Valve Jet Nozzle for Mask-Free 2K Coating
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Solution Overview
Problem
Current industrial painting technologies face challenges in achieving well-defined paint edges without masking substrates, particularly in efficiently applying industry-standard paint formulations in the transport, furniture, and flooring industries, where precise application and minimal solvent evaporation are required.
Innovation Solution
A digital printing process utilizing a nozzle with a closable opening, allowing controlled discharge of solvent-based two-component paint droplets, which combine to form an uninterrupted layer on the substrate, with parameters such as pressure ≥1.2 bar and nozzle diameter ≥80 μm to ≤250 μm, enabling precise placement and reduced solvent evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spray painting is used, then coating application is achieved, but paint edges are poorly defined and masking is required
Solution Approach 1:
The coating application is segmented into discrete droplets that are individually controlled and deposited at precise locations. The printing head contains multiple independently controllable nozzles that discharge droplets only where needed, creating well-defined edges without requiring physical masks to prevent overspray.
Solution Approach 2:
The mechanical masking system is replaced with a digitally controlled droplet discharge system. Instead of using physical masks to define boundaries, the invention uses electronically controlled valves to open or close nozzle openings based on digital instructions, achieving precise edge definition through digital control rather than mechanical barriers.
2Quantity of substance
If standard inkjet printing is used, then material application is achieved, but high viscosity coating compositions cannot be processed
Solution Approach 1:
The nozzle parameters are specifically optimized to handle high viscosity materials. The nozzle opening diameter is set between 80 μm and 250 μm, and the closing pressure is maintained between 1.2 bar and 3.5 bar. These parameter changes enable the system to process coating compositions with viscosities up to 3000 mPa s, which is ten times higher than typical inkjet materials, while still achieving reliable droplet discharge.
3Productivity
If rapid droplet discharge is used, then productivity is improved, but solvent evaporation increases reducing material yield
Solution Approach 1:
The system uses periodic, pulsed droplet discharge rather than continuous spraying. Each droplet is discharged as a discrete pulse with controlled timing and spacing. This periodic action allows the droplets to be deposited quickly for high productivity while minimizing the time droplets are in transit, thereby reducing solvent evaporation and improving material yield.
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 process allows for efficient and economic application of coatings with high material yield, achieving well-defined edges and reduced environmental impact by minimizing solvent loss, resulting in high-quality, uninterrupted coatings with significant time and cost savings.
Implementation Method 1
the discharge of droplets of coating composition from a nozzle having a closable opening... when the opening of the nozzle is closed a pressure of ≥1.2 bar to ≤3.5 bar acts upon the coating composition
Data Source
AI summary
The invention relates to a 2K coating formulation that is printed without a mask using a valve jet printer.