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WO2010008533A1 - Dispositif de pulvérisation de revêtement en poudre - Google Patents

Dispositif de pulvérisation de revêtement en poudre Download PDF

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Publication number
WO2010008533A1
WO2010008533A1 PCT/US2009/004074 US2009004074W WO2010008533A1 WO 2010008533 A1 WO2010008533 A1 WO 2010008533A1 US 2009004074 W US2009004074 W US 2009004074W WO 2010008533 A1 WO2010008533 A1 WO 2010008533A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder
flame
air
thermal spray
coating device
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2009/004074
Other languages
English (en)
Inventor
Thomas Gardega
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Xiom Corp USA
Original Assignee
Xiom Corp USA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Xiom Corp USA filed Critical Xiom Corp USA
Publication of WO2010008533A1 publication Critical patent/WO2010008533A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/20—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion
    • B05B7/201—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle
    • B05B7/205—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle the material to be sprayed being originally a particulate material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
    • B05B1/26—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means with means for mechanically breaking-up or deflecting the jet after discharge, e.g. with fixed deflectors; Breaking-up the discharged liquid or other fluent material by impinging jets

Definitions

  • the powder-coating gun of the present invention can be used in a variety of fields where spraying plastic powder coating is desired.
  • the powder coating gun is designed to use liquid, gel or gaseous fuels such as propane or butane.
  • the design of the gun enables the spray produced by the gun to cover both large and small areas, mostly due to its modular nozzle design. Being compact and lightweight, any powder coater will be able to control the gun and spray material for much longer periods of time than when using other powder spray guns. In addition, the time required to complete a job will most often be greatly reduced due to the wider spray pattern.
  • Powder coating is a method of applying a coating onto a substrate in the form of a heat-treated powder.
  • Traditional spray guns used to spray powder compositions utilize an oven to melt and cure the powder.
  • As need for anti-corrosion, anti microbial, anti-fouling, and electrically resistant versatile coatings increases, the need to apply them quickly and efficiently has become more and more critical.
  • a fast way of applying these coatings to any surface without having to bake the part is needed.
  • combustion guns produced by Xiom® Corp. are able to eliminate the need for oven melting of the powder particles. This is achieved by melting the particles in mid air right before contact is made with the surface to be treated. The powders then cure almost instantly, providing a very durable coating.
  • combustion guns can utilize compressed air to run a control console, powder feeder and the gun. These guns can also use Oxygen and Propane in order to create the flame, which is used to melt the powders. Flame temperatures ranging from 600 degrees F to 1000 degrees F melt the powders for application (depending on the material). This system reduces the time needed to thermally spray a surface/device and cure the sprayed coating by melting and curing the powder simultaneously, hi other words, the hours needed to bake and cure the surface/device in a conventional powder coating system are no longer needed, saving time and money. In order to increase efficiency of the thermal spraying process, a gun capable of covering a larger area than currently available is in great demand. The present invention described in the sections and figures below fills this need.
  • the thermal spray-coating device of the present invention produces a wider spray width than conventional guns available on the market today. This allows the device to be used almost anywhere which makes it a very useful tool for any powder coater. Its lightweight, compact design, allows it to be taken to jobs which were once thought of as impossible to powder coat. For example, the thermal coating device of the present invention will allow for the coating of ships, rooms, airplanes, etc. without any disassembly.
  • the wider spray pattern produced by the thermal spray device of the present invention allows for fast application of various powder compositions thereby efficiently covering large surfaces.
  • the only required inputs into this gun and system are air and fuel. The air can be obtained from the surrounding atmosphere either by using or not using a Venturi system and the fuel used can be propane.
  • the thermal spray device of the present invention uses at least two directed streams of thermal spray material focused at a specific angle to create a point of collision.
  • the point of collision is referred hereinto as the apex point.
  • the two streams become a single stream and fan out in such a way as to create a wide pattern of thermal spray material.
  • Also positioned to intersect at the apex point is the flame from at least one planar flame nozzle. The heat provided by the planar flame nozzle melts the fanned pattern of thermal spray material as it comes in contact with the material at the apex point. This produces an enlarged area of coverage as the melted material is applied to a surface to be coated.
  • the thermal spray-coating device of the present invention can spray the same material from each of the angled streams or different materials depending on the desired coverage. If different materials are to be used, the specific gravity of each of the two materials must be the same and/or similar so that the resulting pathway at the apex is not persuaded by one material over the other. That is, if one material has a much higher specific gravity, it will have more inertia when it collides with the second less dense material and results in a stream that is off the center line of the device and possibly outside of the straight ahead flame. If materials with different specific gravities are required then a minimum of four powder tubes are required so that each different material is impinged by similar material injected 180 degrees opposed.
