Rotatable Disc Spray Applicator for Uniform Coating

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Solution Overview

Problem

Automated spray applicator systems often fail to produce a uniform spray pattern, leading to increased assembly time, labor, and costs when manual systems are required to complete the painting process.

Innovation Solution

A spray apparatus comprising a stand, a motor, a spray applicator, and a rotatable disc positioned within the spray field, where the disc is coupled to the motor to rotate and receive overspray, generating a uniform spray pattern, and a scraper is used to remove accumulated material from the disc.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated spray applicator systems are used, then productivity is improved, but manufacturing precision deteriorates due to non-uniform spray patterns

Engineering Contradiction:

Improvepainting process efficiencyVSAvoidspray pattern uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

A rotatable disc is introduced as an intermediary component between the spray applicator and the target surface. The disc receives overspray material and redistributes it uniformly across the spray pattern area, transforming the non-uniform spray output into a uniform coating pattern on the manufactured object.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spray pattern uniformity is improved by changing the physical state and distribution parameters of the spray material. The rotatable disc converts the direct spray pattern into a redistributed pattern through rotation, altering how the material is deposited across the target surface.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual painting systems are used to correct automated system failures, then manufacturing precision is improved, but productivity deteriorates due to increased assembly time and labor

Engineering Contradiction:

Improvespray pattern uniformityVSAvoidassembly time and labor

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The rotatable disc system enables the automated spray applicator to self-correct its non-uniform spray pattern output. The disc automatically redistributes the overspray material without requiring manual intervention, allowing the automated system to maintain both productivity and manufacturing precision simultaneously.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If a rotatable disc is added to the spray apparatus, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvespray pattern uniformityVSAvoidspray apparatus structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The spray apparatus is segmented into distinct functional components: the spray applicator that generates the spray pattern, the rotatable disc that redistributes the material, and the scraper that removes accumulated material. This segmentation allows each component to perform its specific function independently, simplifying the overall system design and maintenance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The scraper component continuously removes accumulated overspray material from the rotatable disc surface. This prevents material buildup that would disrupt the uniform redistribution function, ensuring consistent performance over time and reducing the need for manual cleaning or maintenance.

Inventive Principle:

Principle #34Discarding and recovering

4Device complexity

If overspray is allowed to accumulate on the rotatable disc, then device complexity is reduced, but manufacturing precision deteriorates due to inconsistent material distribution

Engineering Contradiction:

Improvematerial removal mechanismVSAvoidmaterial distribution consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The scraper is configured to continuously remove overspray material from the rotatable disc as it rotates, ensuring that the disc surface remains consistent in its material distribution function. This continuous action maintains uniform spray pattern quality throughout operation without requiring periodic manual intervention.

Inventive Principle:

Principle #20Continuity of useful action

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

The solution enables the generation of a uniform spray pattern, reducing errors and costs associated with manual painting processes by maintaining a consistent material distribution and minimizing material waste.

Implementation Method 1

The rotatable disc is configured to receive an overspray of the spray field to generate a spray pattern from the spray applicator

Methodology Applied

Scientific EffectOverspray:

Implementation Method 2

a scraper positioned in fixed engagement with the rotatable disc, where the scraper is configured to remove accumulated overspray from the rotatable disc

Methodology Applied

Scientific EffectAccumulated overspray removal:

Data Source

PatentUS11691186B2Spray applicator apparatuses for generating uniform spray patterns and methods incorporating the same

Publication Date: 2023.07.04 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC

AI summary

A spray apparatus that includes a stand, a motor secured to the stand, a spray applicator secured to the stand, and a rotatable disc secured to the stand relatively above the spray applicator such that the rotatable disc is positioned within a spray field of the spray applicator. The rotatable disc is coupled to the motor such that the rotatable disc is configured to rotate in response to activation of the motor. The rotatable disc is configured to receive an overspray from the spray field to generate a spray pattern from the spray applicator. The apparatus includes a scraper positioned in fixed engagement with the rotatable disc, where the scraper is configured to remove accumulated overspray from the rotatable disc.