Patent Grant
11919022
This application is a national stage of, and claims priority to, Patent Cooperation Treaty Application No. PCT/EP2020/081565, filed on May 13, 2022, which application claims priority to German Application No. DE 10 2019 130 612.4, filed on Nov. 13, 2019, which applications are hereby incorporated herein by reference in their entireties.
The disclosure relates to an atomizer (e.g. rotary atomizer) for applying a multi-component paint and an associated operating method.
In modern painting plants for painting motor vehicle body components, rotary atomizers are usually used as application devices, which in one design can also apply a multi-component paint, which is mixed together in the rotary atomizer from a master paint and a hardener. Such a painting system is known, for example, from DE 10 2015 010 158 A1.
A problem here is the collection of paint residues that occur, for example, during a color change.
One possibility for this is the use of so-called wet washout systems. In this case, the multicomponent reactive coating material introduced into the wet washout is filtered out of water with suitable chemicals (e.g. flocculation, floatulation), whereby the filter residue must then be disposed of as hazardous waste, which is extremely costly.
Another possibility is the use of so-called dry rinsing. In this case, the multi-component reactive paint material must not be discharged directly into the paint booth. Separate installations are currently required for this, such as solvent-flushed collection hoppers or collection containers with filter mats, which require a great deal of maintenance and cleaning.
With all currently available solutions, volatile organic compounds (VOCs), among other things, are introduced into the paint booth. These organic components may then have to be purified from the exhaust air in a further process step.
In the case of a color change with the associated flushing and pressurizing processes, the rotary atomizer is arranged, for example, above a rinsed collecting hopper or a collecting container, whereupon the paint residue of the multicomponent paint can then be rinsed out of the rotary atomizer into the collecting hopper or collecting container. However, this requires the rotary atomizer to move to the collecting hopper, which takes additional time and results in a high loss of cycle time, i.e. the time required for a paint change extends the required cycle time of the paint system.
Another disadvantage of this flushing of the multicomponent paint into a collecting hopper or a collecting container is that parallel cleaning of the outer surfaces of the atomizer is not possible during a paint change. As a result, these process steps have to be carried out one after the other, which in turn requires additional time. For example, the rotary atomizer can first be moved into a collecting hopper or collecting container to rinse out paint residues from the multicomponent paint. The rotary atomizer can then be moved into a cleaning device to clean the outer surfaces of the rotary atomizer.
Furthermore, DE 10 2009 020 064 A1 discloses a painting system for painting single-component paint, whereby an intrinsically medium-actuated return valve enables the recirculation of paint foam during a color change.
The disclosure is based on the task of creating a correspondingly improved atomizer and a corresponding operating method.
The disclosure comprises the general technical teaching of flushing paint residues of the multicomponent paint out of the rotary atomizer not in the direction of the application element (e.g., bell cup), but into a separate return. This offers the advantage that two process steps can take place at the same time during a color change, namely on the one hand the flushing of residues of the multicomponent paint from the atomizer and on the other hand the external cleaning of the atomizer. This makes it possible to shorten the cycle time of the painting system, i.e. the operating speed is increased.
The atomizer according to the disclosure has many similarities with the known atomizers as they are known from the prior art.
Thus, the atomizer according to the disclosure also has a master paint connection for supplying a master paint and a hardener connection for supplying a hardener.
In addition, the atomizer according to the disclosure also has a mixer for mixing the master paint with the hardener to form the multicomponent paint. Such a mixer is usually designed as a static mixer (e.g. grid mixer, spiral mixer).
In the atomizer, a hardener line runs from the hardener connection to the mixer. Furthermore, a master paint line runs in the atomizer from the master paint connection to the mixer.
Furthermore, the atomizer contains a main valve for controlling the paint delivery, the main valve being arranged downstream of the mixer and controlling the flow of the multicomponent paint to an application element (e.g. bell cup).
The atomizer according to the disclosure thus takes up hardener and basecoat on the input side, mixes these paint components in the mixer to form a multicomponent paint and then delivers the multicomponent paint via the application element (e.g. bell cup) to the component to be coated.
