Composite Ultrasonic Applicators with Embedded Gas Micro-Applicators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High volume vehicle painting processes face significant capital and operational costs due to high overspray rates and inefficiencies in paint application, with existing equipment struggling to redirect paint momentum effectively and achieve uniform coatings.
Innovation Solution
A method utilizing an array of individually addressable micro-applicators with apertures for fluid and shaping gas flow, allowing precise control over paint application, including varying flow rates, pressures, and droplet sizes, to reduce overspray and improve transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional rotating bell equipment is used to atomize paint, then paint can be applied to vehicles, but overspray increases and transfer efficiency decreases (up to 40% paint waste)
Solution Approach 1:
The patent divides the traditional rotating bell applicator into multiple individual micro-applicators arranged in an array. Each micro-applicator operates independently with its own atomization and shaping gas flow, allowing precise control over paint application to specific zones of the vehicle body, thereby reducing overall overspray while maintaining productivity
Solution Approach 2:
The patent applies shaping gas flow locally at each micro-applicator position to control the direction and distribution of paint droplets. This localized shaping action ensures paint is directed precisely where needed on the vehicle body, improving transfer efficiency and reducing waste compared to the uniform but inefficient atomization of traditional rotating bells
2Ease of operation
If shaping air is applied to redirect paint droplets towards the vehicle, then paint momentum can be compensated, but additional equipment complexity and energy consumption increase
Solution Approach 1:
The patent combines the paint atomization function and the shaping gas delivery function into a single integrated micro-applicator structure. The shaping gas flow is delivered through the same nozzle assembly that atomizes the paint, eliminating the need for separate shaping air systems and reducing overall equipment complexity while maintaining paint direction control
Solution Approach 2:
Each micro-applicator serves multiple functions: it atomizes the paint, delivers shaping gas to control droplet direction, and applies paint to the vehicle body. This multi-functional design reduces the number of separate systems needed compared to traditional equipment that requires separate atomization and shaping air delivery systems
3Productivity
If electrostatics are used to steer droplets towards the vehicle, then paint transfer efficiency improves, but operational costs and equipment complexity increase
Solution Approach 1:
The patent replaces electrostatic fields with a pneumatic shaping gas flow system to control paint droplet direction. The shaping gas (typically air) flows through the micro-applicator and creates a focused jet that directs paint droplets toward the vehicle body, achieving paint steering without requiring complex electrostatic equipment and reducing operational costs
4Productivity
If paint is ejected from an annular slot on a rotating disk, then paint can be transported to the edges of the bell via centrifugal force, but paint momentum becomes mostly lateral rather than towards the vehicle
Solution Approach 1:
The patent replaces the mechanical centrifugal force system of rotating bells with a pneumatic jet system. Instead of relying on centrifugal force to move paint to the edges of a rotating disk, the shaping gas flow directly propels paint droplets toward the vehicle body in the desired direction, eliminating the lateral momentum problem inherent in rotating bell designs
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 approach significantly reduces overspray and increases paint transfer efficiency, leading to lower material and energy consumption, improved paint uniformity, and reduced equipment costs by enabling precise control over paint application patterns and widths.
Implementation Method 1
a shaping gas flows through the second subset of micro-applicators. In some variations, the flow of shaping gas shapes the flow of the liquid from the first subset of micro-applicators to the substrate
Implementation Method 2
Each of the micro-applicators in the first subset of micro-applicators is configured to vibrate an array plate such that a stream of atomized droplets is provided
Implementation Method 3
Each of the micro-applicators in the first subset of micro-applicators is configured to vibrate an array plate such that a stream of atomized droplets is provided
Data Source
AI summary
A method of controlling application of at least one material onto a substrate includes configuring a material applicator having an array plate with an applicator array. The applicator array has a plurality of micro-applicators with a first subset of micro-applicators and a second subset of micro-applicators. Each of the plurality of micro-applicators has a plurality of apertures through which fluid is ejected. The first subset of micro-applicators and the second subset of micro-applicators are individually addressable, and a liquid flows through the first subset of micro-applicators and a shaping gas, e.g., air, flows through the second subset of micro-applicators. The flow of shaping gas shapes the flow of the liquid from the first subset of micro-applicators to the substrate.