Implementation Method 1
a rotary atomizer having a coating performance improved as compared to a conventional one in such a manner that paint is discharged at a higher discharge rate and is then atomized in a bell cup which is put in very high speed rotation
Implementation Method 2
spraying the paint onto the surface of the object
Implementation Method 3
the impact velocity of the paint particles toward the surface of the object to be coated
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A coating method of coating a surface of an object with a paint containing a glitter pigment, including: spraying the paint onto the surface of the object; and controlling a color shade of the paint on the object by adjusting a particle size of paint particles to be sprayed according to a spray width indicating a width of a spread of the paint particles.