Rotary Atomizer Pattern Control via Twisted Airflow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary electrostatic coating devices face challenges in varying the diameter of the coating pattern effectively, as increasing the flow speed of shaping air reduces the pattern diameter, and previous solutions either rely on adjusting the orientation of shaping air holes or using control air to merge with shaping air, which either enlarges or reduces the pattern diameter but lacks versatility.
Innovation Solution
A rotary electrostatic coating device with shaping air holes and control air holes oriented in the same torsion angle direction, where the control air merges with the shaping air close to the outer peripheral edge of the rotary head, allowing for intensified centrifugal force without altering the torsion angle, thereby enabling adjustable coating pattern diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the flow speed of shaping air is increased to improve coating quality, then the coating quality improves, but the diameter of the coating pattern becomes smaller
Solution Approach 1:
The air flow control is segmented into two independent systems: shaping air holes for coating quality control and control air holes for pattern diameter control. This segmentation allows independent optimization of coating quality and pattern size without mutual interference.
Solution Approach 2:
Control air acts as an intermediary substance that interacts with shaping air to adjust the coating pattern diameter. By introducing this intermediate medium, the patent resolves the contradiction between high-speed shaping air (for quality) and large pattern diameter (for coverage).
2Area of stationary object
If control air holes are positioned radially outward with zero torsion angle to control pattern width, then the coating pattern diameter can be controlled, but the control air merges with shaping air reducing the swirling force
Solution Approach 1:
The control air holes are positioned on a different radial dimension (inner radius) compared to shaping air holes (outer radius). This spatial differentiation in the radial dimension allows control air to affect pattern diameter without completely merging with and neutralizing the swirling force of shaping air.
Solution Approach 2:
Different regions of the air ring serve different functions: the outer region (shaping air holes) provides swirling flow for coating quality, while the inner region (control air holes) provides radial control for pattern diameter. This local differentiation of function resolves the contradiction between diameter control and swirling force maintenance.
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 allows for the enlargement or reduction of the coating pattern diameter by controlling the flow rate of pattern control air, providing a more versatile method to manage coating pattern size without significantly changing the swirling torsion angle of the shaping airflow.
Implementation Method 1
the flow speed thereof is reduced. This means that the flow of shaping air which has already passed by the bell cup is drawn radially inward because of the negative pressure in front of the bell cup
Implementation Method 2
The shaping air forms a helical swirling flow due to the shaping air holes whereof the torsion direction has been oriented in this way, and the diameter of the coating pattern can be increased by the centrifugal force of this swirling flow
Implementation Method 3
the diameter of the coating pattern can be increased by the centrifugal force of this swirling flow
Implementation Method 4
the pattern control air merges with the shaping air at the outer peripheral edge of the bell cup, then the amount of outflow of pattern control air is changed, whereby the coating pattern width is controlled
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A rotary electrostatic atomizer uses shaping air (Fs) and pattern control air (Fp). Shaping airflow (Fs) is supplied from shaping air holes (17) aligned along outer one of concentric circles that are concentric with the rotation axis (L) of the bell cup (13) and located behind the front end of the bell cup (13). Pattern control airflow (Fp) is supplied from pattern control air holes (18) aligned along inner one of the concentric circles. Both the shaping air flow (Fs) and the pattern control airflow (Fp) are expelled in circumferentially twisted directions substantially with an equal twist angle opposite from the rotating direction of the bell cup (13). The shaping airflow (Fs) passes a circular line near to and radially outwardly apart from the outer perimeter of the bell cup (13). The pattern control airflow (Fp) intersects the shaping airflow (Fs) from radially inside at the position near to and radially outwardly apart from the outer perimeter of the bell cup (13). Thereby, the pattern control airflow (Fp) gives the shaping airflow (Fs) a radially outward force to enhance the centrifugal force of the shaping air (Fs) and enlarge the coating pattern regulated by the shaping airflow (Fs).