Rotary Atomizer with Integrated Enveloping Flow Nozzles
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Solution Overview
Problem
Existing rotary atomizers for painting require complex and energy-intensive air conditioning of paint booths to maintain consistent evaporation conditions, leading to high energy consumption and equipment costs, and previous solutions with external adapters for conditioned air are cumbersome and prone to failure.
Innovation Solution
Integration of enveloping flow nozzles directly into the atomizer housing, allowing for controlled evaporation conditions around the coating medium jet without external adapters, reducing energy needs and improving handling and cleaning efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If full air conditioning with combined cooling and dehumidification is used in the paint booth, then evaporation conditions are controlled, but energy consumption increases significantly
Solution Approach 1:
The patent applies local quality by creating a conditioned enveloping flow only in the immediate vicinity of the coating agent jet rather than conditioning the entire paint booth atmosphere. The enveloping flow nozzles deliver conditioned air locally where evaporation control is needed, while the rest of the paint booth remains unconditioned, dramatically reducing energy consumption while maintaining controlled evaporation conditions at the application point
Solution Approach 2:
The patent segments the air conditioning function by separating the enveloping flow system from the general booth atmosphere. Instead of a unified air conditioning system for the entire space, the invention divides the system into localized enveloping flow nozzles that condition only the necessary micro-environment around the spray jet, enabling independent control of evaporation conditions without conditioning the whole booth
2Temperature
If an external adapter is added to generate enveloping flow, then evaporation conditions are defined, but the device complexity and cleaning difficulty increase
Solution Approach 1:
The patent merges the enveloping flow nozzles directly into the atomizer housing, integrating two previously separate functions (atomization and enveloping flow generation) into a single unified structure. This eliminates the need for external adapters and hoses, simplifying the overall device structure while maintaining the ability to define evaporation conditions through the integrated nozzles
Solution Approach 2:
The atomizer housing is designed to serve multiple functions: it performs the primary atomization function and simultaneously generates the enveloping flow through integrated nozzles. This multi-functionality eliminates the need for separate adapter components, reducing device complexity while maintaining controlled evaporation conditions
3Temperature
If an external adapter is added to generate enveloping flow, then evaporation conditions are defined, but the reliability decreases due to hose fatigue and tearing
Solution Approach 1:
The patent merges the enveloping flow nozzles directly into the atomizer housing, eliminating the need for external hoses and connections. By integrating the nozzles into the housing structure, the system removes the failure-prone hose connections that are subject to fatigue and tearing, thereby significantly improving reliability while maintaining controlled evaporation conditions
4Temperature
If an external adapter is added to generate enveloping flow, then evaporation conditions are defined, but the ease of operation deteriorates due to increased mass inertia and external dimensions
Solution Approach 1:
The patent merges the enveloping flow nozzles into the atomizer housing, eliminating the external adapter that increased the overall dimensions and mass inertia. The integrated design maintains a compact structure that is easy to handle and maneuver, while still providing controlled evaporation conditions through the built-in nozzles
5Temperature
If an external adapter is added to generate enveloping flow, then evaporation conditions are defined, but the ease of manufacture decreases due to disrupted outer contour
Solution Approach 1:
The patent merges the enveloping flow nozzles into the atomizer housing in such a way that the smooth outer contour is preserved. The integrated nozzles are designed to be flush with or seamlessly integrated into the housing surface, maintaining ease of cleaning and manufacturing while still delivering controlled enveloping flow for defined evaporation conditions
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 solution creates a defined microclimate for the coating medium, reducing the need for extensive booth air conditioning, lowering energy consumption, and enhancing the atomizer's handling and maintenance by maintaining consistent evaporation conditions and reducing energy expenditure.
Implementation Method 1
the jet of coating medium loses volatile components during atomization and during application, such as solvents in the case of solvent-based paints or water in the case of water-based paints, which evaporate into the ambient air
Implementation Method 2
a bell cup (2) which is mounted so as to be rotatable about a bell cup axis (3) and delivers a jet of coating medium (5)
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to an atomizer (1), in particular a rotary atomizer, with an application element (2) for applying a coating agent jet (5) to a component to be coated and at least one envelope nozzle (10) for delivering a conditioned envelope stream (11) that at least partially surrounds the coating agent jet (5). The invention further comprises a corresponding operating method.