  • the design of the present invention not only effectively reduces the amount of time necessary to complete a particular job, but it also allows two different materials to be mixed together at the apex to so as to dispose the mixed material on a surface. All in all, the time associated with coating an area is reduced since each pass of the spray gun covers a larger coverage area than currently available thermal spray guns.
  • the currently available thermal spray guns have a maximum spray width of about 3 inches
  • the thermal spray gun of the present invention has a maximum spray width of about 8 inches or greater depending on the type of nozzle used.
  • the thermal spray-coating device of the present invention solves many problems that exist with previous systems.
  • the time to spray large and small surfaces is greatly reduced.
  • the high portability allows the thermal spray gun to be used at almost any job site and in a more efficient manner.
  • the directing of the at least two streams of material allow produces a fanned pattern that can be composed of different streams of the same stream of materials. Using at least two different streams and one flame allows for reduced heat and less possibility of scorching the material used.
  • the thermal spray gun of the present invention does not only use compressed air but also takes air from the surrounding atmosphere and therefore no longer requires an oxygen tank, thus increasing the portability and reducing the weight of the total system.
  • the thermal spray coating device comprises a spray body having at least two angled conduits for passage there through of powdered coating material.
  • the at least two angled conduits can be adjustable so as to allow for different predetermined angles to be achieved or can be free moving so as to allow for every angle within the capacity of the spray nozzle to be achieved.
  • the spray body may also be configured to have a handle for easy grip. Attached to the spray body is at least one flame nozzle body, each having at least one attaching means for attaching the flame nozzle bodies to the spray body.
  • the flame nozzle bodies comprise at least one air compression blade having at least one conduit for passage of air there through that is configured so as to direct a flame away from the flame nozzle bodies to a desired compression angle formed between at least two powder streams and at least one flame.
  • the compression angle measured between the body of the gun and the material port can vary from about 6 degrees to about 60 degrees.
  • the thermal spray coating device of the present invention also comprises at least one fuel blade having at least one conduit for passage of compressed gaseous combustible fuel that is attached to or near the flame nozzle body described above. Also attached to or near the flame nozzle body is at least one air injection blade having at least one conduit for passage of air.
  • the air injection blade is configured to inject air into the flame produced by the flame nozzle so as to aid in combustion of the fuel source and to cool off the flame so that it does not get too hot so as to burn, instead of melt, the composition being applied to the surface.
  • the thermal spray coating device is also equipped with at least two powder nozzles 180 degrees opposed having attaching means for attaching to the spray body and at least two powder jets, each of which have at least one conduit for the passage of air there through.
  • the passage of air through each of the conduits of the powder nozzles impact each of the powder streams and causes the powder streams to be projected forward out of the spray body.
  • the exiting ports of the powder streams are positioned at an angle towards a common apex point as described above. That is, the right hand and left hand exiting ports are positioned towards the center of the device either at fixed angles or in an alternative embodiment at an adjustable angle.
  • the powder nozzles of the present invention may further comprise air blades having at least one conduit for the passage of air there through. Air passed through the conduits produces an air stream positioned between the powder coating stream from the spray body and the flame so as to prevent the powder coating from coming in direct contact with said flame. In other words, the stream of air allows the powder coating to come close enough to the flame to melt but not too close so as to burn.
  • thermal spray device can be used with a variety of thermal spray composition and is further described in the drawings and description that follows.
  • Figure 1 is a diametric view of the thermal spray device of the present invention.
  • the thermal spray device of the present invention is unlike any currently available thermal spray device available on the market today.
  • the thermal spray device of the present invention provides a thin, smooth thermal spray coating and produces spray patterns up to about 9 inches in width using at least two thermal powder spray streams.
  • Each of the at least two thermal powder spray streams are specifically angled inwards towards each other so as to meet at an apex point.
  • a flame is also provided that also intersects the apex point.
  • the twin powder feed is accomplished via two powders feed tubes wherein the forward portions of each of the powder feed tubes are positioned inward at a specific angle.
  • the forward portions of the two powder feeds can be configured so that multiple angles can be achieved.
  • the inward angle of the powder feed tubes the flow of the thermal spray powdered materials intersects at an apex point and forms a compression wave.
  • the position of the apex point is not fixed and will change with the change in the angle of the forward nozzle. That is, as the angle of the forward nozzle is increased, the apex point will form further away from the gun. Similarly, as angle of the forward nozzle is decreased the apex point will form closer to the gun.
