Spray Gun Nozzle Taper Angles for Uniform Mist Distribution
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Solution Overview
Problem
Conventional spray guns for powder and particle processing have a narrow spray pattern and significant variations in spray amount, leading to uneven coating and increased processing time, which can be costly and inefficient due to the need for multiple guns and increased maintenance.
Innovation Solution
A spray gun design that includes a nozzle body with a liquid ejection port and an air cap with pattern air holes to control the spray mist flow, maintaining a stable oval-shaped pattern and reducing spray area variations by jetting atomizing air towards the nozzle's periphery and pattern air to the mist flow in a spreading-suppressed region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional spray gun is used, then the spray gun structure is simple, but the spray pattern is narrow and the spray amount varies significantly within the spray area
Solution Approach 1:
The air cap is divided into multiple functional regions: a central atomizing air jetting portion that atomizes the liquid, and multiple pattern air jetting portions arranged radially that control the spray pattern. This segmentation allows independent control of atomization and pattern formation, achieving both wide coverage and uniform distribution.
Solution Approach 2:
Different regions of the air cap provide different air flow characteristics: the central region provides high-velocity atomizing air, while the peripheral pattern air holes provide controlled flow to shape the spray pattern. This local differentiation enables precise control over spray uniformity and width simultaneously.
2Manufacturing precision
If the supply amount of coating liquid is reduced to suppress variation in spray amount, then the spray amount uniformity is improved, but the coating process time increases
Solution Approach 1:
Compressed air is utilized through multiple pathways: atomizing air breaks the liquid into fine droplets, while pattern air actively shapes and distributes the spray cone. This pneumatic control system enables large liquid flow rates to be delivered uniformly across the spray area, maintaining precision while increasing productivity.
3Manufacturing precision
If multiple spray guns are used to achieve wide and uniform spraying, then the spray uniformity is improved, but the apparatus price and maintenance requirements increase
Solution Approach 1:
The air cap integrates multiple functions into a single component: it provides atomization, pattern formation, and spray distribution control all in one device. This multi-functional design replaces what would otherwise require multiple separate spray guns, reducing system complexity while maintaining uniform wide-area coverage.
4Manufacturing precision
If multiple spray guns are used to achieve wide and uniform spraying, then the spray uniformity is improved, but the installation and maintenance time increases
Solution Approach 1:
The spray gun merges the functions of multiple spray guns into a single integrated nozzle assembly with a unified air cap. This consolidation reduces the number of components that need to be installed and maintained, cutting down setup and maintenance time while delivering the uniform wide spray pattern that would otherwise require multiple guns.
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 achieves a wider, more uniform spray pattern, preventing local wetting and ensuring stable product quality while reducing processing time and costs by minimizing the number of spray guns and maintenance requirements.
Implementation Method 1
spray liquid ejected from the liquid ejection port and atomized by atomizing air jetted from the periphery of the nozzle portion
Implementation Method 2
pattern air hole which is disposed on the front side relative to the liquid ejection port and through which pattern air is jetted to a mist flow of the spray liquid
Data Source
AI summary
A spray gun (1) forms a desired spray pattern by atomizing by means of atomizing air (A) a spray liquid which is sprayed from a liquid ejection port (44) opened/closed by a needle valve (4), and jetting pattern air (P) to the flow of spray mist of the atomized spray liquid. A nozzle taper angle (θ1) is set in a range of 5° to 15°, and a cap taper angle (θ2) is set in a range of 20° to 40°. Atomizing air (A) is jetted from a nozzle insertion hole (58) toward the center of a nozzle (3). Pattern air (P) is jetted in a spreading suppressed region (R) wherein the flow of the spray mist does not spread over an area greater than or equal to a predetermined cross-sectional area, to the flow of spray mist, and as a result, the spray mist is more uniformly sprayed over a wide range.