The atomizer according to the disclosure is now characterized by a first return connection for returning the multicomponent paint from the atomizer to a return system, which occurs, for example, during a color change, as will be described in detail. A first return line runs in the atomizer, which branches off in the atomizer between the mixer and the main valve and opens into the first return connection. During a color change, the main valve is usually closed so that no more multicomponent paint is dispensed via the application element. The residues of the multicomponent paint still present in the atomizer can then be fed via the first return line into the first return connection, which is usually connected to a return system.
It should be mentioned here that the atomizer can also have several main needle valves and several 2K return systems.
In general, it should be mentioned that the atomizer according to the disclosure is preferably a rotary atomizer which has a bell cup as an application element, as is in itself sufficiently known from the prior art. In principle, however, the disclosure can also be implemented with other atomizer types, such as air atomizers.
In a preferred embodiment of the disclosure, a downstream-located controllable first return valve and an upstream-located controllable second return valve, which can preferably be controlled independently of each other, are located in series in the first return line in the atomizer. This offers the possibility that flushing medium is trapped between the two return valves in the first return line to prevent a reaction between different mixed paint systems or to reduce it to a tolerable level.
In addition, the atomizer according to the disclosure preferably has a first flushing connection to supply thinner (flushing agent) and/or pulse air. In practice, pulsed air blasts and thinner are supplied alternately to achieve the best possible flushing effect. A first flushing line runs in the atomizer, starting from the first flushing connection and opening into the first return line downstream of the downstream first return valve. The return line provided in accordance with the disclosure can thus be flushed via this first flushing connection and the first flushing line originating therefrom. For this purpose, a first flushing valve is preferably arranged in the first flushing line in order to control the inflow of thinner or pulsed air from the first flush connection into the first return line.
Furthermore, the atomizer according to the disclosure preferably comprises at least one controllable hardener valve arranged in the hardener line to control the inflow of the hardener. Similarly, there is preferably at least one controllable master paint valve arranged in the master paint line and controlling the inflow of the master paint.
In addition, the atomizer according to the disclosure preferably has a second return connection for returning the master paint separately from the hardener before mixing with the hardener. A second return line runs in the atomizer, which branches off from the master paint line upstream of the master paint valve and opens into the second return connection. A controllable third return valve is preferably arranged in this second return line, which controls the recirculation of the master paint through the second return connection. Thus, during a recirculation of master paint, the master paint valve is usually closed while the third return valve is open, so that the master paint supplied on the inlet side is recirculated into the second return line.
Furthermore, the atomizer according to the disclosure preferably has a second flushing line which starts from a second flushing connection or from the first flushing connection and opens into the master paint line downstream of the master paint valve. Preferably, a second flushing valve is provided, which is arranged in the second flushing line and controls the inflow of flushing agent into the master paint line. In addition, a third flushing line is preferably provided, which starts from a third flushing connection or from the first flushing connection or the second flushing connection and opens into the hardener line downstream of the hardener valve. A third flushing valve is preferably arranged in this third flushing line, which controls the inflow of flushing agent into the hardener line.
Thus, in the atomizer according to the disclosure, the hardener line and the master paint line can preferably be flushed independently of one another, with the flushing agent supply being controlled in each case by a flushing valve.
In addition, the atomizer according to the disclosure can have a short-flushing line which leads downstream of the main valve to the application element and starts from the first flushing connection or from the second flushing connection or from a third flushing connection or from a further fourth flushing connection. In this short-flushing line there is preferably a controllable short-flushing valve which controls the flow of the flushing agent through the short-flushing line.
Furthermore, it should be mentioned that the atomizer according to the disclosure preferably includes a paint tube containing the mixer and the upstream second return valve. Here it should be mentioned that the paint tube preferably also contains the main valve, which can be designed as a main needle valve and has a displaceable valve needle. Here it is possible that the valve needle of the main needle valve is designed as a static mixer (e.g. lattice mixer, spiral mixer), i.e. the valve needle fulfills two functions here. On the one hand, the valve needle serves as a valve element for controlling the material flow. On the other hand, the valve needle also forms the static mixer.
