Ultrasonic atomizer with acoustic focusing device

Abstract

An atomizer for applying a coating includes a nozzle plate, an actuator, and an acoustic focusing device. The nozzle plate defines at least one aperture. The actuator is configured to oscillate to form pressure waves within a fluid to eject the fluid from the nozzle plate. The acoustic focusing device focuses the pressure waves toward the apertures.

Claims

1. An atomizer for applying a coating comprising: a nozzle plate defining a plurality of apertures; an actuator configured to oscillate the nozzle plate to form pressure waves within a fluid to eject the fluid from the nozzle plate; and an acoustic reflector that includes a rigid concave shaped surface facing toward the nozzle plate configured to reflect the pressure waves back toward the nozzle plate as secondary pressure waves and focus the secondary pressure waves toward the plurality of apertures, the acoustic reflector having a focal point that is exterior of an exterior side of the nozzle plate such that the nozzle plate is between the acoustic reflector and the focal point and the acoustic reflector focuses the secondary pressure waves across more than one aperture of the plurality of apertures.

2. The atomizer of claim 1, further comprising a plurality of the acoustic reflectors configured to split the pressure waves into discrete sets of the plurality of secondary pressure waves, each acoustic reflector focusing a corresponding set of the discrete sets toward a corresponding set of apertures of the plurality of apertures.

3. The atomizer of claim 1, further comprising a plurality of the nozzle plates and a plurality of the actuators, each actuator configured to oscillate a corresponding one of the nozzle plates, wherein the atomizer includes a plurality of acoustic reflectors, each acoustic reflector associated with a corresponding one of the nozzle plates.

4. The atomizer of claim 3, wherein each acoustic reflector defines a plurality of the rigid concave shaped surfaces and is configured to split the pressure waves into discrete sets of the plurality of secondary pressure waves with each rigid concave shaped surface focusing a corresponding set of the discrete sets toward a corresponding set of apertures of the plurality of apertures of the corresponding nozzle plate.

5. The atomizer of claim 1, wherein the actuator is integrally formed with the nozzle plate.

6. The atomizer of claim 1, wherein the actuator is piezoelectric material.

7. The atomizer of claim 1, wherein the nozzle plate is a piezoelectric material and defines the actuator.

8. The atomizer of claim 1, wherein the actuator is configured to oscillate the nozzle plate such that the pressure waves originate from the nozzle plate and propagate therefrom toward the acoustic reflector.

9. The atomizer of claim 1, wherein the actuator is an annular shape disposed about the nozzle plate.

10. An atomizer for applying a coating comprising: a nozzle plate defining a plurality of apertures; an actuator configured to oscillate the nozzle plate to form a pressure wavefront in a fluid that propagates from the nozzle plate; and at least one acoustic reflector that has a rigid concave shaped surface facing toward the nozzle plate configured to reflect the pressure wavefront back toward the nozzle plate as secondary pressure waves and focus the secondary pressure waves toward at least one aperture of the plurality of apertures, every acoustic reflector of the at least one acoustic reflector having a focal point that is exterior of an exterior side of the nozzle plate such that the nozzle plate is between the acoustic reflector and the focal point and the acoustic reflector focuses the secondary pressure waves across more than one aperture of the plurality of apertures.

11. The atomizer of claim 10, wherein the at least one acoustic reflector includes a second acoustic reflector, the rigid concave shaped surface of the second acoustic reflector being configured to focus the secondary pressure waves toward a corresponding set of apertures of the plurality of apertures.

12. The atomizer of claim 10, wherein the at least one acoustic reflector includes a plurality of acoustic reflectors configured to split the pressure waves into discrete sets of the plurality of secondary pressure waves, each acoustic reflector focusing a corresponding set of the discrete sets toward a corresponding one of the apertures.

13. The atomizer of claim 10 further comprising a plurality of the nozzle plates and a plurality of the actuators, each actuator configured to oscillate a corresponding one of the nozzle plates, wherein the at least one acoustic reflector includes a plurality of acoustic reflectors, each acoustic reflector associated with a corresponding one of the nozzle plates.

