Fluid sprinkling – spraying – and diffusing – Processes – Including mixing or combining with air – gas or steam
Patent
1990-11-07
1993-01-12
Kashnikow, Andres
Fluid sprinkling, spraying, and diffusing
Processes
Including mixing or combining with air, gas or steam
239 11, 239296, 239299, 239422, B05B 708, B05B 128, B05B 908
Patent
active
051783266
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND ART
The present invention relates generally to multi-component spraying systems and, more particularly, to air-assisted, airless-atomization, plural component spraying systems and methods.
Multi-component spraying systems have been used, for example, in manufacturing plastic articles by applying resinous materials to a mold or preform for an article. In such systems, a liquid resin and a catalyst for the resin are formed into spray particles directed to a substrate where the catalyst and resin react and harden to form the article. In such applications, the resin and catalyst components are preferably mixed together; and the mixture is sprayed onto the substrate. For example, in manufacturing articles with polyester resin, a catalyzing agent for the polyester resin is mixed with the resin; and the resin-catalyst mixture is applied to the substrate. In internal mix systems, the resin and catalyst are mixed within the spraying apparatus; and the mixture is atomized by a spray nozzle and directed onto the substrate. In external mix systems, the resin and catalyst are mixed externally of the apparatus after the resin and catalyst have been atomized. In both external mix and internal mix systems, complete and thorough mixing of the resin and catalyst is important to avoid non-uniform hardening of the resin on the substrate and other undesirable results. Multi-component materials have also been used, for example, in the manufacture of insulating foams by mixing and spraying the components of a foam-producing combination onto a substrate where they produce a hardened foam-like coating. More recently, multi-component painting systems have been developed that include plural components that react, when mixed, to form hardened decorative and protective coatings. Multi-component spraying systems have thus a multiplicity of applications, each with its specific requirements.
In many spraying systems, large quantities of pressurized air are used to atomize the liquid components. Such systems are expensive to operate and have a number of operational inadequacies. It is expensive to compress air, and the large quantities of compressed air used by existing systems impose a significant operating cost on the system. In addition, the blast of compressed air used to atomize the liquid components carries a significant quantity of spray particles away from the substrate, wastes the expensive material, creates an unclean spray area and generally requires overspray collection systems and contributes to the problem of operating such manufacturing operations safely. Furthermore, the use of large quantities of air during operation of the system can often create an undesirable spread of fumes.
In order to overcome some of the inadequacies attending the use of pressurized air to atomize components dispensed from a spraying apparatus, spraying systems have been developed which incorporate airless atomization techniques.
In prior airless atomization devices, an airless spray nozzle has been used to atomize liquid materials which are pumped at high pressure, that is, pressures generally exceeding 500-600 psi and more frequently in excess of 800 psi, typical operating pressure being 1000-1500 psi. The most commonly used airless nozzle includes an internal, hemispherical passage termination which is cut through by an external, V-shaped groove to form an elongated, elliptical-like orifice. Liquid material pumped at high pressures through such a spray nozzle is forced by the hemispherical termination of the passageway to converge in its flow at and through the elongated orifice. Because of the converging flow at the orifice, the liquid material is expelled through the orifice into a planar, expanding, fan-like film which breaks into spray particles which are carried by their momentum to the article target.
With viscous fluids, high pressures of 1000-1500 psi are required. Such high operating pressures impose a strain on system components reducing their reliability, require generally expensive components in the fluid delivery systems
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Kukesh Timothy S.
Mansfield Gregory
Glas-Craft, Inc.
Grant William
Kashnikow Andres
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