In the preferred embodiment, the upstream second return valve is designed as a diaphragm needle valve. This means that the diaphragm needle valve has a valve seat and a displaceable valve needle which releases or blocks the valve seat depending on its position. In addition, such a diaphragm needle valve is characterized by a valve diaphragm which annularly surrounds the valve needle and serves to drive the valve needle and/or to seal it. Such diaphragm needle valves are known, for example, from WO 2009/019036 A1, so that the contents of this patent application can be fully attributed to the present description with regard to the design structure and operation of a diaphragm needle valve.
Here, the valve seat of the second return valve may be made of steel, while the valve needle of the second return valve may pass through a sealing disc made of plastic and may be made of titanium, for example. Furthermore, the mixer can open into a distributor on the outlet side, which passes on the mixed multicomponent paint and is at least partially made of metal.
It has already been explained above what is meant by a membrane needle valve in the context of the disclosure. In the preferred embodiment, the main valve, the first return valve, the second return valve, the hardener valve and/or the master paint valve are also designed as such membrane needle valves.
Furthermore, it should be mentioned that the disclosure does not only claim protection for the above generally described atomizer according to the disclosure. Rather, the disclosure also claims protection for a corresponding operating method for such an atomizer, in which master paint and hardener are supplied and mixed in the atomizer to form the multicomponent paint, and then finally applied, for example via a rotating bell cup.
The operating method according to the disclosure is characterized by the fact that the multicomponent paint is recirculated through the first return line, which branches off between the mixer and the main valve, during a color change. In contrast to the known rotary atomizer, the residues of the multicomponent paint are therefore not discharged via the application element.
Preferably, the main valve (e.g. main needle valve) of the atomizer (e.g. rotary atomizer) is closed during recirculation of the multicomponent paint.
In the case of a color change, the following steps are then preferably carried out in this sequence to press on the atomizer with new paint:
Closing of the main valve,
In the operating method according to the disclosure, the following steps are preferably carried out for flushing the atomizer during a color change:
To flush the first return line during application of the multicomponent paint, the first flushing valve is then preferably closed and flushing agent is introduced into the first return line. Preferably, solvent and pulsed air are alternately fed in to achieve a good cleaning effect. At the end of the flushing process, solvent is then preferably supplied to partially fill the first return line with the flushing agent.
The design of the atomizer according to the disclosure allows the following steps to be carried out simultaneously or at least overlapping in time:
The disclosure offers several advantages that can be summarized as follows.
The rotary atomizer 1 is used to apply a multicomponent paint via a rotating bell cup 3, as is known from the prior art.
For the supply of a master paint, the rotary atomizer 1 has a master paint connection 4, the master paint connection 4 of the rotary atomizer 1 being supplied with the desired master paint by a color changer 5 in the robot arm 2.
A metering pump 6 is arranged between the color changer 5 and the master paint connection 4 of the rotary atomizer 1, which delivers the master paint with the desired paint flow. The metering pump 6 can be bypassed by a bypass valve By1 connected in parallel.
In addition, the rotary atomizer 1 has a hardener connection 7 for supplying hardener. The hardener is supplied by a valve unit 8 with a hardener valve H1 and a thinner valve VH via a metering pump 9.
In the rotary atomizer 1, a master paint line 10 starts from the master paint connection 4, which opens via a master paint valve SL1 into a static mixer 11, which in the preferred embodiment is designed as a spiral mixer, as shown in
Accordingly, a hardener line 12, in which a hardener valve H1 is arranged to control the inflow of hardener, emanates from the hardener connection 7. The hardener line 12 also opens into the mixer 11, so that the mixer 11 mixes the master paint with the hardener.
Downstream of the mixer 11, a main needle valve HN1 is arranged to control the flow of the multicomponent paint from the mixer 11 to the bell cup 3. The structure and operation of the main needle valve HN1 are shown in
In addition, the rotary atomizer 1 has a return connection 13 for returning master paint to a recirculation system not shown. For this purpose, a return line 14 runs in the rotary atomizer 1, which branches off from the master paint line 10 between the master paint connection 4 and the master paint valve SL1 and opens into the return connection 13. A return valve RF1/SL1 is located in this return line 14, which controls the flow into the recirculation.
