US3843054A - Powder apparatus - Google Patents

Abstract

An electrostatic powder spraying apparatus that includes a nonrotating disk-like member having an edge; the electrostatic field extends between the edge of disk and articles to be coated. A first means of the apparatus deflects powder radially outwardly into a chamber. The chamber is adjacent the first means and provides space in which tangential streams impart a spiral motion or whirling cyclone-type motion to the radially deflected powder. An apertured means is spaced from the non-rotating disk-like member. The spiral motion of entrained powder moves it outwardly along the surface of the non-rotating disk-like member and causes air to be aspirated through the aperture to mix with the powder moving radially outwardly along the surface of the disk-like member. By this means the powder is given sufficient momentum to be ejected from the edge of the disk to the vicinity of an article at a powder attracting potential where the electrostatic field forces can guide the charged powder to the article.

Description

United States Patent [19] Kendall et al.

[451 Oct. 22, 1974 POWDER APPARATUS [75] Inventors: Ronald R. Kendall; Richard O.

Probst, both of Indianapolis, Ind.

[73] Assignee: Ransburg Electro-Coating Corp.,

Indianapolis, lnd.

[22] Filed: Aug. 7, I972 [21] Appl. No.: 278,594

Related U.S. Application Data I [63] Continuation of Ser. No, 126,621, March 22, 1971,

Primary ExaminerM. Henson Wood, Jr.

Assistant Examiner-lohn J. Love Attorney, Agent, or FirmMerrill N. Johnson; David H. Badger 5 ABSTRACT An electrostatic powder spraying apparatus that includes a non-rotating disk-like member having an edge; the electrostatic field extends between the edge of disk and articles to be coated. A first means of the apparatus deflects powder radially outwardly into a chamber. The chamber is adjacent the first means and provides space in which tangential streams impart a spiral motion or whirling cyclone-type motion to the radially deflected powder. An apertured means is spaced from the non-rotating disk-like member. The spiral motion of entrained powder moves it outwardly along the surface of the non-rotating disk-like member and causes air to be aspirated through the aperture to mix with the powder moving radially outwardly along the surface of the disk-like member. By this means the powder is given sufficient momentum to be ejected from the edge of the disk to the vicinity of an article at a powder attracting potential where the electrostatic field forces can guide the charged powder to the article.

31 Claims, 4 Drawing Figures "I, I II JALLV/ 82 69 49 41 61 I5 PATENTEDsm 22 m4 8 L] w m o Z59 t POWDER APPARATUS This is a continuation of application Ser. No. 126,621, filed Mar. 22, 1971 now abandoned.

The present invention relates to coating articles with powder particles entrained in a gas, such as in air, and, more particularly, to an apparatus for and method of substantially uniformly distributing powder particles over the surface of a non-rotating member as a nonrotating disk-like member of the apparatus and ejecting thepowder particles radially from the edge of the disk using aspirated air. An electrostatic field is used to electros'tatically charge the powder particles. Preferably, the electrostatic field extends between the edge of the disk and articles to be coated.

It is highly desirable to have an apparatus which will form particles of power into a radially expanding spray pattern having substantially uniform powder distribution therein so that the articles to be coated can be moved around the apparatus and through the pattern to receive a coating of powder particles. In this manner the powder deposition zone can be extended, as compared to the zone provided by several other previously suggested devices, and the powder is deposited on the article surface over a longer period of time. This latter feature is particularly desirable where the accumulation of heavier powder layers on the article is required to meet coating specifications.

Further, it is a desideratum to provide a non-rotating member which ejects the powder into an electrostatic field substantially uniformly and with sufficient momentum to carry the powder to the vicinity of the article to be coated, even though such article is 6 to 19 inches away from theedge of the non-rotating member, without establishing a flow of air in the direction of the articles being coated of such a character as to blow powder particles already deposited on the article away from the article. In addition, the powder should be conveyed across the surface of the non-rotating member in a manner to bring the powder as close as is possible to such surface of the member so that the powder, when ejected from the edge of the member, is brought in close proximity to the edge of the member. The field gradient is the greatest at the edge of the non-rotating member and by having the powder pass closely by this region, the powder particles are provided with a high charge-to-mass ratio and thus the tendency of the powder to deposit upon the article is greatly increased.

The present invention, directed to satisfying these desires, provides an apparatus for and a method of projecting or ejecting and charging powder from a nonrotating member. Powder entrained in air is conveyed to the non-rotating member in such a manner as to strike a first powder deflector means which reduces the forward velocity of the powder, deflects it about 90 and causes it to essentially mushroom out in all directions. The powder travels in the deflected direction to ward and into an annular chamber. In the chamber a swirl of air is provided by a plurality of jets of air entering the chamber approximately tangential to the side walls of the chamber. The deflected powder is picked up by and mixes with the swirl air in the chamber. Swirling the powder-air mixture in the chamber carries the mixture to an opening in the chamber. The powder particles and the carrier air composed of the entraining air and the swirl air escape from the chamber under the action of centrifugal force and are directed radially outwardly across the surface of the non-rotating member in a spiral fashion. The powder is propelled outwardly from the edge of the member as an expanding pattern having a relatively uniform distribution of powder therein.

