UNIVERSAL ATOMIZER

• US 20110086166A1
• Filed: 06/12/2009
• Published: 04/14/2011
• Est. Priority Date: 06/12/2008
• Status: Active Grant

• Current Assignee: Duerr Systems GmbH
• Original Assignee: Duerr Systems GmbH
• Inventors: Nolte, Hans-Jürgen, Fischer, Andreas, Marquardt, Peter, Berkowitsch, Jürgen
• Granted Patent: US 8,881,672 B2
• Time in Patent Office: Days
• US Class Current: 427/248.1
• CPC Class Codes: B05B 5/0403 characterised by the rotating member
• CPC Class Codes: B05B 5/0407 with a spraying edge, e.g. like a cup or a bell
• CPC Class Codes: B05B 5/0426 Means for supplying shaping gas
• CPC Class Codes: B05C 5/00 Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work B05C7/00 takes precedence; essentially involving spraying or electrostatic projection B05B
• CPC Class Codes: C23C 16/06 characterised by the deposition of metallic material

Abstract

The exemplary illustrations relate to an atomization system for a rotary atomizer for applying a coating agent, comprising a rotatably supported bell plate for atomizing the coating agent and for dispensing a spray jet of the coating agent, and comprising a guiding air ring for dispensing a first guiding air flow and a second guiding air flow for producing the spray jet dispensed by the bell plate. The two guiding air flows may comprise separate guiding air flow feeds and may further be set independently from each other. An exemplary bell plate and the guiding air ring may be designed such that the atomization system is suitable for coating the inside of chassis parts of motor vehicles and for coating the outside of chassis parts of motor vehicles.

Claims

1. Atomisation system for a rotary atomiser for the application of a coating agent, comprising:

a rotatably mounted bell cup configured to atomize of the coating agent and discharge a spray jet of the coating agent,

a shaping air ring configured to discharge a first shaping air and a second shaping air for shaping the spray jet discharged by the bell cup, wherein the two shaping airs have separate shaping air inlets and are adjustable independently of one another,

wherein the bell cup and the shaping air ring are designed in such a manner that the atomisation system is suitable for an interior painting of motor vehicle body components and for an exterior painting of motor vehicle body components.

2. Atomisation system according to claim 1, wherein the bell cup and the shaping air ring are configured to apply a metallic paint.

3. Atomisation system according to claim 1, wherein

a) the bell cup has an annular circumferential spray edge with a predetermined external diameter, and

b) for discharging the first shaping air, the shaping air ring has a first shaping air nozzle annulus with a plurality of shaping air nozzles arranged in an annularly distributed manner, wherein the first shaping air nozzle annulus has a first diameter which is essentially equal to the external diameter of the spray edge of the bell cup, so that the first shaping air is directed onto the spray edge of the bell cup, and

b) for discharging the second shaping air, the shaping air ring has a second shaping air nozzle annulus with a plurality of shaping air nozzles arranged in an annularly distributed manner, wherein the second shaping air nozzle annulus has a second diameter which is essentially equal to the external diameter of the spray edge of the bell cup, so that the second shaping air is directed onto the spray edge of the bell cup.

4. Atomisation system according to claim 3, wherein

a) the shaping air nozzles of the first shaping air nozzle annulus are orientated axially and axially discharge the first shaping air, and

b) the shaping air nozzles of the second shaping air nozzle annulus are orientated in the circumferential direction against the direction of rotation of the bell cup and discharge the second shaping air with a predetermined angle of twist in the circumferential direction.

5. Atomisation system according to claim 4, wherein

a) the twisted shaping air nozzles of the second shaping air nozzle annulus are arranged with a predetermined radial inward offset with respect to the axially orientated shaping air nozzles of the first shaping air nozzle annulus,

b) the radial offset between the twisted shaping air nozzles and the axially orientated shaping air nozzles is dimensioned as a function of the angle of twist in such a manner that the twisted second shaping air is directed onto the spray edge of the bell cup.

6. Atomisation system according to claim 4, wherein

a) the twisted shaping air nozzles have a smaller nozzle opening than the axially orientated shaping air nozzles, and

b) the twisted shaping air nozzles have a smaller jet expansion than the axially orientated shaping air nozzles.