Furthermore, the rotary atomizer has a flushing connection 15 for flushing the master paint line 10. A flushing line 16 starts from the flushing connection 15 and opens into the master paint line 10 downstream of the master paint valve SL1. A flushing valve V/PL is located in the flushing line 16 for flushing the master paint line 10.
A valve unit 17 with a thinner valve V and a pulsed air valve PL is located in the robot arm 2 of the painting robot, whereby the valve unit 17 can optionally supply thinner (flushing agent) or pulsed air to the flushing connection 15.
Furthermore, the rotary atomizer 1 comprises a flushing connection 18 for flushing the hardener line 12. A flushing line 19 starts from the flushing connection 18 and opens into the hardener line 12, a flushing valve V/H1 being arranged in the flushing line 19.
Furthermore, the rotary atomizer 1 has short-flushing connections 20, 21 for short-flushing of the rotary atomizer 1, as is known per se from the prior art and therefore need not be described in detail. It is only to be mentioned that the rotary atomizer 1 contains short-flushing valves KSL, KS for short-flushing.
The rotary atomizer 1 is now characterized by a return connection 22, which enables recirculation of the multicomponent paint into a recirculation system not shown. For this purpose, a return line 23 branches off in the rotary atomizer 1 between the mixer 11 and the main needle valve HN1 and opens into the return connection 22. Two return valves RF4, RF41 are located one after the other in the return line 23, whereby the return valve RF4 located upstream is also shown in
For flushing the return line 23, the rotary atomizer 1 has a further flushing connection 24, which can be supplied with thinner or pulse air by the valve unit 17. In the rotary atomizer 1, a flushing line 25 starts from the flushing connection 24, which opens into the return line 23 via a flushing valve V2/PL2 and enables flushing of the return line.
The valves in the robot arm 2 and in the rotary atomizer 1 are partly designed as conventional needle valves without a separating diaphragm, which can be recognized by the corresponding hatching, as indicated in the drawing legend. In part, however, the valves are designed as needle valves with a separating diaphragm, as known per se from WO 2009/019036 A1 GINA—see if there is a U.S. equivalent and if so add the words “which is incorporated herein by reference.
In the following,
The drawings here show an paint tube 26 accommodating the main needle valve HN1, the mixer 11 and the return valve RF4, whereby the paint tube 26 also leads to the bell cup 3, as is known per se from the prior art.
A needle seat 27 is connected to the paint tube 26, with a sealing disk 28 made of POM (polyoxymethylene) being arranged between the paint tube 26 and the needle seat 27.
Finally, a distributor 29 is arranged behind the needle seat 27, which is also made of POM and contains a paint line 30 that leads to the bell cup 3.
The paint tube 26, the sealing disk 28 and the needle seat 27 contain an axially continuous bore 31 which opens into the paint line 30.
A valve needle 32 is displaceable in the bore 31 in the direction of the double arrow, the valve needle 32 having two functions.
Firstly, the valve needle 32 is designed as a spiral mixer and thus forms the mixer 11 for mixing the master paint and the hardener.
On the other hand, the valve needle 32 serves in a conventional manner as a valve element for controlling the paint flow into the paint line 30. For this purpose, the valve needle 32 has a valve head 33 which either clears or closes a corresponding valve seat.
The return valve RF4 is arranged in a further axial bore 34 and has a valve needle 35 which is displaceable in the bore 34 in the direction of the double arrow. The valve needle 35 of the return valve RF4 also has a valve head 36 that either closes (as in
Further,
In the following, the flowchart in
In a first step S1, an initial situation is first shown.
In this initial situation, the main channel is filled with flushing medium, while the return line 23 between the return valves RF4, RF41 is filled with flushing medium. In this initial situation, the return valves RF4, RF41, RF1/SL1 are closed. The main needle valve HN1, the master paint valve SL1 and the hardener valve H1 are also closed, as are the flushing valves V/PL, V/H1 and V2/PL2.
Step S2 now shows the pressurizing of the rotary atomizer 1 with a new paint.