A second deflector, spaced at short distance from the non-rotating member assists in locking" the airpowder mixture to the surface of the member so that the powder does not leave that surface prematurely and so that substantially all of the powder passes in close proximity to the outer edge of the member. An aperture in the center of the second deflector allows air to be aspirated into the mixing chamber by the movement of the powder-air mixture from the chamber where it is added to the primary conveying air and the swirl air provided by tangential jets of air in the chamber. The aspirated air helps to maintain the required air velocity for conveying the powder particles and, therefore, the velocity necessary to m'ove the powder particles outwardly to the edge of-the member with sufficient momentum to carry the powder particles to the vicinity of the article to be coated. Electrostatic forces can then guide the powder particles to the article in the desired fashion. It should be understood that the effective flow area of a non-rotating member such as a non-rotating disk-like member increases as the powder particles move radially outward, and therefore, a greater volume of air is required to provide the powder velocity at the edge of the disk-like member necessary to maintain the powder air-entrained and to propel it outward toward the article to be coated with sufficient momentum to carry it to the vicinity of the article. If the aperture is not provided in the second deflector, an undesirable accumulation of powder particles occurs on the disklike member and significant amounts of powder fail to reach the immediate vicinity of the article. The air aspirated into the chamber is essentially free air as opposed to the jets of air used to entrain and convey the powder initially or the jets of air used to provide the swirl air in the chamber and across the non-rotating disk-like member. An aperture in the second deflector significantly increases the air flow across the surface of the disk-like member over the air flow across the disk when an aperture is not provided in the second deflector.

The non-rotating disk-like member is fabricated from a non-conductive material. A coating having relatively high electrical resistance is applied to the uppermost surface of the disk-like member, that is, the surface opposite the surface across which the powder particles are propelled. This coating extends from about center of the disk-like member to its outer edge. A high voltage direct current potential is applied to the coating. The coating conducts the potential to the outer edge of the disk-like member and thus the edge becomes one terminus of a divergent electric field extending radially outwardly from the edge to the article. This field is concentrated at the edge of the disk-like member. As the powder particles are propelled through the high gradient field, they become electrically charged so each particle receives a high charge-to-mass ratio. Being projected to the vicinity of the article, the charged particles are attracted to the article surface and collect thereon by virtue of the charge carried by the powder particles. Because the nomrotating disk-like member is fabricated from a non-conductive material and the coating is of relatively high electrical resistance, deleterious disruptive discharges are kept to a minimum when the edge of the disk-like member is contacted by the article being coated with particles of powder.

The present invention causes the powder particles to be ejected from the non-rotating disk-like member in a substantially flat plane and in a direction which is substantially parallel to the electrical forces of the field. The ports or apertures from which the jets of air are introduced into the mixing chamber are displaced further from the axis of the mixing chamber than the air ports associated with spray devices providing a conical spray. The present invention uses a first powder deflector to deflect the-powder outwardly and into a chamber containing swirl air, and an apertured second deflector to assist in locking the powder onto the surface of the disk-like member. The use of a non-rotating disk-like member has advantages over a rotating powder disk in that no bearings are required, no source of energy for rotating the disk is required, and no seals are required between the stationary powder feed hose and the rotating shaft .necessary to rotate the disk. The present invention also does not depend upon any mechanical means for imparting circular motion to the powder to move it toward the article.

The appended drawings are intended to illustrate an apparatus embodying the concepts of the. present invention constructed to function in the most advantageous mode presently devised for the practical application of the principles involved in the hereinafter described invention.

In the drawings:

FIG. 1 is a diagrammatic illustration of a system embodying a form of the present invention;

FIG. 2 is a partial cross sectional view of an apparatus including the non-rotating disk-like member taken across the line 2-2 of FIG. 3;

FIG. 3 is a partial cross sectional view of the apparatus taken across the line 3-3 of FIG. 2; and

FIG. 4 is a powder reclamation system that can be used with the invention.

Powder, as that word is used herein, means and includes thermoplastic dry powders such as polyester, polyvinyl chloride, polypropylene, polyethylene, nylon, cellulose acetate butyrate; thermosetting dry powders such as epoxies, polyesters, acrylics; other dry powders such as starch, talc, vitreous enamel; and the like.

Many powders, and particularly synthetic thermosetting and thermoplastic powders, when fused, provide films which have characteristics, such as corrosion resistance, color and dielectric strength which make them desirable as coating materials. For example, epoxy resins may be applied and fused to pipe and fittings used in handling corrosive materials; and fused polyesters, butyrates and acrylics may be used as protective and decorative coatings for large flat surfaced articles such as automotive parts, appliance parts and the like, or tubular articles such as bicycle frames and the like. Still other powders such as powdered fluxes can be applied to a surface to be used ultimately in the powder form. Also powdered talc can be applied to prevent self-adhesion of the surfaces being coated. The particular powder used to coat the article will depend on, among other things, the purpose for which the coating is to be used, the nature of the finish required, the environmental conditions to which the article is to be subjected and the like.

