Two-Component Spray Gun Post-Atomization Mixing
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Solution Overview
Problem
Conventional coating compositions with multiple reactive components face challenges in 'pot life' due to increased viscosity after mixing, leading to clogging issues and VOC emissions, and existing solutions either require separate atomization of components or chemical additives that may affect curing times.
Innovation Solution
A spray gun design that separates and atomizes two components just before application, using a hollow spray needle and inlet valve system to maintain constant viscosity of individual components, preventing premature mixing and clogging, while allowing for controlled mixing and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
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 over time leading to clogging and limited pot life
Solution Approach 1:
The coating composition is divided into multiple reactive components that are stored separately in individual reservoirs within the spray device. Each component remains separate until the moment of application, preventing premature polymerization and viscosity increase that would cause clogging.
Solution Approach 2:
The spray device is pre-configured with multiple reservoirs containing the reactive components in separate compartments. The system is prepared in advance with all necessary components loaded and separated, ready for immediate simultaneous dispensing without requiring pre-mixing that would start the polymerization reaction.
2Duration of action of moving object
If a greater amount of thinning solvent is added to the pot mix, then the pot life is extended, but VOC emissions increase and curing time is extended
Solution Approach 1:
The coating system separates reactive components from thinning solvents into different reservoirs. The reactive components are kept separate to prevent polymerization, while the solvent can be added in controlled amounts without needing to excessively thin the mixture, reducing VOC emissions while maintaining workable pot life.
Solution Approach 2:
The system changes the physical state and timing of component mixing, keeping reactive components in a separate, non-reacting state until application. This allows for better control of viscosity and pot life without relying on excessive solvent addition.
3Duration of action of moving object
If chemical additives are used to extend pot life, then the reactive components remain stable longer, but the curing rate may be adversely affected
Solution Approach 1:
The system physically separates reactive components that would otherwise require chemical stabilizers to prevent premature reaction. By keeping components in separate reservoirs until the moment of application, the system extends pot life through physical separation rather than chemical inhibition, avoiding any negative impact on curing rate.
4Ease of operation
If two components are separately atomized using separate pumps and injection means, then the components can be mixed after spray, but the device complexity increases
Solution Approach 1:
The spray device combines multiple reservoirs and dispensing mechanisms into a single integrated unit. Multiple reactive components are delivered through a unified spray nozzle system that atomizes all components simultaneously, merging what would otherwise require separate pumps and injection systems into one coordinated device.
Solution Approach 2:
The spray device is designed as a multi-functional unit that can store, dispense, and atomize multiple different reactive components through a single system. The universal design allows the same device to handle various coating formulations with different numbers of components without requiring separate specialized equipment for each component.
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 method extends the 'pot life' of coating compositions by maintaining constant viscosity of individual components during spraying, reducing VOC emissions, and ensuring effective application without premature curing or clogging, enhancing the efficiency and environmental sustainability of the coating process.
Implementation Method 1
separately atomize two components, such as a catalyst and a resin, of a coating composition, and mix the two atomized components after spray
Implementation Method 2
Coatings on automotives or other objects typically comprise polymer networks formed by multiple reactive components of a coating composition
Data Source
AI summary
This invention is directed to a method for producing a coating layer of a coating composition comprising two or more components. The two or more components are mixed post atomization. This invention is further directed to a method for producing a layer of a coating composition comprising a first component and a second component on a substrate using the spray gun.