Variable Flow Pneumatic Piston for Two-Component Spray Gun
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Solution Overview
Problem
Existing spray guns for applying plural component materials, such as fast set foams, lack the ability to adjust flow rates dynamically, limiting operator control over the application process.
Innovation Solution
A pneumatic piston travel mechanism with a multi-position mechanical stop allows for on-the-fly selection of fluid flow rates, enabling the operator to close, partially open, or fully open fluid ports, with fine-tune adjustment for the partially open position, using a simple knob or operator input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed piston travel mechanism is used, then the structure is simple, but the flow rate cannot be adjusted dynamically
Solution Approach 1:
The piston travel mechanism is made dynamic by allowing the piston position to be adjusted along the cylinder bore. The piston can be positioned at different locations (first position for closed ports, second position for partially open ports, third position for fully open ports) to enable variable flow rates during operation.
Solution Approach 2:
The flow rate parameter is changed by altering the piston position parameter. By moving the piston to different positions along the cylinder bore, the degree of port opening changes, thereby controlling the fluid flow rate. This includes fine-tune adjustment capability for precise flow control.
2Ease of operation
If multi-position mechanical stop is added, then flow rate selection is enabled, but device complexity increases
Solution Approach 1:
The mechanical stop is designed to be self-positioning through the interaction between the piston and the stop surface. When the piston moves, it automatically engages with the mechanical stop at predetermined positions, eliminating the need for complex external control mechanisms. The operator simply needs to move the piston, and the system automatically selects the appropriate flow rate position.
3Measurement precision
If fine-tune adjustment is incorporated, then flow control precision is improved, but mechanism complexity increases
Solution Approach 1:
Instead of providing continuous adjustment mechanism, the design provides partial adjustment through discrete piston positions. The fine-tune adjustment is achieved by allowing the piston to be positioned at multiple discrete locations along the cylinder bore, providing sufficient flow control precision without requiring complex continuous adjustment mechanisms.
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
Enables precise control over the flow rates of two-component materials, allowing for optimized application of plural component materials by allowing the operator to select and adjust flow rates as needed, enhancing operational efficiency.
Implementation Method 1
Pneumatic piston travel, which determines on/off fluid flow
Data Source
AI summary
A two component spray gun with low/high flow rates allows the operator to spray in confined areas at lower flow without having to change the mix module. The lower flow reduces undesirable “spray back” and will also help reduce material waste. Pneumatic piston 12 travel, which determines on/off fluid flow, can be selected on the fly to either close the fluid ports 14 which stops fluid flow, partially open the fluid ports 14 which limits fluid flow, or to fully open the fluid ports 14 to allow for maximum flow. Pneumatic piston 12 travel can be limited by means of a simple multi-position mechanical stop plunger 16. The stop bar 22 can be connected to a knob 18 or other operator input and turned or adjusted to the desired position.