Generally, powders are prepared by grinding bulk material, usually at a low temperature. Powder having a particle size in the order of 20 to 200 microns is preferred for electrostatic powder spraying, however, the powder may be coarser or finer, depending on the particular material and application thereof.

Referring now to FIG. 1 of the drawing, a powder dispensing or spraying apparatus is indicated by thereference numeral 10. Thepowder apparatus 10 is nonrotating. A conveyor 11 is provided with electrically conductive hook means 12 for carrying a plurality of articles to be coated with particles of powder such astubular articles 13 in an arcuate path around thepowder apparatus 10. Thepowder apparatus 10 may be mounted for vertical reciprocation by hydraulically operatedreciprocator 14. Thesupport housing 26, attachingapparatus 10 to thereciprocator 14, is fabricated from a dielectric material such as nylon or the like.

The lower end ofreciprocator 14 carries thepowder apparatus 10 which includes a non-rotating member as a substantially fiat, non-rotating disk-like member 15 and a second deflector orbaffie 41, as shown in FIG. 2, each fabricated from a suitable dielectric material such as phenolic or the like. Theapparatus 10 is connected to aventuri pump 17 byhose 21. Thepump 17 drawspowder particles 18 from fluidized powder container orbed 19 and delivers the powder particles topowder disk assembly 10.

Conveyor l1 and hook means 12 maintainarticles 13 at a powder particle attracting potential during the period of time the articles are in the powder coating zone. Preferably, conveyor 11 and hook means 12 are maintained at ground or earth potential. Thesharp edge 58 of the non-rotating disk-like member 15 from which powder is ejected is maintained at a high electrical potential relative to ground by means of a suitable directcurrent powder supply 20 connected to the disk-like member throughcable 25. The directcurrent powder supply 20 is capable of supplying any desired voltage up to about 100,000 volts direct current to theapparatus 10, Preferably, the polarity of the voltage applied to theapparatus 10 is negative although for some applications a positive voltage may be desired.

It should be noted thatarticles 13 are carried by conveyor 11 in an arcuate path (exceeding a semi-circle) around theapparatus 10. The path may be characterized by the Greek letter omega. It is also noted that the path over whicharticles 13 are carried is spaced radially outwardly from theapparatus 10. The electrostatic force existing betweenedge 58 of theapparatus 10 and groundedarticles 13 assists in directing the powder particles outwardly toward the articles along a path which is substantially parallel to the path dictated by the momentum of the particles. During movement around theapparatus 10, thearticles 13, if adequately symmetric, may be rotated by suitable means (not shown) about an axis determined by hook means 12 so that all sides of thearticles 13 are presented a number of times to the action of theapparatus 10.

Powder particles 18 are entrained in air by means ofventuri pump 17 immersed in the powder inbed 19 and delivered to theapparatus 10 throughhose 21. Thepowder bed 19 includes a foraminous sheet means (not shown) for assisting in fiuidizing thepowder particles 18. The powder is fluidized by passing flowing air through the foraminous sheet located near the bottom ofbed 19. Airflowing through the powder causes the powder to expand so as to occupy a greater volume in the bed and to thus become fluidized.

Acontrol panel assembly 29 includes a suitable valve means 30 which controls the flow of air from a source (not shown) throughhose 31 to the fluidizingbed 19. Aventuri pump 17 positioned in thepowder bed 19 has associated therewith anair inlet hose 32, an on-offsolenoid valve 85, an air hose 3:3,pressure regulating valve 34 andair supply hose 35 connected to a suitable compressed air source (not shown). The outlet ofpump 17 is connected throughhose 21 with the rear end of thepowder apparatus 10. The rate of flow of air throughventuri pump 17 is controlled bypressure regulating valve 34. The air pressure, as indicated ongauge 38, provides a reference which can be used to conveniently and readily duplicate desired powder flow rates.

A high voltageD.C. powder supply 20, capable of supplying any desired voltage up to 100,000 volts or more to the powder apparatus is connected with theedge 58 of the non-rotating disk-like member throughcable 25 and a current limiting series resistor 80, as shown in FIG. 2, enclosed in thehousing 26 which is of suitable dielectric material such as plastic. An electrostatic field is established fromedge 58 of the non-rotating disk-like member 15 toarticles 13 being coated. The powder ejected from the disk-like member 15 acquires an electrical charge and is projected into the electrostatic field betweenedge 58 of the disk-like member 15 and thearticles 13 and attracted to and deposited on the articles thereby providing the articles with a coating of powder. Thearticles 13 are subsequently subjected to a suitable temperature so that the powder will be fused and flow in a substantially continuous film or coating.

