Self-Cleaning Spray Tips for Surface Treatment
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Solution Overview
Problem
Asphalt surface treatments applied to roadways often face issues with environmental conditions causing uneven application, leading to clogging of spray systems due to congealed material, and inefficient maintenance procedures that result in reduced operational effectiveness.
Innovation Solution
A truck-mountable surface treatment distributor apparatus with self-cleaning spray tips and a recirculation system that uses load cells, pumps, filters, and a control panel to manage application rates and prevent clogging, featuring a self-cleaning mechanism within each spray tip and a recirculation circuit to maintain fluid suspension and prevent coagulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spray system operates intermittently due to environmental conditions, then the surface treatment application quality is improved, but the liquid surface treatment begins to congeal and thicken causing clogging of spray applicators
Solution Approach 1:
The recirculation system maintains continuous flow of the liquid surface treatment through the spray applicators even when spraying is temporarily stopped, preventing the liquid from standing still and congealing. The system circulates the material through pumps and back through the spray tips, keeping it in constant motion to avoid thickening and clogging while allowing intermittent application based on environmental conditions.
Solution Approach 2:
The recirculation circuit acts as an intermediary system between the storage tank and spray applicators, providing a separate flow path that maintains material movement independently of the spraying action. This intermediary recirculation loop ensures material continues to flow and be agitated even when the primary spray function is paused.
2Reliability
If the spray applicators are cleaned frequently to prevent clogging, then the spray system reliability is improved, but the operational time and productivity are reduced
Solution Approach 1:
The recirculation system performs preliminary prevention of clogging by continuously moving the liquid material through the spray applicators during operation and during temporary stops. By maintaining continuous circulation, the system prevents material from settling and congealing in the first place, eliminating the need for frequent cleaning interruptions.
Solution Approach 2:
The recirculation system provides self-maintenance by continuously agitating and moving the liquid material through the spray tips, effectively self-cleaning the applicators during normal operation. The constant flow prevents material from adhering to and clogging the spray tips, reducing or eliminating the need for separate cleaning operations.
3Adaptability or versatility
If the liquid surface treatment is stored in the tank during intermittent spraying, then the system can respond to environmental conditions, but the liquid begins to congeal and form agglomerated particles
Solution Approach 1:
The recirculation system maintains continuous movement of the liquid surface treatment material even when stored in the tank during intermittent spraying operations. The material is constantly pumped and circulated through the system, preventing it from standing still and congealing, thereby maintaining its liquid consistency and preventing formation of agglomerated particles while allowing the system to pause spraying for environmental reasons.
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
Enables real-time control of application rates and prevents clogging by removing debris from spray tips and maintaining fluid suspension, ensuring continuous and efficient operation even under varying environmental conditions.
Implementation Method 1
drawn from the tank through a pump and into the spray bar
Implementation Method 2
A compressed air source is provided in communication with each spray tip and acts to blow debris out of each spray tip
Implementation Method 3
a tank mounted on load cells secured to a subframe assembly
Data Source
AI summary
The invention generally relates to a surface treatment distribution apparatus and spray assembly apparatus method capable of applying a variety of surface treatments, for example mastic surface treatments, to a variety of highways, roadways and other asphalt surfaces of variable shapes and sizes. The invention generally includes a tank, pumps, operator station, control inputs, filter assemblies, spray bar and self cleaning spray tip assemblies. Each spray tip assembly includes a self cleaning functionality whereby the operator may remove any debris or clogging material from one or more spray tips with a pneumatically actuated plunger located in the spray tip assembly that acts to force the debris or blockage out of the spray tip. The plunger retracts after actuation and the spray tip assembly is then ready to resume spray operations as desired by the operator.