  • the flame used to melt the powdered thermal spray material is directed straight out of the flame nozzle and will also intersect the apex point causing the powdered material to melt.
  • powder is projected from the forward portions (25) (30) of powder feed tubes (15) and (20) in the pathway (60) and (55) and converge at the apex point (50) of thermal spray device (10) of the present invention.
  • the pathway of the each stream is diverted so that the powder stream projects substantially forward in a wide fanned out pattern. It is noted that if different materials are used in each feedstock then the pathway of the resulting collision is at least in part dependent on the specific gravity of each of the materials used. The closer the specific gravity of each material is to each other the more centerline the resulting flow would be at the apex point.
  • the flame (75) from the flame nozzle (70) travels forward to intersect with the powder streams at the apex point.
  • the angles of the forward nozzles can be adjusted according to the powdered thermal spray being used. That is, if the thermal spray material being used requires a hotter flame to form a coating, the angle of the forward nozzles can be adjusted smaller in order to achieve this objective.
  • the angle can be adjusted larger so as to produce an apex point further away from the flame nozzle and allow more time for the flame to cool before coming in contact with the thermal spray composition.
  • the two thermal spray streams collide at the apex point the resulting stream fans out and is melted by the flame so as to cover a larger area than if two separate streams were used. This larger spray pattern is accomplished without jeopardizing the quality of the coat being applied, and in fact, produces a superior coating in terms of texture and thickness.
  • the apparatus of the present invention is also equipped with first and second powder supply lines (40) and (45) that are attach to the powder feed tubes (15) and (20) respectively.
  • Each of the powder supply lines (40) and (45) may either be attached directly to their respective powder feeder supplies or can connect to a powder splitter joint connection that then connects to the powder feeder supply.
  • the thermal spray device of the present invention is also equipped with Venturi systems that aid in the operation of the device by drawings more air and increasing the velocity of the thermal spray materials as described above.
  • Fuel gas supply is connected to the device via the connection for fuel gas (35).
  • the fuel gas supply can either be in a portable can or a large supply canister.
  • Other parts and components may also be used to enhance the function of the apparatus as may be seem necessary during optimization of the device. It is full appreciated that these additional components are also envisioned to be part of the present apparatus.
  • the apparatus of the present invention is especially useful with materials that require less heat to be applied and with materials that burn when they come in contact with excess heat.
  • the fact that the present invention uses one flame nozzle and at least two powder streams allows the apparatus present invention to be used with the above- described materials.
  • the thermal spray device of the present invention uses a unique design that allows for the use of propane gas to fuel its flame. Since oxygen must be mixed with the propane for combustion, oxygen is taken directly from the surrounding air using the fuel blade of the present invention. The ability to siphon oxygen from the surrounding air saves on cost associated with compressed oxygen and reduces the overall weight of the system. In addition, since an oxygen tank is not needed, the gun is less expensive to produce and safer to use.
  • the gun of the present invention utilizes several unique components. In order to siphon the right amount of oxygen needed to make the oxygen propane mixture rich enough for combustion, the gun can either use a conduit in the fuel blade to provide oxygen to combine with the fuel for combustion.
  • the present invention may incorporate a Venturi system so as to siphon even more air from the surrounding area thereby making the fuel mixture even richer.
  • the fuel blade can be equipped with a double or triple Venturi system.
  • the fuel nozzle body of the present invention is positioned substantially at the medium centerline front end of the thermal spray device and is designed to allow the flame to stand proud from the nozzle, meaning it burns away from the nozzle.
  • This design feature ensures that the device does not get hot and also keeps the flame from burning back into the system.
  • a double or triple Venturi system allows the flame to extinguish, eliminating a flame burn back into the device.
  • the propane/oxygen mixture will be rich enough for the propane to combust in the first and second stage of a double Venturi system. This protects against flashback.
  • the present invention can regulate the temperature of the flame by adjusting the apex point and the amount of oxygen supplied to the flame. As mentioned above, since this device contains only one flame nozzle, the amount of heat applied is already reduced as compared to a device with multiple flame nozzles.
  • the inclusion of the oxygen port not only aids in achieving higher temperature but it also makes the device more portable. Since using only compressed air and atmospheric air to mix with the propane to enable combustion, the air compressor must be large enough to supply enough air for mixing with the propane and enough to cool the produced flame. By adding the oxygen port, the coater only needs to add a small amount of oxygen gas into the device that will aid in the combustion. Thus, the compressed air can only be used for flame cooling. The coater's compressor would not need to be upgraded to a larger size if more air is needed.
  • the thermal spray device of the present invention utilizes a unique heating system to apply powder coating material onto a substrate. Since the device has the ability to spray a large area, a special heating source is required that is able to uniformly heat and melt the powder throughout its full length. This heating system is able to preheat the substrate sufficiently in order for the coating to be able to have high bond strength.