Referring now to FIG. 2, theapparatus 10 is mounted at the lowermost end ofhousing 26 which supports the apparatus on thereciprocator 14. Theventuri pump 17 andpowder supply 20 are connected to theapparatus 10 through conduits associated with thehousing 26. Theapparatus 10 includes a first powder particle baffle or deflector 40, an apertured second powder particle baffle ordeflector 41, a non-rotating disk-like member 15,chamber 49,cylindrical block 45 and a cup-shapedhousing 68. Thedeflectors 40 and 41,disk 15,cylindrical block 45 andhousing 68 are fabricated from nonconductive or dielectric material such as phenolic or the like.

The rear face orupper surface 42 ofdisk 15 is provided with a substantially continuousconductive coating 43 having a high resistivity. A suitable material for coating 43 is described in U.S. Pat. No. 3,021,077. The disk end ofhigh voltage cable 25 is connected to the rearward end of current limiting multi-megohm resistor 80, which in turn is connected to theconductive coating 43 by way ofpath 27 including a resistive portion and a wire portion. It is desirable to minimize the quantity of metallic conductive material associated with theapparatus 10 to minimize the effective electrical capacity of the powder spraying apparatus. The advantages of minimizing the effective capacity are disclosed in U.S. Pat. No. 3,048,498. The safety features disclosed in that patent are desirably incorporated inapparatus 10.

The first powder baffle or deflector 40 is carried by a plurality offasteners 69 such as plastic bolts or the like which couple deflector 40 to block 45. Powder deflector 40 and theblock 45 cooperate so as to provideannular opening 46. The configuration of the periphery of deflector 40 may be round, ellipsoidal, or the like so as to provide a substantially uniform distribution of powder particles inannular opening 46. The radial extent of deflector 40 should be greater than the radial extent of orifice 47. Orifice 47 is the powder outlet orifree oftube 21 at the disk and is connected tobed 19 throughconduit 21. The forward velocity of the powder ejected from orifice 47 is decreased when the powder strikes therear surface 48 of deflector 40. The powder is deflected about in all directions. A substantially conically shaped means 39 may be located at the center of the deflector 40 to aid in the deflection of the powder into a 360 outwardly moving pattern. Preferably, the axes of thedeflectors 40 and 41 and the orifice 47 are coincident.

Powder particles 18 are deflected towardchamber 49 at a reduced velocity.Chamber 49 is formed, in part, by the structural cooperation between deflector 40,deflector 41 andblock 45. Jets of air are introduced into thechamber 49 substantially tangentially to the direction of the flow of powder particles ejected from orifice 47. The jets of air are introduced through a plurality of apertures illustrated, in part, byapertures 50, 51 and 52 formed in the side walls of thechamber 49 to thereby assist in effecting a uniform distribution of the powder oversurface 53 ofdisk 15 and in aspirating air throughaperture 59. As many apertures as are necessary to achieve the desired results may be formed in the walls of thechamber 49. The jets of air intercept and swirl the powder oversurface 53 in a substantially whirling cyclone-type fashion. The velocity of, air entraining the powder and the velocity of the jets of air entering thechamber 49 are so interrelated that the powder moves substantially radially along the undersurface 53 ofdisk 15 in restricted slot-like opening 81 provided by the cooperative relationship betweendisk 15 anddeflector 41.

As shown in FIG. 3, theapertures 50, S1 and 52 extend fromplenum 67 intochamber 49 so as to lie along a tangent to the circumference tochamber 49. Air from a compressed source (not shown) is caused to flow to theapertures 50, 51 and 52 throughair passage 66 andplenum 67.Plenum 67 is formed by the structural cooperation betweenhousing 66 andblock 45.

Thedeflector 41 functions to assist in locking the air-entrained powder to surface 535 so that the powder does not prematurely leave thedisk 15, and so that substantially all of the powder particles pass in close proximity tosharp edge 58 of thedisk 15.

Aperture 59 formed in thedeflector 41 allows air to be aspirated into the mixingchamber 49 by the movement of the powder-air mixture from the chamber. The aspirated air is added to the primary entraining air used to entrain the powder drawn frompowder bed 19 and to the swirl air provided through the various apertures in the side walls ofchamber 49. The aspirated air assists in maintaining the desired velocity of the air used to entrain and carry the powder particles as the particles move radially out towardedge 58 ofdisk 15 and toward the articles to be coated with the momentum necessary to carry the powder to the article to be coated. It should be understood that the cross-sectional flow area increases as the powder moves radially outwardly alongsurface 53 ofdisk 15, and, therefore, a large volume of air is required to provide an air velocity at theedge 58 coated. Upon being propelled to the vicinity of the article, the electrostatic forces guide the powder particles to the surface of the article. The electrostatic field for charging and depositing the powder ejected from theapparatus 10 extends fromsharp edge 58 of disk toarticles 13 being coated. The charge on the particles is greatest when the powder particles are caused to pass in close proximity to theedge 58 ofdisk 15 since the field gradient is great at the edgeof the disk.