14. The atomizer of claim 10, wherein the nozzle plate is a piezoelectric material and defines the actuator.

15. The atomizer of claim 10, wherein the actuator is an annular shape disposed about the nozzle plate.

16. An atomizer for applying a coating comprising: a plurality of nozzle plates, each nozzle plate defining a plurality of apertures; a plurality of actuators; and a plurality of acoustic reflectors, wherein each nozzle plate is associated with a corresponding one of the actuators of the plurality of actuators and a corresponding one of the acoustic reflectors of the plurality of acoustic reflectors, wherein each actuator is configured to oscillate the associated nozzle plate to form pressure waves within a fluid to eject the fluid from the associated nozzle plate, wherein each acoustic reflector defines a plurality of concave shaped surfaces that face toward the associated nozzle plate and are configured to split the pressure waves into discrete sets of secondary pressure waves that are reflected back toward the associated nozzle plate, wherein each concave shaped surface of the plurality of concave shaped surfaces focuses a corresponding set of the discrete sets toward a corresponding set of apertures of the plurality of apertures of the associated nozzle plate.

Description

DRAWINGS

(1) In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

(2) FIG. 1 is a planar view of an exemplary coating spray system according to the teachings of the present disclosure;

(3) FIG. 2 schematically depicts a planar view of an applicator of the spray system of FIG. 1, having an array of micro-applicators according to the teachings of the present disclosure;

(4) FIG. 3 schematically depicts a portion of the applicator of FIG. 2, illustrating one of the micro-applicators;

(5) FIG. 4 schematically depicts a side cross-sectional view of section 4-4 in FIG. 3, illustrating a nozzle with an acoustic focusing device according to the teachings of the present disclosure;

(6) FIG. 5 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of a second construction according to the teachings of the present disclosure;

(7) FIG. 6 schematically depicts a portion of the side cross-sectional view of FIG. 5;

(8) FIG. 7 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of a third construction according to the teachings of the present disclosure;

(9) FIG. 8 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of a fourth construction according to the teachings of the present disclosure;

(10) FIG. 9 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of a fifth construction according to the teachings of the present disclosure;

(11) FIG. 10 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of a sixth construction according to the teachings of the present disclosure;

(12) FIG. 11 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of a seventh construction according to the teachings of the present disclosure; and

(13) FIG. 12 schematically depicts a side cross-sectional view similar to FIG. 4, illustrating a nozzle with an acoustic focusing device of an eighth construction according to the teachings of the present disclosure.

(14) The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

(15) The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Examples are provided to fully convey the scope of the disclosure to those who are skilled in the art. Numerous specific details are set forth such as types of specific components, devices, and methods, to provide a thorough understanding of variations of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed and that the examples provided herein, may include alternative embodiments and are not intended to limit the scope of the disclosure. In some examples, well-known processes, well-known device structures, and well-known technologies are not described in detail.

(16) The present disclosure provides a variety of devices, methods, and systems for controlling the application of paint to automotive vehicles in a high production environment, which reduce overspray and increase transfer efficiency of the paint. It should be understood that the reference to automotive vehicles is merely exemplary and that other objects that are painted, such as industrial equipment and appliances, among others, may also be painted in accordance with the teachings of the present disclosure. Further, the use of “paint” or “painting” should not be construed as limiting the present disclosure, and thus other materials such as coatings, primers, sealants, cleaning solvents, among others, are to be understood as falling within the scope of the present disclosure.

(17) Generally, the teachings of the present disclosure are based on a droplet spray generation device in which a perforate membrane is driven by a piezoelectric transducer. This device and variations thereof are described in U.S. Pat. Nos. 6,394,363, 7,550,897, 7,977,849, 8,317,299, 8,191,982, 9,156,049, 7,976,135, 9,452,442, and U.S. Published Application Nos. 2014/0110500, 2016/0228902, and 2016/0158789, which are incorporated herein by reference in their entirety.

(18) Referring now to FIG. 1, a paint spray system 2 for painting a part P using a robotic arm 4 is schematically depicted. The robotic arm 4 is coupled to at least one material applicator 10 and a rack 5. A material source 8 (e.g., a paint source) is included and includes at least one material M (materials M.sub.1, M.sub.2, M.sub.3, . . . M.sub.n shown in FIG. 1; also referred to herein simply as “material M”). In some aspects of the present disclosure the at least one material M includes different paint materials, different adhesive materials, different sealant materials, and the like. The arm 4 moves according to xyz coordinates with respect to rack 4 such that the material applicator 10 moves across a surface (not labeled) of the part P. Also, a power source 6 is configured to supply power to arm 4 and rack 5. Arm 4 and rack 5 are configured to supply material M from the material source 8 to the material applicator 10 such that a coating is applied to the surface of the part P.

