Static Mixer Cartridge Layout for Compact Multi-Component Sprayers
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Solution Overview
Problem
Existing multi-component coating sprayers face challenges in achieving effective mixing of components without increasing the overall size, which complicates application and increases material costs and inertia, making them unsuitable for certain applications like vehicle body coating and requiring separate programming for single and multi-component products.
Innovation Solution
A multi-component product injection module with a static mixer cartridge that extends the mixing path beyond the length of the mixing body, mounted at the top of the sprayer, and incorporates a helical mixing path within a compact design, allowing efficient mixing without increasing the sprayer's overall length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the axial length of the mixing body is increased to achieve effective mixing, then the mixing efficiency is improved, but the overall axial size of the injection module is increased, making the sprayer bulkier and more difficult to move
Solution Approach 1:
The patent transforms the linear axial extension of the mixing path into a three-dimensional helical path within the cartridge. The helical baffles create a mixing path that winds through the mixing body, allowing the developed length of the mixing path to be strictly greater than the axial length of the mixing body. This dimensional transformation enables effective mixing without increasing the overall axial size of the injection module.
Solution Approach 2:
The patent employs a helical (curved) mixing path instead of a straight linear path. The helical baffles create a curved flow path that maximizes the mixing length within the limited axial space of the cartridge. This curvature allows the mixing path to extend beyond the axial length of the mixing body while maintaining a compact overall size.
2Manufacturing precision
If the length of the mixing body is increased to achieve effective mixing, then the mixing efficiency is improved, but the material cost and inertia of the sprayer are increased
Solution Approach 1:
The helical three-dimensional mixing path allows the mixing length to be extended without proportionally increasing the axial length and volume of the mixing body. This enables effective mixing with reduced material usage and lower cost compared to a linear extension approach.
Solution Approach 2:
The helical baffles are nested within the mixing body, creating a compact structure where the mixing path is contained within the limited volume of the cartridge. This nested arrangement maximizes the mixing path length within the available space, reducing the overall size and material requirements.
3Manufacturing precision
If the axial length of the mixing body is increased, then the mixing path length is extended, but the overhang and inertia of the sprayer relative to the robot handle are increased
Solution Approach 1:
The helical mixing path achieves extended mixing length through three-dimensional winding within the cartridge rather than axial extension. This maintains a compact overall sprayer size with reduced overhang, improving handling characteristics and allowing consistent trajectory programming for both single-component and multi-component sprayers.
Solution Approach 2:
The curved helical path within the compact cartridge reduces the axial overhang of the sprayer. This improved balance and reduced overhang enhance the ease of operation and simplify trajectory programming compared to linear extensions.
4Manufacturing precision
If different axial lengths are used for single-component and multi-component sprayers, then effective mixing is achieved, but the trajectory programming becomes complex
Solution Approach 1:
The helical mixing cartridge provides a compact multi-component mixing solution that matches the axial length of single-component sprayers. This universality allows both single-component and multi-component sprayers to share the same trajectory programming, simplifying operations in workshops where both types are used.
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 solution ensures effective mixing of coating components while maintaining the sprayer's compactness, reducing overhang and material costs, and allowing shared trajectory programming for single and multi-component products, suitable for vehicle body coating.
Implementation Method 1
a multi-component product mixing path equipped with fluid mixing baffles
Data Source
Figure 1
Figure 2A~2E
Figure 3A~3B
AI summary
The present invention relates to a multi-component product injection module for a coating product sprayer. This injection module comprises an injector and a cartridge (40) forming a static mixer and defining, within a mixing body (402), a mixing path (T1) for the multi-component product, equipped with fluid mixing baffles (410). A developed length of the multi-component product mixing path (T1) is strictly greater than a length (L402) of the mixing body (402), measured parallel to a longitudinal axis (X40) of the cartridge (40). The cartridge (40) is configured to be mounted at the top of the coating product sprayer (1), on the side of this sprayer facing its spraying element (6), by being inserted in the center of a rotor of a turbine (8) of this sprayer, or in the spraying element.