Preferably, the major surfaces ofdisk 15 and thedeflectors 40 and 41 are substantially flat. The radial, swirling flow of powder across surfaces of thedeflectors 40 and 41 tends to prevent a build-up of powder particles on such surfaces and does not establish an air flow in the direction ofarticles 13 being coated which would blow from the articles, powder particles already deposited thereon. It is seen thatapparatus 10 should not have any air flows associated with it that are likely to blow off powder that has heretofore been deposited and thereby decrease deposition efficiency.

Edge 58 ofdisk 15 is provided with asurface 65 having-an angle in the order of 30 with the lower surface of the disk. This sharpensedge 58 so that the electrical field gradient at the edge is sufficiently high to provide the powder particles with a high charge-to-mass ratio. However, the angle ofsurface 65 can be varied considerably consistent with physical strength and maximum field gradient required.

During .the coating operation, the groundedarticles 13 are moved to a coating zone where charged particles of powder ejected from theapparatus 10 are attracted by thearticles 13 to be coated and are retained on the articles by electrostatic attraction. As the coating becomes thicker, a surface charge is established on the articles because the particles tend to retain their electric charges. This charge tends to inhibit the accumula tion of additional powder. The maximum thickness of the coating which can be applied varies with the electrical properties of the different powdered materials and with the voltage applied tosharp edge 58 of thedisk 15. The powder deposited on the articles being coated will tend to accumulate first in the area most closely aligned withedge 58 of thedisk 15. As the maximum coating thickness on this area is achieved, the deposition pattern expands and the particles are deposited on more distant portions of the article surfaces. The result is that theentire article 13 tends to acquire a substantially uniform coating with a minimum of relative movement between theapparatus 10 and thearticle 13. If spraying is continued after the article is coated to maximum thickness, the powder particles will merely fail to be deposited on the article. Such excess powder will go past thearticles 13 as oversprayed material, accumulate within theenclosure 70 and may be recovered in any suitable manner as by filter-separator 72.

After a coating of the desired thickness is deposited onarticle 13, it is removed from the coating zone, and the powder is cured in a suitable manner, as by heating to the melting temperature of the powder particles. In some cases additional applications of powder may be necessary to achieve a thicker coating. Preheating of the article to be coated increases the maximum thickness of the coating which'can be achieved. The powder particles are heated upon contact with the article and since the electrical properties of the hot material are different from those of the cold, the charge is dissipated rapidly permitting the deposition 'of additional powder particles.

The following examples are given to further illustrate the concepts of the presentinvention.

EXAMPLE 1 Unheatedcylindrical metal articles 13 having a length of about 42 inches, a diameter of about l inch and arranged on about 3-inch centers are conveyed in an arc of about 270 in extent around the nonrotating disk-like member 15 ofapparatus 10 at a rate of about 9 to 10 feet per minute. Powdered epoxy 202, manufactured by Minnesota Mining and Manufacturing Company, having an average particle size of about 20 to 150 microns, is ejected from theapparatus 10 using air pressure at the pump of about 45 pounds per square inch and having an air flow rate of about 1.5 scfm with a delivery rate of about 240 grams of powder per minute. The spacing between thedisk edge 58 andarticles 13, when the articles are adjacent theapparatus 10, is about 14 to 19 inches. The articles are in the coating zone for about 45 to 60 seconds. The voltage applied to disk edge 58 from thepower supply 20 through resistor is approximately kilovolts. Thereciprocator 14 moves theapparatus 10 vertically over the length of the articles at about 10 times per minute. After spraying the articles with the epoxy powder, the coated articles are subjected to a fusing cycle of about 375450 F for about 2 minutes or more depending on the thickness of the metal wall of the cylindrical articles. An epoxy film of 2 to 3 mils thickness is formed on the articles. It is to be understood that the length of time required to fuse the epoxy powder can be reduced if the articles are appropriately pre-heated prior to depositing powder thereon.

EXAMPLE 2 The above example is repeated using a suitable vinyl powder such as vinyl power 1315, manufactured by the Polymer Corp, having an average particle size of about 20 to microns. The fusion cycle for the pow der is about 450-475 F for about 2 minutes or more depending on the thickness of the metal wall of the cylindrical article. A vinyl film of 2 to 3 mils thickness is formed on the article.

The relationship between the diameters ofdeflector 41 anddisk 15 and the spacing betweendeflector 41 anddisk 15 should be such that the entrained powder does not leave the surface of the disk prior to passing in close proximity to edge 58 of the disk. Preferably,deflector 41 has a diameter substantially equal to or a few inches less than the diameter ofdisk 15; adeflector 41 having adiameter 1 to 3 inches less than the diameter of thedisk 15 is most preferred.