The main channel is filled with the new paint. During this process, the return valves RF4, RF41 are open, while the return valve RF1/SL1 and the main needle valve HN1 are closed. The master paint valve SL1 and the hardener valve H1, on the other hand, are open, while the flushing valves V/PL, V/H1 and V2/PL2 are closed.
At the end of this pressure, the master paint valve SL1 and the hardener valve H1 are then closed first. Next, the return valve RF41 is closed. The return valve RF4 is then closed last. This sequence for closing the valves during press-on ensures that the paint medium/solvent mixture is sealed airtight in the atomizer recirculation. In addition, a reaction with atmospheric moisture can thus be prevented.
In a step S3, painting is then carried out with the new paint. During this step, the return valves RF4, RF41, RF1/SL1 are closed, while the main needle valve HN1, the master paint valve SL1 and the hardener valve H1 are open. The flushing valves V/PL, V/H1 and V2/PL2 are also closed during painting. At the end of the painting process, the main needle valve HN1, the hardener valve H1 and the master paint valve SL1 are closed.
In a next step S4, flushing of the rotary atomizer 1 is then carried out after the end of the painting process. In this process, the return valves RF4, RF41 are opened, while the return valve RF1/SL1, the main needle valve HN1, the master paint valve SL1 and the hardener valve H1 are closed, while the flushing valves V/PL and V/H1 are opened.
In a next step S5, the filling with flushing agent then takes place, whereby the main channel and the flushing line 23 between the flushing valves RF4 and RF41 are filled with flushing agent. The valve position of the various valves is indicated here in step S5.
Finally, in a step S6, a flushing of the recirculation is carried out according to the disclosure, whereby the return line 23 can be flushed during the painting process described above. During this process, the main needle valve HN1, the master paint valve SL1, the hardener valve H1 are open to allow painting. The flushing valves V/PL and V/H1, on the other hand, are closed, which also applies to the return valves RF4, RF41. The flushing valve V2/PL2, on the other hand, is open, and the flushing valve V2/PL2 is closed again at the end of the flushing process.
The disclosure is not limited to the preferred embodiment described above. Rather, a large number of variants and modifications are possible which also make use of the inventive idea and therefore fall within the scope of protection. In particular, the disclosure also claims protection for the subject-matter and the features of the dependent claims independently of the claims referred to in each case and in particular also without the features of the main claim. The disclosure thus comprises various aspects of disclosure which enjoy protection independently of one another.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2019 130 612.4 | Nov 2019 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2020/081565 | 11/10/2020 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2021/094278 | 5/20/2021 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 9782786 | Melcher et al. | Oct 2017 | B2 |
| 10302215 | Melcher et al. | May 2019 | B2 |
| 10807110 | Herre et al. | Oct 2020 | B2 |
| 20040249105 | Nolte et al. | Dec 2004 | A1 |
| 20120114849 | Melcher et al. | May 2012 | A1 |
| 20130108796 | Michelfelder et al. | May 2013 | A1 |
| 20150090347 | Melcher et al. | Apr 2015 | A1 |
| 20180029062 | Melcher et al. | Feb 2018 | A1 |
| 20180185860 | Herre et al. | Jul 2018 | A1 |
| Number | Date | Country |
|---|---|---|
| 201728173 | Feb 2011 | CN |
| 10322998 | Sep 2004 | DE |
| 10 2009 020 064 | Nov 2010 | DE |
| 10 2015 010 158 | Jan 2017 | DE |
| 3444025 | Feb 2019 | EP |
| S62247853 | Oct 1987 | JP |
| 2004076515 | Sep 2004 | WO |
| 2009019036 | Feb 2009 | WO |
| Entry |
|---|
| International Search Report and Written Opinion for PCT/EP2020/081565 dated Feb. 12, 2021 (11 pages; with English translation). |
| German Patent and Trademark Office Action for Application No. DE 10 2019 130 612.4 dated Jul. 15, 2020 (12 pages; with English machine translation). |
| China State Intellectual Property Office First Notice of Examination Action for related application No. CN202080079099.2 dated Nov. 9, 2023 (22 pages; with English machine translation). |
| Number | Date | Country | |
|---|---|---|---|
| 20230148199 A1 | May 2023 | US |