(19) Referring to FIG. 2 a material applicator 10a or atomizer according to the teachings of the present disclosure is schematically shown. In one form of the present disclosure, the material applicator 10a includes an array body 100a or nozzle with an applicator array 102a including a plurality of micro-applicators 110a or sub-nozzles. In some aspects of the present disclosure, the array body 100a with the applicator array 102a is positioned on a base 140a. In one configuration, the base 140a is supported at the end of the articulating robotic arm 4 (FIG. 1). In another configuration, the base 140a is supported by a spray bar (not shown) which can be stationary or can move in one, two, or three dimensions relative to a substrate S (shown in FIG. 4). Each of the micro-applicators 110a includes a plurality of apertures 112a through which a material M (FIG. 4) is ejected such that atomized droplets 3 (FIG. 4) of the material is provided. As described above, the material M (FIG. 4) is generally a liquid material (e.g., primer, basecoat, clearcoat, etc.) but may optionally include interspersed solids, such as metallic flecks or other particles to provide a particular aesthetic look. The micro-applicators 110a can be arranged in any arrangement, such as a regular or an irregular pattern across the array body 100a.

(20) Referring to FIGS. 3 and 4, each of the micro-applicators 110a includes a micro-applicator plate 114a, an actuator 120a, and an acoustic focusing device 124a. Each micro-applicator plate 114a defines a plurality of the apertures 112a extending through the micro-applicator plate 114a. The actuator 120a can be a transducer such as a piezoelectric material. The micro-applicator plate 114a is in mechanical communication with the actuator 120a such that activation of the actuator 120a (e.g., providing electrical power to the actuator 120a) vibrates or oscillates the micro-applicator plate 114a as schematically depicted by the horizontal (z-direction) double-headed arrows in FIG. 4.

(21) In the example provided, the array body 100a includes a material inlet 136a corresponding to each micro-applicator 110a. The array body 100a includes a back wall 131a and a cylindrical sidewall 132a. A reservoir 134a for containing the material M is defined between the back wall 131a and the micro-applicator plate 114a. In the example provided, at least the back wall 131a and the side of the micro-applicator plate 114a that faces the back wall 131a cooperate to define the reservoir 134a. In the example provided, the reservoir 134a is in fluid communication with similar reservoirs of the other micro-applicators 110a shown in FIG. 2, such that all of the micro-applicators 110a share a common fluid chamber. In an alternative configuration, not specifically shown, the reservoirs of some or all of the micro-applicators 110a can be separate from each other.

(22) The inlet 136a is in fluid communication with the reservoir 134a such that the material M flows through the inlet 136a and into the reservoir 134a. In the example provided, the actuator 120a is positioned between the micro-applicator plate 114a and the sidewall 132a so that the array body 100a supports the actuator 120a and the actuator 120a supports the micro-applicator plate 114a. For example, the actuator 120a may be positioned between an outer edge surface 115a of the micro-applicator plate 114a and an inner surface of the array body 100a. In one configuration, the actuator 120a is an annular shape disposed about the micro-applicator plate 114a. In another configuration, not specifically shown, the actuator 120a can be integrally formed with the micro-applicator plate 114a such that supplying power to the micro-applicator plate 114a oscillates the plate 114a. In the example provided, a control module 164a is in electric communication with the actuator 120a to provide power to and control operation of the actuator 120a.

(23) In the example provided, the back wall 131a, or a portion thereof, has a concave shaped surface that faces toward the micro-applicator plate 114a to define the acoustic focusing device 124a. In the example provided, the acoustic focusing device 124a is an acoustic reflector or acoustic mirror that has a curvature, such as parabolic or spherical for example, that has a focal point proximate to the apertures 112a of the micro-applicator plate 114a. The focal point can be within the reservoir 134a, at the micro-applicator plate 114a, or exterior of the micro-applicator plate 114a.