The spacing betweendisk 15 anddeflector 41 should be such as to cause the powder to remain in close proximity withsurface 53. The distance betweendeflector 41 and surfaces 53 ofdisk 15 is adjusted by turningfasteners 69 into or out of cooperatively associated threaded apertures to thereby compress or release compressive pressure heretofore exerted upon resilientplastic spacers 82. Thedistance separating deflector 41 andsurface 53 should be substantially constant over the radial extent of both elements. Deflector 40 is predeterminately spaced from orifice 47 byplastic spacers 83.

The radial extent of chamber d9 should be such so that the multiple of circumferentially directed air jets impart to the air entrained powder in the chamber a whirling cyclone-type motion which causes the entrained powder particles to escape from the chamber as an expanding powder-air mixture into the slot-like opening 81 provided by the structural cooperation between disk anddeflector 41. The escape of the expanding powder-air mixture from the chamber is of such a nature as to aspirate air throughaperture 59 intoslot 81.

Although substantially all of the powder ejected fromapparatus 10 is attracted to and deposited onarticles 13 bythe action of the electrostatic forces, a small amount of the ejected powder will not be deposited. To reclaim the nondeposited powder particles, an air tube (not shown) connected to a source of air under pressure is suitably connected to floor 73in the powder particle coating zone.Floor 73 is foraminous and directs streams of air upwardly so as to fluidize powder that has fallen to the floor. The nondeposited particles that have fallen upon theinclined floor 73 are fluidized by air forced upwardly through said floor so that the powder particles on the floor tend to flow downwardly along said floor to centrally locatedaperture 71.

Acollector 72 such as a filter-separator is connected toaperture 71 throughconduit 74. Preferably,collector 72 is maintained under at least a partial vacuum to assist in drawing the undeposited particles therein. In this manner, the non-deposited particles moving along thefloor 73 will pass intoconduit 74 and intocollector 72 so that they can be collected for possible-reuse.

An embodiment of a reclaiming means shown in FIG. 1 is shown in FIG. 4. Theenclosure 70, essentially a cylinder body, has a height of about 8 feet with aconical bottom portion 75 and a substantiallyflat roof 76. Preferably,theenclosure 70 includes appropriate entrance and exit silhouettes and tunnels for the articles to be coated with powder. Conveyor 11 is outside and above roof 756. The enclosure is exhausted of undeposited powder particles through the lower part of theconical bottom 75. Air input to the enclosure will be through the silhouettes, the conveyor slot in the roof and through such other openings as may be formed inroof 76. Preferably, these openings are covered with a suitable plenum which receives some air from arecovery system exhaust 82. These latter openings can be arranged with adjustable covers to permit air flow adjustment. Preferably,enclosure 70 is maintained at a negative pressure.

At the bottom center ofenclosure 70 is a column support 77 to retain in position the center of a forami- Although the present invention has particular applicability to electrostatic powder coating, it should be understood that the concepts are also applicable to non-electrostatic powder coating if the powder is projected to the surface ofarticles 13. Whenapparatus 10 is used in non-electrostatic powder coating situations, the powder particles are entrained in air and projected by an air stream as described above onto heated articles. The articles must be heated to or above the softening point of the powder particles before the powder particles are applied, so that the particles are softened on contact with the article, adhere to the article and coalesce forming a substantially continuous coating. in this method, heat is required in order that the powder particles adhere to the article. It should be understood that the necessity of preheating the article and the problems involved in maintaining the entire article at a relatively uniform temperature during the coating operation, which is necessary in order to obtain a uniform coating, makes such a method less desirable than electrostatically charging and depositing powder particles.

As regards electrostatic coating, it appears that, in the alternative,articles 13 can be connected to highvoltage power supply 20 and thatdisk edge 58 can be grounded. An electrostatic field exists between the groundededge 58 of the disk and thearticles 13; such an electrostatic field appears to have substantially the same effect on the powder particles as does the electrostatic field provided when the article is grounded and the disk edge is connected to thepower supply 20. Preferably, however,disk edge 58 is connected to the highvoltage power supply 20 andarticles 13 are grounded. Also, in the event the surface of articles 13 t is electrically non-conductive, the surface may be ren- We claim: 1. An apparatus for coating an article with particles of powder entrained in a gas including means having an orifice adapted to receive and project powder entrained in a gas, means spaced from the orifice and in the path of powder flow from the orifice for deflecting outwardly the powder projected from the orifice, a non-rotating surface adjacent the means for deflecting the powder, the deflected powder traveling across the surface, means adjacent the surface across which the powder is traveling allowing gas to be aspirated so as to provide an additional volume of gas to assist in conveying the powder outwardly from an extremity of the surface and to the article to be coated. with sufficient momentum to carry substantially all of the powderto the vicinity of the article, and means providing a high voltage gradient at the extremity of the surface for charging powder adjacent the extremity.

2. The apparatus for coating an article with particles of powder entrained in a gas as claimed inclaim 1,

wherein the surface is formed by a substantially flat, disk-like non-rotating member and wherein the means allowing gas to be aspirated is apertured and includes a substantially flat surface spaced from and parallel to the surface of the disk-like member.

