Spray Applicator Nozzle Backpressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current spray technologies waste approximately 30% of materials due to the need to shut down and restart the spray process off-target, and they struggle with spraying both Newtonian and non-Newtonian compounds without significant changes in equipment, leading to errors in spray patterns and increased waste.
Innovation Solution
A spray applicator with a nozzle assembly that maintains constant backpressure, allowing for error-free starting and stopping of the spray process without leaving the target, and capable of handling both Newtonian and non-Newtonian compounds using an open barrel bore design and a cartridge system, eliminating the need for frequent equipment changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If convergent-divergent nozzle with small orifice is used to create spray, then spray is produced, but material waste increases due to pressure build-up time required to start/stop spray
Solution Approach 1:
The system pre-charges the reservoir to operating pressure before spray is needed, so that when the spray valve opens, material flows immediately without delay. This eliminates the pressure build-up time that causes material waste in conventional systems.
Solution Approach 2:
The invention extracts the pressure build-up function from the nozzle itself and places it in a separate reservoir system. The reservoir pre-charges to pressure independently, allowing the nozzle to simply open and close without needing to build pressure, thereby eliminating waste associated with pressure cycling in the nozzle.
2Ease of operation
If convergent-divergent nozzle is used for spraying, then spray is produced, but user must leave target surface to shut down materials flow
Solution Approach 1:
The system uses a solenoid valve that automatically opens and closes based on electrical control signals, eliminating the need for manual intervention to start/stop spray. The reservoir self-regulates pressure, and the system can be controlled remotely, allowing the operator to remain on the target surface.
Solution Approach 2:
The invention replaces manual mechanical control of spray flow with an electrically actuated solenoid valve. This allows remote, precise control of the spray valve without requiring the operator to physically move to shut off material flow, thereby eliminating material waste and improving ease of operation.
3Adaptability or versatility
If conventional spray technology is used, then Newtonian compounds can be sprayed, but equipment must be changed to spray non-Newtonian compounds
Solution Approach 1:
The reservoir system is designed to accommodate both Newtonian and non-Newtonian fluids with the same basic configuration. By using a large reservoir that allows material to settle and air to separate, the system handles viscous non-Newtonian compounds effectively without requiring equipment changes, making it universal for different fluid types.
Solution Approach 2:
The system changes the operating parameters by using a large reservoir volume and allowing extended settling time, which transforms how materials are delivered to the nozzle. This parameter change enables the same equipment to effectively spray both low-viscosity Newtonian fluids and high-viscosity non-Newtonian compounds without configuration changes.
4Productivity
If material flow is continuously supplied to nozzle, then spray can be started immediately on-target, but backpressure must be controlled to prevent errors
Solution Approach 1:
The reservoir pre-charges to operating pressure continuously before spray is initiated. This preliminary pressure build-up ensures that when the spray valve opens, material flows immediately on-target without delay, while the pre-established pressure prevents backpressure errors during spray initiation.
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 spray applicator significantly reduces material waste, maintains accurate spray patterns, and allows for seamless switching between different viscosities without equipment changes, improving operational efficiency and reducing errors.
Implementation Method 1
maintains constant backpressure, allowing for error-free starting and stopping of the spray process
Implementation Method 2
an open barrel bore, into which a stream of air breaks up the material stream into droplets
Data Source
AI summary
A spray applicator assembly discharges distributable product from a cartridge using low air pressure. The cartridge is held captive between a piston advancing from the rear to expel contents and a nozzle snugly attached at the front to receive expelled contents and to convert the contents into droplets by subjecting the contents to an array of focused high velocity air streams. The nozzle has an open barrel design and is able to discharge a variety of liquid or viscous distributable product without readjustment, other than resetting a proportioning valve in the low pressure air feed line. An air chamber immediately in front of the cartridge nose provides constant backpressure, which dominates to cleanly stop flow of distributable product into the nozzle whenever the piston stops advancing. When the piston resumes advancement, the flow restarts cleanly. Clean stopping and starting saves distributable product from waste. Variations in the distributable product might include, without limitation, a broad variety of materials including coating materials and combustibles.