(24) In operation, the material M is supplied to the reservoir 134a at a very low pressure or no pressure, such that surface tension of the material M resists the material M from flowing through the apertures 112a of the micro-applicator plate 114a unless the actuator 120a is activated and oscillates. The oscillating micro-applicator plate 114a produces primary waves Wa that propagate from the micro-applicator plate 114a toward the back wall 131a. The primary waves Wa reflect off the acoustic focusing device 124a as secondary waves Wa′ that travel toward the micro-applicator plate 114a. In the example provided, the primary waves Wa are generally unfocused, parallel waves. The acoustic focusing device 124a focuses the waves such that the secondary waves Wa′ are focused or concentrated toward the apertures 112a. This focused wave energy causes the material M to be ejected from the apertures 112a. In the example provided, the secondary waves Wa′ impact the micro-applicator plate 114a across an area that encompasses all of the apertures 112a, but less than the entire oscillating micro-applicator plate 114a. Thus, the wave energy is concentrated at the apertures 112a to eject the material M.

(25) That is, when the actuator 120a is activated and vibrates, the material M is ejected through and/or from the plurality of apertures 112a to provide a stream 5 of atomized droplets 3. The stream 5 of atomized droplets 3 propagates generally parallel to a micro-applicator axis 2′ and forms a coating C on a surface s′ of the substrate S. The substrate S can be any suitable workpiece such as a vehicle part, frame, or body for example. As schematically depicted in FIG. 4, the atomized droplets 3 have a narrow droplet size distribution (e.g., average droplet diameter).

(26) Referring to FIG. 5, a cross-section of a material applicator 10b of a second construction is illustrated. The material applicator 10b is similar to the material applicator 10 and 10a (FIGS. 1-4) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIGS. 1-4 are similar to those features of applicator 10, 10a and only differences are described herein. The back wall 131b of the material applicator 10b includes a plurality of acoustic focusing devices 124b that are acoustic mirrors or reflectors. Each acoustic focusing device 124b is associated with a corresponding one of the apertures 112b and has a focal point proximate to that aperture 112b. Similar to the applicator 10, 10a (FIGS. 1-4), oscillation of the micro-applicator plate 114b produces parallel, primary waves Wb. The primary waves Wb are then reflected by the individual acoustic focusing devices 124b as secondary waves Wb′ directed specifically at each individual aperture 112b. In an alternative configuration, not specifically shown, multiple acoustic focusing devices 124b can be used, but with each focusing device 124b focusing on more than one aperture 112b.

(27) In one particular configuration shown in FIG. 6, a distance between similar points on adjacent acoustic focusing devices d.sub.1 can be equal to a distance d.sub.2 between similar points on adjacent apertures 112b, though other configurations can be used.

(28) Referring to FIG. 7, a cross section of a material applicator 10c of a third construction is illustrated. The material applicator 10c is similar to the material applicator 10, 10a, or 10b (FIGS. 1-6) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIGS. 1-6 are similar to those features of applicator 10, 10a and 10b and only differences are described herein. In the example provided, the micro-applicator plate 114c is not supported by or oscillated by the actuator 120c. Instead, the acoustic focusing device 124c is an acoustic lens disposed between the micro-applicator plate 114c and the actuator 120c. In the example provided, the acoustic focusing device 124c defines the back wall 131c and has a concave shape such that the back wall 131c is concave in a direction that faces toward the micro-applicator plate 114c. Activation of the actuator 120c creates primary waves Wc that propagate toward the acoustic focusing device 124c. The shape of the acoustic focusing device 124c focuses the acoustic waves so that the secondary waves Wc′ (i.e., that pass through the acoustic focusing device 124c) are focused toward the apertures 112c. In the example provided, the secondary waves Wc′ are focused toward a plurality of the apertures 112c. The space between the actuator 120c and the acoustic focusing device 124c can be any suitable gas, liquid, or solid for propagating the primary waves Wc, or the actuator 120c can be in direct contact with the acoustic focusing device 124c.