7. Atomisation system according to claim 1, wherein

a) the axially orientated first shaping air has a jet expansion which is dimensioned in such a manner that the shaping air jets from the directly adjacent shaping air nozzles adjoin one another without any gaps in the circumferential direction or overlap in the circumferential direction at the spray edge of the bell cup, and

b) the first shaping air twisted in the circumferential direction has a jet expansion which is dimensioned in such a manner that the shaping air jets from the directly adjacent shaping air nozzles adjoin one another without any gaps in the circumferential direction or overlap in the circumferential direction at the spray edge of the bell cup.

8. Atomisation system according to claim 1, wherein

a) the shaping air ring has an annular depression in its end face, and

b) in that the bell cup has an annular1y circumferential bell cup rear edge on its rear side, which fits axially into the annular depression in the shaping air ring, so that the bell cup has a certain axial enclosure depth.

9. Atomisation system according to claim 8, wherein

a) the bell cup rear edge is rounded with a certain radius of curvature, and

b) the annular depression in the shaping air ring is rounded with a certain radius of curvature, and

c) the radius of curvature of the rounding of the bell cup rear edge is smaller than the radius of curvature of the rounding of the annular depression.

10. Atomisation system according to claim 1, wherein between the bell cup and the shaping air ring, there is here a gap with a certain gap width, wherein the gap width increases inwardly from the outside in the gap longitudinal direction.

11. Atomisation system according to claim 1, wherein

a) a turbine is provided for driving the bell cup, which drives a bell cup shaft, on which the bell cup is mounted, and

b) the shaping air ring is fixed directly on the turbine.

12. Atomisation system according to claim 11, wherein the shaping air ring encases the region of the bell cup shaft between the bell cup and the turbine completely.

13. Atomisation system according to claim 1, wherein

a) the external diameter of the bell cup and the diameter of the two shaping air nozzle annuluses is larger than 45 mm, and

b) the external diameter of the bell cup and the diameter of the two shaping air nozzle annuluses is smaller than 60 mm, and

c) the twisted shaping air nozzles have a nozzle diameter of more than 0.5 mm, and

d) the twisted shaping air nozzles have a nozzle diameter of less than 0.9 mm, and

e) the axially orientated shaping air nozzles have a nozzle diameter of more than 0.5 mm, and

f) the axially orientated shaping air nozzles have a nozzle diameter of less than 0.9 mm, and

g) the diameter of the first and of the second shaping air nozzle annulus has a radial deviation of less than ±

3 mm compared to the external diameter of the bell cup, and

h) the angle of twist of the twisted shaping air nozzles is larger than 40°

, and

i) the angle of twist of the twisted shaping air nozzles is smaller than 70°

, and

j) the bell cup has a peripheral surface with a peripheral surface angle of more than 5°

with respect to the axis of rotation of the bell cup, and

k) the bell cup has a peripheral surface with a peripheral surface angle of less than 40°

with respect to the axis of rotation of the bell cup, and

l) the bell cup has an axial peripheral surface length of less than 25 mm, and

m) the bell cup has an axial peripheral surface length of more than 5 mm, and

n) the bell cup and the shaping air ring have an enclosure depth in the axial direction of less than 10 mm, and

o) the bell cup and the shaping air ring have an enclosure depth in the axial direction of more than 2 mm, and

p) an axial spacing of more than 1 mm, between the shaping air nozzles and the spray edge of the bell cup, and

q) an axial spacing of less than 15 mm, between the shaping air nozzles and the spray edge of the bell cup, and

r) the radius of curvature of the rounding of the bell cup rear edge is larger than 2 mm, and

s) the radius of curvature of the rounding of the bell cup rear edge is smaller than 5 mm, and

t) the radius of curvature of the rounding of the annular depression in the shaping air ring is larger than 2 mm, and

u) the radius of curvature of the rounding of the annular depression in the shaping air ring is smaller than 5 mm, and

v) in that the gap width between the bell cup and the shaping air ring is larger than 0.5 mm, and

w) the gap width between the bell cup and the shaping air ring is smaller than 5 mm, and

x) the gap width between the bell cup and the shaping air ring increases inwardly from the outside by more than 1 mm, and

y) the bell cup has an overflow surface which is inclined with an angle of more than 50°

with respect to the axis of rotation of the bell cup, and

z) the bell cup has an overflow surface which is inclined with an angle of less than 90°

with respect to the axis of rotation of the bell cup.