3. The apparatus for coating an article with particles of powder entrained in a gas as claimed inclaim 2, wherein the powder particles are projected from the extremity of the surface in a plane substantially parallel to the plane of an electrostatic field between the extremity of the surface and the article being coated.

4. The apparatus for coating an article with particles of powder entrained in a gas as claimed inclaim 2, wherein the radial extent of the disk like member is at least equal the radial extent of the substantially flat surface of the apertured means.

5. The apparatus for coating an article with particles of powderflentrained in a gas as claimed inclaim 2, wherein the axis of the orifice for projecting the en trained powder, the axis of the means for deflecting the powder outwardly and the axis of the aperture of the apertured means are substantially coincident.

6. The apparatus for coating an article with particles of powder entrained in a gas as claimed inclaim 2, including means for providing the powder with swirling gas to assist in conveying the powder radially outward and to the article to be coated.

' 7. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 6, wherein the means for providing swirling gas includes a chamber having apertured side walls that introduce jets of gas into the chamber substantially tangential to the side walls of the chamber.

8. An electrostatic apparatus for coating an article maintained at a particle attracting potential with particles of powder entrained in a gas including means having an orifice adapted to receive and project powder entrained in a gas, means spaced from the orifice and in the path of powder flow from the orifice for deflecting outwardly the powder projected from the orifice, a non-rotating surface adjacent the means for deflecting the powder and having a sharp edge, the deflected powder traveling across the non-rotating surface and passing in close proximity to the edge, the edge being adapted to be connected to a voltage source to provide a high voltage gradient at the edge for charging powder adjacent the edge, and apertured means adjacent the non-rotating surface across which the powder is traveling allowing gas to be aspirated through the apertured meansto provide an additional volume of gas to assist in conveying the charged powder radially outwardly from the edge and to the article to be coated with sufficient momentum to carrying substantially all of the charged powder to the vicinity of the article.

9. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 8, wherein the surface is provided by a disk-like member and the powder particles are projected from the edge of the disk in a plane substantially parallel to the plane of an electrostatic field between the edge of the disklike member and the article being coated.

10. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 8, further including means for reclaiming the powder not deposited on the article.

11. An electrostatic powder spraying apparatus in cluding a non-rotating disk-like member having a sharp voltage source to provide a high field gradient at the sharp edge for charging powder particles adjacent the edge, means defining a passage adapted to be connected to powder entrained in air for providing entrained powder to the non-rotating disk-lil e member, a first deflector deflecting powder radially outwardly along the surface of the disk-like member, a chamber adjacent the first deflector providing air to the radially deflected powder and an apertured second deflector spaced from the disk-like member, the movement of entrained powder outwardly along the surface of the disk aspirating air through the aperture so that the powder has sufficient momentum to be ejected from the edge of the disk to the vicinity of an article at a powder attracting potential.

12. The electrostatic powder spraying apparatus as claimed in claim 11, wherein the first and second deflectors are substantially disk-like.

13. The electrostatic powder spraying apparatus as claimed inclaim 12, wherein the apertured disk-like second deflector has a substantially flat surface in close proximity with the disk-like member.

14. The electrostatic powder spraying apparatus as claimed inclaim 13, including means for adjusting the distance between the flat surface of the second deflector and the surface of the disk-like member.

15. Means for coating an article with particles of powder comprising a non-rotating apparatus for providing a spray of powder, the apparatus having an interior portion and an opening to permit flow from its interior portion, first means to deliver a flow of entrained powder to the interior portion of the apparatus, second means to deliver a jet of air to the interior portion of the apparatus to effect a more uniform flow of powder from the opening of the apparatus, third means to permit a flow of atmosphere to be induced into the interior portion of the apparatus by the flow of powder and air through the opening, and to be added to the flow of powder and air from the opening means to form the flowing powder and air into a radially expanding spray and electrostatic means to charge the powder spray to effect its deposition on the article to be coated.

16. Means as set forth inclaim 15, the interior portion of the powder spraying apparatus including a chamber joined with the opening to permit flow from the chamber to the opening, the first means delivering the flow of powder to the chamber, the second means delivering the jet of air to the chamber and directing it to effect a more uniform distribution of powder in the chamber, and the third means adjoining the chamber and adding the induced flow of atmosphere to the flow of powder and air from the chamber.

17. Means as set forth inclaim 15 in which the means to form the flowing powder and air into a radially expanding spray includes a substantially flat, radially extending disk-like member and the flow of powder, air and atmosphere from the interior portion of the apparatus is directed across a disk-like surface of the member.

18. The means asset forth inclaim 15 wherein the first means includes an orifice that directs the flow of powder into the interior portion of the apparatus but not toward the opening and the second means directs the jet of air into the interior portion of the apparatus with a velocity to move the entrained powder from the orifice toward the opening.