  • the present invention is equipped with a unique heating nozzle designed with several jetted air blades and a similar propane blade to accomplish this task.
  • the heating system of the present invention consists of the flame nozzle body, fuel delivery barrel, air compression blade, propane blade, and air injection blade.
  • the spray gun of the present invention uses a single specially designed flame nozzle position approximately at the centerline of the device, in order for optimum performance.
  • the flame nozzle body connects the other parts to form the flame nozzle.
  • the flame nozzle consists of essentially three inputs, two for air and one for propane.
  • the fuel delivery barrel delivers the propane to the flame nozzle while it mixes it with the siphoned air from the Venturi system. If oxygen is inputted through the oxygen port then the oxygen, propane, and the siphoned air mixes along the length of the barrel.
  • the propane blade propels the propane at a velocity greater than the rate of combustion. This also prevents the flame from burning back into the nozzle and also allows it to stand off of the propane blade. By having the flame stand off of the propane blade it prevents the flame heat from being transferred to the blade itself and further being transferred to other parts of the gun.
  • the outlets on the blade are milled at about .03125 inches in diameter. To enable the flame to cover the 9- inch pattern of the powder nozzle about 24 outlets is drilled into the blade to create about 24 flame jets along its length.
  • outlets can be drilled straight into the blade, it is a preferred embodiment of the present invention to drill the outlets in the blade at about a 20-degree angle to allow the stream of propane to hit the surface of the flame nozzle body for dispersion. This creates a flame curtain that will heat the large powder pattern.
  • the air compression blade creates the compression plane as mentioned earlier. Since air contains 21% oxygen, the air compression blade supplies enough oxygen to the propane in order for it to combust. When two flame nozzles are put together the flame tends to wrap back due to a vacuum that is created by the compression plane. There are also about 24 outlets drilled at about 20 degrees into the air compression plane. The diameters of the outlets are about the same as those of the propane blade, namely about .03125 inches. The 24 or so outlets allow for the compression of the large flame curtain throughout its length.
  • An air injection blade is placed in cooperation with the flame nozzle of the present invention so as to force the flame forward.
  • the added air not only prevents the flame from wrapping back but also provides extra oxygen to the flame for complete combustion of the propane.
  • the added air also cools down the temperature of the flame to the temperatures needed to melt the powder particles without burning.
  • the present invention is also equipped with an air knife, also having about 24 outlets with about a .03125-inch diameter drilled at 20-degree angle into it, in order to uniformly cool and direct the flame curtain forward.
  • the thermal spray device of the present invention is also unique in its modular front end.
  • the powder nozzles of the present invention are easy to remove and replace with a new nozzle or different nozzles for different spray patterns. It's crucial to be able to change between nozzles quickly without difficulty in order to make the thermal spray device easy to use. For this reason alone, the thermal spray device of the present invention is designed with a modular front end. Nozzles that can be used in the thermal spray gun of the present invention can produce patterns that range from about 3 inches to about 9 inches depending on the job and its requirements.
  • Each of the powder nozzles also includes their own pair of air blades.
  • the air blades are situated at the distal end of each nozzle.
  • the air blades aid in the acceleration of the powder as it exits the nozzles and it also cools the flame when the powder passes through it. Since the powders can fuel the flame and burn up the air provided by these air blades, protecting the powders from being burned while allowing enough heat through to melt the particles is a critical criterion to manage. This is done by the air compression blade in concert with the other components of the thermal spray device of the present invention as well as the adjustment of the amount of air feed to the flame and the positioning of the apex point in relationship to the gun body.
  • Each air compression blade of the present invention contains about 24 jets that are approximately about 0.015 inches to about 0.100 inches, preferably about .076 inches in diameter. This allows a larger volume of air to envelop the powders as they pass through the flame.
  • one object of the present invention is to maintain a light gun that is easy to use.
  • the maximum weight of the thermal spray device of the present invention is about 6 lbs. This is considered being extremely light in comparison to other thermal spray devices available.
  • the simple, but unique design of the thermal spray device of the present invention decreases the chance of improperly installing components leading to failure.
  • the thermal spray device of the present invention may utilize a double or triple Venturi system to supply oxygen to the fuel for the combustion.
  • An optional oxygen input port may also be used to import additional oxygen if needed. This unique combination produces an air mixture that is rich enough to combust propane when combined in the first stage if it is a double Venturi or in stage one and two if it's a triple Venturi in order to prevent flashback.
  • the various air blades used in the thermal spray device of the present invention in order to compress the flame and powder to about 20 degrees can also be used to cover a range of about 8 to about 60 degrees. It is believed that this unique air blade has never been used on any thermal spray equipment.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Nozzles (AREA)

