Spray Gun Nozzle Guide Faces for Adjustable Spray Area
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Solution Overview
Problem
Conventional spray guns have a limited spray area and cannot adjust the pattern of the spray, making them inefficient for applying paint to larger areas without modifying the existing parts.
Innovation Solution
The nozzle features two symmetrically located guide faces with tapered surfaces between inner peripheries of the air cap, which increase the range of air flow and paint spray area, allowing for adjustment by rotating the air cap and varying the shape and size of the guide faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If conventional spray gun design is used, then the structure is simple and easy to manufacture, but the spray area is limited and cannot be adjusted
Solution Approach 1:
The air cap is divided into multiple functional sections: central path for main air flow, multiple sub-paths for secondary air flow, and multiple air paths around the central path. This segmentation allows each section to contribute differently to the overall spray pattern, enabling wider coverage area while maintaining a relatively simple integrated structure that can be manufactured as a single component.
Solution Approach 2:
The invention extends the spray area by utilizing multiple dimensions: the central path provides vertical spray coverage, while the surrounding air paths and sub-paths extend horizontal coverage. The air cap rotates to adjust the spray pattern in different directions, effectively using angular dimension to expand the covered area without increasing the linear dimensions of the nozzle components.
2Adaptability or versatility
If the spray pattern is made adjustable, then the versatility increases, but the device complexity increases requiring modification of existing parts
Solution Approach 1:
The air cap is designed with multiple air paths and sub-paths that can serve different functions depending on rotation position. The same air cap structure can produce different spray patterns (circular, flat, concentrated, or dispersed) by rotating to different angles, eliminating the need for multiple specialized components or modifications to the existing spray gun structure.
Solution Approach 2:
The air cap is made rotatable relative to the nozzle, transforming a static spray pattern into a dynamic adjustable one. This rotational degree of freedom allows the user to adjust the spray pattern on-the-fly without changing physical components or modifying the spray gun structure, achieving versatility through simple mechanical movement.
3Productivity
If fixed spray pattern is used, then the manufacturing precision is easier to achieve, but the productivity is reduced due to limited coverage area
Solution Approach 1:
The spray pattern is segmented into multiple zones controlled by different air paths: central path for core spray, sub-paths for edge coverage, and surrounding air paths for intermediate zones. This segmentation allows each zone to be optimized independently while maintaining overall pattern control, achieving both wide coverage and sufficient precision for productive paint application.
Solution Approach 2:
The invention achieves wider coverage (improving productivity) by utilizing angular dimension through rotation of the air cap. Different rotation angles provide different spray patterns suitable for different application scenarios, allowing the system to maintain manufacturing precision while expanding the effective work area and reducing the number of passes needed.
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
This design enables a wider and longer spray area without changing the existing spray gun parts, saving time and labor costs, and allows for flexible adjustment of the spray area according to practical needs.
Implementation Method 1
by the Siphon principle, the air is ejected from the gap 111 between the central path 121 and the nozzle 11, so that the paint in the paint path 112 is sprayed out from the nozzle 11
Implementation Method 2
Two guide faces each are a tapered face which is connected between the first and second inner peripheries of the central path of the air cap. The two guide faces are located symmetrically relative to the central path. Two air holes are respectively defined between the two guide faces and the nozzle.
Data Source
AI summary
A nozzle of a spray gun includes an air cap, a board, a cover and a nozzle. The air cap has a central path. The central path has a first inner periphery and a second inner periphery which is larger than the first inner periphery. Two guide faces each are a tapered face which is connected between the first and second inner peripheries of the central path of the air cap. The two guide faces are located symmetrically relative to the central path. Two air holes are respectively defined between the two guide faces and the nozzle. The air flow from the guide faces interests the air flow form the air holes to increase the range of the air flow to guide the paint in the paint path to be ejected from the nozzle.