Two-Component Spray Gun Gravity Feed Atomization
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Solution Overview
Problem
Coating compositions with multiple reactive components face a short 'pot life' due to increased viscosity after mixing, leading to clogging issues and VOC emissions when thinning agents are used to extend this life, and existing solutions require separate atomization and complex pumping systems.
Innovation Solution
A spray gun design that maintains two components separate until atomization, using a hollow spray needle and inlet valve system to control the flow, allowing each component to be conveyed to the nozzle by gravity and mixed only during spraying, preventing premature reaction and maintaining constant viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple reactive components are mixed together to form a pot mix prior to spraying, then the coating composition can be applied, but the viscosity increases rapidly causing short pot life and clogging
Solution Approach 1:
The spray device segments the coating composition into multiple separate components that are stored in individual reservoirs and delivered through separate pathways. The components remain separated until the moment of atomization at the nozzle, preventing premature polymerization and viscosity increase, thereby extending pot life while maintaining application efficiency.
2Loss of time
If thinning solvent is added to extend pot life, then the spraying time is extended, but VOC emissions increase and curing time increases
Solution Approach 1:
The invention changes the physical state and delivery mechanism of the coating components by using separate reservoirs and gravity-fed delivery systems with atomization. This eliminates the need for thinning solvents to extend pot life, thereby reducing VOC emissions while maintaining extended sprayability through controlled separation of reactive components.
3Loss of time
If separate atomization of two components is used, then pot life is extended, but separate pumps and injection means are required increasing device complexity
Solution Approach 1:
The invention extracts the reactive components from a pre-mixed state and places them in separate reservoirs with separate delivery pathways. This eliminates the need for complex pumping and injection systems while achieving separate atomization, as the components are delivered through simple gravity-fed systems with separate nozzles or mixed at the atomization point.
4Ease of operation
If components are mixed prior to spraying, then coating application is possible, but the spray gun may become clogged with crosslinked polymer materials
Solution Approach 1:
The invention performs preliminary separation of the reactive components, storing them in separate reservoirs and delivering them through separate pathways to the atomization point. This prevents premature crosslinking and polymerization that would cause clogging, while still enabling complete coating application when the components are properly mixed at the nozzle during atomization.
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 extends the 'pot life' of the coating composition, reduces VOC emissions, and allows for efficient spraying without clogging, while maintaining individual component viscosities constant during use, enabling effective application of coatings with rapid viscosity increase when mixed together.
Implementation Method 1
said second inlet (8) is configured to receive said second component by gravity and connected to said longitudinal channel for conveying said second component to said nozzle
Implementation Method 2
providing a pressurized carrier to said carrier inlet; and producing atomized said first component and atomized said second component to form an atomized coating mixture
Data Source
AI summary
This invention is directed to a spray device for spraying two or more components. The two or more components are maintained separated in the spray device and are mixed post atomization. This invention is also directed to a gravity fed spray gun and a system for spraying two or more components. This invention is further directed to a kit for converting an existing conventional single-component spray gun typically used for spraying a single component to a two-component spray gun for spraying two components.