Abstract

L'invention porte sur un dispositif de pulvérisation thermique pour appliquer des revêtements en poudre et polymères, à de grandes zones au moyen d'un système Venturi à double ou triple étages, orienté au niveau de l'extrémité distale, et d'au moins deux buses à poudre inclinées l'une vers l'autre de façon à produire une onde de compression. Les motifs de pulvérisation produits par les buses peuvent se situer dans la plage d'environ trois pouces à environ neuf pouces. La conception compacte et légère permet un confort et une aptitude à la portabilité élevée.
PCT/US2009/004074 2008-07-14 2009-07-14 Dispositif de pulvérisation de revêtement en poudre Ceased WO2010008533A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13483108P 2008-07-14 2008-07-14
US61/134,831 2008-07-14

Publications (1)

Publication Number Publication Date
WO2010008533A1 true WO2010008533A1 (fr) 2010-01-21

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PCT/US2009/004074 Ceased WO2010008533A1 (fr) 2008-07-14 2009-07-14 Dispositif de pulvérisation de revêtement en poudre

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101775550B1 (ko) 2015-10-22 2017-09-19 가람환경기술(주) 열효율이 증대된 수지분말 코팅장치
CN112662980A (zh) * 2020-12-22 2021-04-16 郑州立佳热喷涂机械有限公司 空气助燃型超音速火焰喷涂系统及方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004028222A1 (fr) * 2002-09-18 2004-04-01 Volvo Aero Corporation Dispositif de pulverisation thermique
US20060222777A1 (en) * 2005-04-05 2006-10-05 General Electric Company Method for applying a plasma sprayed coating using liquid injection
WO2008033458A2 (fr) * 2006-09-13 2008-03-20 Xiom Corporation Dispositif de pulverisation de revetement en poudre

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004028222A1 (fr) * 2002-09-18 2004-04-01 Volvo Aero Corporation Dispositif de pulverisation thermique
US20060222777A1 (en) * 2005-04-05 2006-10-05 General Electric Company Method for applying a plasma sprayed coating using liquid injection
WO2008033458A2 (fr) * 2006-09-13 2008-03-20 Xiom Corporation Dispositif de pulverisation de revetement en poudre

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101775550B1 (ko) 2015-10-22 2017-09-19 가람환경기술(주) 열효율이 증대된 수지분말 코팅장치
CN112662980A (zh) * 2020-12-22 2021-04-16 郑州立佳热喷涂机械有限公司 空气助燃型超音速火焰喷涂系统及方法

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