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What are the principles and characteristics of airless sprayers?

Release Date:

Feb 23,2022

The actuating component is a double‑acting pneumatic‑hydraulic booster pump, and the directional control mechanism is a specially designed pilot‑operated pneumatic valve. An airless sprayer uses a high‑pressure plunger pump to boost paint pressure up to 3,000 psi (210 kg/cm²), delivers the pressurized paint through a high‑pressure hose to a high‑pressure spray gun, and releases the pressure via the nozzle to create atomization, thereby forming a dense coating on the wall surface. Because the paint is atomized without compressed air, this method is referred to as airless spraying.

After years of development, spray‑coating technology has also been refined. The key working component of the sprayer is a double‑acting pneumatic‑hydraulic booster pump, while the directional‑control mechanism employs a specialized pilot‑operated pneumatic valve. Airless sprayer It refers to using a high-pressure plunger pump to increase the paint pressure to 3,000 psi (210 kg/cm²), delivering it through a high-pressure hose to a high-pressure spray gun. The pressure is then released through the nozzle, creating an atomized mist that forms a dense coating on the wall surface. Since this method does not require compressed air for atomization, it is known as airless spraying.

High voltage Airless sprayer A high-pressure plunger pump is used to boost the coating pressure to 3,000 PSI (210 kg/cm²), generating a high‑pressure stream that is conveyed through a high‑pressure hose to the spray gun. At the nozzle, the working pressure is gradually released, producing a fine atomization that ensures the coating does not form a dense film on the surface of the wall material. High‑pressure airless spraying enables the coating particles to penetrate deeply into the wall’s pores, creating mechanical interlocking between the paint film and the substrate, thereby enhancing adhesion and extending the service life of the coating.

　　Comparison Between Airless Spraying and Other Spraying Methods

　　It has the following advantages:

　　1. Extremely high coating efficiency. Spray application rates reach 500–1,200 square meters per hour, more than ten times that of conventional roller application.

　　2. The coating is smooth, glossy, dense, and free of brush marks, roller marks, and particles.

3. It extends the service life of the coating by enabling paint particles to penetrate deep into the wall’s pores, creating mechanical interlocking between the paint film and the wall surface, thereby enhancing adhesion and prolonging durability.

4. Easily tackle hard-to-reach areas such as corners, gaps, and uneven surfaces.

　　5. Reduced paint consumption. Brush application results in highly uneven film thickness, typically ranging from 30 to 250 microns, leading to low paint utilization. In contrast, airless sprayers can easily achieve a uniform coating thickness of 30 microns, yielding a 20–30% reduction in paint usage.

6. Electric airless sprayers do not require an air compressor, offering low energy consumption, quiet operation, excellent portability, and high efficiency.

7. High Voltage Airless sprayer The paint used has a high viscosity and a high solids content, resulting in a relatively thick coating with a single spray application. This reduces the number of coats required, saves labor, and shortens the construction schedule.

Precautions

When applying paint with a brush, it is recommended to stroke first vertically, then horizontally, and throughout the process, avoid over‑saturating the brush to prevent drips. When applying heavy‑duty anti‑corrosion coatings, keep the brush strokes relatively close together to prevent the paint film from becoming too thin.

　During the roller‑coating process, the paint applied to the roller should be evenly distributed. Moreover, throughout the coating operation, the rolling speed should remain consistent and not be too fast.

　　In fact, this is a fast coating method that can also produce a very thick paint film. Therefore, in many cases, to better achieve the specified film thickness, it is recommended to use airless spraying.

What are the respective characteristics of air‑assisted sprayers and airless sprayers?

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