Spray Attachment Vanes for Transfer Efficiency

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current spray atomizers face issues such as energy loss, overspray, and bounce-back of coating particles during the transfer process, leading to low transfer efficiency and potential health hazards from microscopic errant particles.

Innovation Solution

An attachment for spray devices that provides a controlled pattern of additional compressed air, using a cylindrical air hub with angled vanes to boost energy and direct atomized coating particles towards the workpiece, enhancing their adherence and reducing errant particle dispersion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If compressed air pressure is increased to move atomized coating toward the workpiece, then transfer efficiency improves, but decompression effect increases causing more errant particles and overspray

Engineering Contradiction:

Improvetransfer efficiencyVSAvoiderrant particles

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The air hub segments the compressed air flow into multiple directional streams through vanes positioned at different angles. This segmentation allows the air flow to be distributed in a controlled pattern that propels coating particles toward the workpiece while reducing uncontrolled decompression that causes errant particles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The vanes create localized regions of different air flow characteristics - some areas have high-velocity direct flow for propelling particles, while other areas have controlled lower-velocity flow that prevents excessive decompression. This local variation in air flow quality optimizes both transfer efficiency and particle control.

Inventive Principle:

Principle #3Local quality

2Productivity

If nozzle is positioned closer to workpiece to increase transfer efficiency, then coating delivery improves, but bounce-back effect increases

Engineering Contradiction:

Improvetransfer efficiencyVSAvoidbounce-back

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The air hub creates a dynamic air flow pattern that adapts to the spray conditions. The vanes are positioned to create a balanced flow field that provides sufficient propulsion force while maintaining control over particle velocity, reducing the bounce-back effect that occurs with excessive particle energy at close distances.

Inventive Principle:

Principle #15Dynamics

3Productivity

If compressed air is used to drive coating to workpiece, then atomization is achieved, but energy depletion occurs during travel

Engineering Contradiction:

Improvecoating deliveryVSAvoidenergy depletion

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The air hub provides preliminary acceleration and directional control to the atomized coating particles before they travel to the workpiece. By establishing the correct trajectory and velocity profile in advance, the coating particles maintain their energy throughout the travel distance rather than depleting it progressively.

Inventive Principle:

Principle #10Preliminary 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

Significantly increases the transfer efficiency of coatings onto the workpiece by providing additional energy and directional flow, reducing overspray and bounce-back, while ensuring safer particle sizes and improved coating quality.

Implementation Method 1

an attachment which would mount on the front portion of the spray device. The attachment would have a second supply of compressed air which would enter an air hub

Methodology Applied

Scientific EffectCompressed air flow: Pressure Gradient

Implementation Method 2

Depending from the outer sidewall of the air hub are four (4) vanes which are located about 90° to each other

Methodology Applied

Scientific EffectFluid flow direction control: Pressure Gradient

Data Source

PatentUS9308539B2Attachment to improve transfer efficiency for a spraying device

Publication Date: 2016.04.12 SMITH WILLIAM C

AI summary

An attachment to be employed with any spray device is disclosed. The attachment includes four vanes which are radially attached to an air hub with a central aperture, the central aperture adapted to receive the front portion of the spray device therethrough which when activated dispenses an atomizable substance in a pattern toward a workpiece. At the distal end of each of the four vanes, the vane is angled forward such that it generally points toward the workpiece. At the terminal end of each vane is a plurality of compressed air exit apertures. A compressed air source is attached to the air hub which guides the air through air conduits interiorly disposed within each of the vanes, where the compressed air is forced to exit each of the compressed air exit apertures forming an a second pattern which surrounds the atomizable substance pattern, and further boosts or pushes the atomizable substance onto the workpiece. The second pattern reduces overspray, bounce-back, and errant particles, and improves the transfer efficiency of the substance to the workpiece.