(29) Referring to FIG. 8, a cross section of a material applicator 10d of a fourth construction is illustrated. The material applicator 10d is similar to the material applicator 10c (FIG. 7) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIG. 7 are similar to those features of applicator 10c and only differences are described herein. In the example provided, the acoustic focusing device 124d is an acoustic lens that defines the back wall 131d, but has a shape that is not concave. Instead, the acoustic focusing device 124d is constructed so that the speed of sound through the acoustic focusing device 124d varies across the acoustic focusing device 124d in a manner that results in the acoustic focusing device 124d focusing the secondary waves Wd′ toward the apertures 112d. In one non-limiting example, the acoustic focusing device 124d can be constructed with different densities to cause the speed of sound to vary across the acoustic focusing device 124d, though other configurations can be used. In the example provided, the secondary waves Wd′ are focused toward a plurality of the apertures 112d. In an alternative construction, the speed of sound can vary across the acoustic focusing device 124d and the acoustic focusing device 124d can have a concave shape.

(30) Referring to FIG. 9, a cross section of a material applicator 10e of a fifth construction is illustrated. The material applicator 10e is similar to the material applicator 10c (FIG. 7) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIG. 7 are similar to those features of applicator 10c and only differences are described herein. In the example provided, the micro-applicator 110e includes a plurality of acoustic focusing devices 124e that are acoustic lenses that define portions of the back wall 131e that have concave shapes that face toward the apertures 112e. The shapes of the acoustic focusing devices 124c focus the acoustic waves so that the secondary waves We′ are focused toward an individual corresponding one of the apertures 112e.

(31) Referring to FIG. 10, a cross section of a material applicator 10f of a sixth construction is illustrated. The material applicator 10f is similar to the material applicator 10e (FIG. 9) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIG. 9 are similar to those features of applicator 10e and only differences are described herein. In the example provided, the acoustic focusing devices 124f are acoustic lenses that define portions of the back wall 131f, but the acoustic focusing devices 124f have a shape that is not concave. Instead, the acoustic focusing devices 124f are constructed so that the speed of sound through the acoustic focusing devices 124f varies across the acoustic focusing devices 124f in a manner that results in the acoustic focusing devices 124f focusing the secondary waves Wf′ toward individual corresponding ones of the apertures 112f. In one non-limiting example, the acoustic focusing device 124f can be constructed with different densities to cause the speed of sound to vary across the acoustic focusing device 124f, though other configurations can be used. In an alternative construction, the speed of sound can vary across the acoustic focusing devices 124f and the acoustic focusing devices 124f can have a concave shape.

(32) Referring to FIG. 11, a cross-section of a material applicator 10g of a seventh construction is illustrated. The material applicator 10g is similar to the material applicator 10 and 10a (FIGS. 1-4) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIGS. 1-4 are similar to those features of applicator 10, 10a and only differences are described herein. In the example provided, the micro-applicator plate 114g is not supported by or oscillated by the actuator 120g. Instead, the actuator 120g defines at least a portion of the back wall 131g and has a concave shape that faces toward the micro-applicator plate 114g. The shape of the actuator 120g is such that it produces waves Wg that are already focused toward the apertures 112g. Thus, the actuator 120g itself forms an acoustic focusing device 124g. In the example provided, the waves Wg are focused toward a plurality of the apertures 112g.

(33) Referring to FIG. 12, a cross section of a material applicator 10h of an eighth construction is illustrated. The material applicator 10h is similar to the material applicator 10g (FIG. 11) except as otherwise shown or described herein. Features denoted with reference numerals similar to those shown and described in FIG. 11 are similar to those features of applicator 10g and only differences are described herein. In the example provided, the micro-applicator 110h includes a plurality of actuators 120h that define portions of the back wall 131h that have concave shapes that face toward the apertures 112h. The shapes of the actuators 120h form acoustic focusing devices 124h such that activating the actuators 120h propagates focuses acoustic waves Wh that are focused toward an individual corresponding one of the apertures 112h.

(34) Accordingly, the acoustic focusing devices 124a-h focus the acoustic waves toward the apertures 112a-h, which can result in greater power efficiency (e.g., lower electrical power needed) and higher droplet ejection velocity, which can also reduce overspray and allow for higher viscosity fluids to be used.

(35) As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.

(36) Unless otherwise expressly indicated, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, manufacturing technology, and testing capability.

(37) The terminology used herein is for the purpose of describing particular example forms only and is not intended to be limiting. The singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

(38) The description of the disclosure is merely exemplary in nature and, thus, examples that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such examples are not to be regarded as a departure from the spirit and scope of the disclosure. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims.