Spray Applicator Guide Element for Secondary Spray Control
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Solution Overview
Problem
Existing spray application systems face challenges in achieving 100% spray transfer efficiency due to secondary spray formation, which leads to contamination and process instability, and current solutions are complex, expensive, and energy-intensive.
Innovation Solution
An application device with guide elements positioned near the nozzle outlet, angled or curved, to redirect and control air flows, minimizing secondary spray formation and preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spray application is used to apply coating medium to moving surface, then application speed and productivity are improved, but secondary spray formation occurs leading to contamination and reduced transfer efficiency
Solution Approach 1:
A guide element is introduced as an intermediary component between the spray nozzle and the moving surface. This guide element redirects air flows and secondary spray away from the application area, preventing contamination while maintaining the high-speed spray application process. The guide element acts as a mediator that manages the interaction between spray curtains and ambient air currents.
Solution Approach 2:
The harmful secondary spray and deflecting air currents are extracted or removed from the application area by the guide element. The guide element directs these unwanted flows away from the substrate, effectively separating the useful spray application from the harmful secondary spray that would otherwise cause contamination.
2Object-generated harmful factors
If extraction systems are used to capture secondary spray, then contamination is reduced, but device complexity and energy consumption increase
Solution Approach 1:
Instead of using complex and expensive extraction systems (vacuum chambers, cyclones, electrostatic precipitators), the invention employs a simple, inexpensive guide element that passively redirects flows. This guide element is a basic structural component that requires no energy input, no moving parts, and minimal maintenance, effectively replacing complex active extraction systems.
Solution Approach 2:
The guide element operates passively by utilizing the existing air flows and spray dynamics to redirect secondary spray away from the application area. It requires no external energy input, control systems, or active components - the system serves itself by leveraging natural flow patterns to achieve contamination control.
3Manufacturing precision
If spray nozzle accelerates liquid jets to generate fine spray, then spray fineness and coating quality are improved, but spray transfer efficiency decreases due to increased secondary spray
Solution Approach 1:
The guide element serves as an intermediary that manages the relationship between high-velocity spray jets and ambient air. It redirects the deflecting air currents and secondary spray away from the application area, allowing the spray nozzle to operate at high velocities for fine spray generation without sacrificing transfer efficiency to the substrate.
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
Stabilizes spray application, reduces secondary spray, and minimizes contamination, achieving efficient and cost-effective spray transfer.
Implementation Method 1
Other reasons for the formation of secondary spray are deflecting air currents that occur due to negative pressure effects or turbulence effects in the vicinity of the spray flow (Bernoulli or Venturi effects or Coanda effects, external flows, etc.)
Implementation Method 2
Other reasons for the formation of secondary spray are deflecting air currents that occur due to negative pressure effects or turbulence effects in the vicinity of the spray flow (Bernoulli or Venturi effects or Coanda effects, external flows, etc.)
Implementation Method 3
Other reasons for the formation of secondary spray are deflecting air currents that occur due to negative pressure effects or turbulence effects in the vicinity of the spray flow (Bernoulli or Venturi effects or Coanda effects, external flows, etc.)
Implementation Method 4
Other reasons for the formation of secondary spray are deflecting air currents that occur due to negative pressure effects or turbulence effects in the vicinity of the spray flow
Implementation Method 5
Single-component spray-generating principles use only the liquid to be atomized and generate the spray by accelerating thin liquid jets produced by suitable fine nozzles. The acceleration of the liquid is generated by a high pressure difference at the outlet of the spray nozzle channel.
Implementation Method 6
Due to the sharp increase in velocity, the fine liquid threads break down into fine droplets. The higher the acceleration, the finer the generated spray.
Data Source
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Figure 5
AI summary
Application device for applying a liquid or pasty coating medium to a moving surface, in particular to a moving surface in a machine for producing or processing a fibrous web, wherein the application device comprises an application nozzle which is configured to spray the coating medium in the form of a spray curtain onto the moving surface, wherein the spray curtain extends over the entire application width of the application device, characterized in that the application device has a first guide element for guiding air flows, which extends over the entire application width of the application device and which is arranged on a first side of the application nozzle in the immediate vicinity of the nozzle outlet of the application nozzle, wherein the first guide element is curved. In addition, a film application unit and application method.