14. Atomisation system according to claim 1, further comprising

a) an application efficiency according to German industrial standard DIN EN 13966-1 which is greater than 55% in the case of interior painting and in the case of exterior painting and in the case of metallic painting, and

b) a total colour difference Δ

E* of less than ±

1 in the case of interior painting and in the case of exterior painting and in the case of metallic painting.

15. Painting installation for the painting of motor vehicle body components with an atomisation system according to claim 1 for the interior painting of the motor vehicle body components and for the exterior painting of the motor vehicle body components and also for the painting of metallic paints and other effect paints.

16. Painting installation according to claim 15, further comprising a paint booth, in which the atomisation system carries out the interior painting of the motor vehicle body components and the exterior painting of the motor vehicle body components and also the painting of metallic paints.

17. Method of operation for an atomisation system with a bell cup and a shaping air ring with two separately controllable shaping airs, according to claim 1, wherein the atomisation system is used for the interior painting of motor vehicle body components and for the interior painting of motor vehicle body components.

18. Method of operation according to claim 17, wherein the atomisation system is also used for the application of metallic paint.

19. Method of operation according to claim 17, wherein

a) the bell cup is driven with a speed of more than 5,000 min⁻

1 during the interior painting, and

b) the bell cup is driven with a speed of less than 40,000 min<sup>−

1</sup> during the interior painting, and

c) the bell cup is driven with a speed of more than 30,000 min<sup>−

1</sup> during the exterior painting, and

d) the bell cup is driven with a speed of less than 70,000 min<sup>−

1</sup> during the exterior painting, and

e) the bell cup is driven with a speed of more than 10,000 min<sup>−

1</sup> during the metallic painting, and

f) the bell cup is driven with a speed of less than 70,000 min<sup>−

1</sup> during the metallic painting, and

g) the bell cup applies a colour quantity of more than 100 ml/min, and

h) the bell cup applies a colour quantity of less than 1,200 ml/min, and

i) a smaller shaping air flow is discharged from the twisted shaping air nozzles than from the axially orientated shaping air nozzles,

j) a shaping air flow of more than 100 Nl/min, is discharged from the twisted shaping air nozzles, and

k) a shaping air flow of less than 700 Nl/min is discharged from the twisted shaping air nozzles, and

l) a shaping air flow of more than 100 Nl/min is discharged from the axially orientated shaping air nozzles, and

m) a shaping air flow of less than 800 Nl/min is discharged from the axially orientated shaping air nozzles, and

n) the application efficiency according to German industrial standard DIN EN 13966-1 is greater than 55% independently of the paint system used, and

o) in that the application efficiency according to German industrial standard DIN EN 13966-1 is greater than 55% during the interior painting independently of the paint system used, and

p) the application efficiency according to DIN EN 13966-1 is greater than 75% during the exterior painting independently of the paint system used, and

q) during exterior painting, a jet width of more than 50 mm is set by means of the shaping airs based on the SB50 value on the component, and

r) during exterior painting, a jet width of less than 600 mm is set by means of the shaping airs based on the SB50 value on the component, and

s) during interior painting, a jet width of more than 50 mm is set by means of the shaping airs based on the SB50 value on the component, and

t) during interior painting, a jet width of less than 300 mm is set by means of the shaping airs based on the SB50 value on the component.

20. Method of operation according claim 17, wherein:

a) the rotating bell cup has a certain atomisation effect on the coating agent, and

b) the two shaping airs have a certain atomisation effect on the coating agent, and

c) the atomisation effect of the shaping airs is at least 30% of the atomisation effect of the rotating bell cup.

22. Method of operation according claim 18, wherein:

the rotating bell cup has a certain atomisation effect on the coating agent, and

the two shaping airs have a certain atomisation effect on the coating agent, and

the atomisation effect of the shaping airs is at least 30% of the atomisation effect of the rotating bell cup.

23. Method of operation according claim 19, wherein:

the rotating bell cup has a certain atomisation effect on the coating agent, and

the two shaping airs have a certain atomisation effect on the coating agent, and

the atomisation effect of the shaping airs is at least 30% of the atomisation effect of the rotating bell cup.

21. Use of a rotary atomiser for the exterior painting of motor vehicle body components and for the interior painting of motor vehicle body components and for metallic painting.