How to solve the nozzle blockage of fine mist sprayer

Physical cleaning technology effectively softens and removes blockages through the synergistic effect of thermal energy and mechanical force. Specifically, the nozzle is preheated with an electric soldering iron for 30 seconds, and the temperature of the residual paint can rise to above 80°C. This temperature gradient significantly reduces the surface tension of high-viscosity materials, thereby improving the removal efficiency. Combined with a conical pick needle with a diameter of 0.1 mm, the softened blockage can be accurately peeled off with an operating accuracy of ±0.02 mm. The use of elbow tweezers can effectively remove the remaining fibrous debris, and its 15° bending angle design ensures 360° no-dead-angle cleaning in a small space. In addition, the straw blowing method is used as an auxiliary means, which can generate 2.5 liters of airflow per second at a pressure of 0.2MPa. This instantaneous impact force has a significant removal effect on particle blockages with a diameter of less than 50 microns.

In terms of chemical cleaning technology, we have developed special solutions for different blockage mechanisms. Taking acetone solvent as an example, it can dissolve 98% of acrylic resin deposits within 15 minutes through molecular-level penetration, and its dissolution rate is 3 times higher than that of traditional alcohol cleaning agents. For cosmetic residues containing silicone oil, a composite solvent system of fluorocarbon surfactant and ethanol can reduce the contact angle from 110° to 45°, thereby achieving efficient wetting and removal. After cleaning, it needs to go through a triple water washing process to ensure that the solvent residue is less than 0.5ppm to avoid secondary contamination.

As the ultimate solution, nozzle replacement technology puts forward strict requirements on material selection and processing accuracy. The nozzle made of liquid crystal polymer (LCP) has a solvent resistance 4 times higher than that of polypropylene (PP) material, and the heat deformation temperature can reach 280℃, which makes it show obvious advantages in high-temperature disinfection scenarios. The processing accuracy of the nozzle inner diameter needs to be controlled within the range of ±0.002 mm, and the surface roughness of Ra0.1μm can be achieved through micro-electrodischarge machining technology. This level of accuracy ensures that the coefficient of variation (CV value) of the droplet size distribution is less than 5%.

In order to solve the clogging problem in the long term, we have built a preventive maintenance system. The moisturizing liquid circulation system forms a 0.1μm thick lubricating film on the nozzle surface, which reduces the drying rate of the ink by 60%. This technology has achieved 1500 hours of continuous operation without clogging in a textile factory. The daily cleaning procedure uses negative pressure suction technology, combined with a 0.5MPa pulse water flow, to remove 95% of potential blockages. The temperature control system strictly limits the operating temperature to the range of 20-25℃, so that the viscosity fluctuation of the material is controlled within ±3%. This precise control significantly reduces the risk of clogging.