19. The means as set forth in claim wherein the interior portion includes a chamber connected with the opening permitting flow from the chamber to the opening, the first means delivers the flow of powder to the chamber, the second means delivers the jet of air to the chamber and directs it to effect a more uniform distribution of powder in the chamber, and the third means is connected with the chamber and adds the induced flow of atmosphere to the flow of powder and air from the chamber to the opening.

20. The means as set forth inclaim 15 wherein the interior portion defines an annular opening between the interior portion and the opening through which the powder and air flow, and the second means includes an orifice to direct the jet of air into the interior portion between the first means and the annular opening.

21. The means as setforth in claim wherein the third means directs the induced flow of atmosphere toward the annularopening of the interior portion to combine with the flow of powder and air through annular opening to the opening.

22. The means as set forth inclaim 20 wherein the third means includes a deflector opposite the annular opening with an aperture near its center.

23. The means as set forth inclaim 20 wherein the annular opening is formed by a first deflector that is provided in the interior portion of the apparatus and located opposite the first means.

24. The means as set forth in claim 23 wherein the third means includes a second deflector opposite the annular opening with an aperture to permit passage of an induced flow of air, the first deflector being interposed between the first means and aperture, and the second means delivers the jet of air into the interior portion of the apparatus with a velocity component that is tangential to the flow entrained powder from the first means.

25. The means as set forth in claim 23 wherein the first means includes an orifice and directs the flow of entrained powder at the third means the second means forms a chamber and includes a plurality of orifices to deliver a plurality of air jets into the chamber tangential to the flow of entrained powder from the orifice of the first means, the first deflector being located to intercept the flow of entrained powder from the orifice of the first means and the entrained powder being moved by the action of the plurality of jets through the annular opening in the direction of the opening, the third means includes a second deflector located opposite the annular opening and including a central aperture so that atmosphere is induced to flow through the aperture to be directed by the deflectors in the direction of annular opening and the opening and to be added to the flow of entrained powder and air from said opening.

26. The means as set forth inclaim 15 wherein a deflector is provided in the interior portion of the apparatus opposite the first means to deliver a flow of entrained powder to the interior portion and the deflector cooperates with the second means to form an annular opening from the interior portion.

27. The means as set forth inclaim 26 wherein the interior portion includes a chamber formed by the second means, the deflector and the third means, and the opening is formed by the third means and a radially extending disk-like surface that carries the electrostatic means to charge the powder spray, said opening. third means and radially extending disk-like surface forming the means to form the flow powder and air into a radially expanding spray.

28. The means as set forth inclaim 27 wherein the third means is adjustably fixed to the appparatus so that the opening between deflector and the radially extending surface may be varied.

29. Means for coating an article with particles of powder comprising a non-rotating apparatus for providing a spray of powder, the apparatus having an interior portion and an opening to permit flow from its interior portion, first means to deliver a flow of entrained powder to the interior portion of the apparatus, second means to deliver a jet of air to the interior portion of the apparatus to effect a more uniform flow of powder from the opening of the apparatus, third means to permit a flow of atmosphere to be induced into the interior portion of the apparatus by the flow of powder and air through the opening, and to be added to the flow of powder and air from the opening in forming a powder spray from apparatus, a substantially flat, radially extending disk-like surface and the flow of powder, air and'atmosphere from the interior portion of the apparatus is directed across the disk-like surface to be dispersed as a radially expanding spray, and electrostatic means to charge the powder spray to effect its deposition on the article to be coated.

30. Means as set forth in claim .29, the interior portion of the powder spraying apparatus including a chamber joined with the opening to permit flow from the chamber to the opening, the first means delivering the flow of powder to the chamber, the second means delivering the jet of air to the chamber and directing it to effect a more uniform distribution of powder in the chamber, and the third means adjoining the chamber and adding the induced flow of atmosphere to the flow of powder and air from the chamber.

31. The means as set forth inclaim 17 wherein the radially extending disk-like member carries the electro-

Claims (31)

1. An apparatus for coating an article with particles of powder entrained in a gas including means having an orifice adaPted to receive and project powder entrained in a gas, means spaced from the orifice and in the path of powder flow from the orifice for deflecting outwardly the powder projected from the orifice, a non-rotating surface adjacent the means for deflecting the powder, the deflected powder traveling across the surface, means adjacent the surface across which the powder is traveling allowing gas to be aspirated so as to provide an additional volume of gas to assist in conveying the powder outwardly from an extremity of the surface and to the article to be coated with sufficient momentum to carry substantially all of the powder to the vicinity of the article, and means providing a high voltage gradient at the extremity of the surface for charging powder adjacent the extremity.

2. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 1, wherein the surface is formed by a substantially flat, disk-like non-rotating member and wherein the means allowing gas to be aspirated is apertured and includes a substantially flat surface spaced from and parallel to the surface of the disk-like member.

3. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 2, wherein the powder particles are projected from the extremity of the surface in a plane substantially parallel to the plane of an electrostatic field between the extremity of the surface and the article being coated.

4. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 2, wherein the radial extent of the disk-like member is at least equal the radial extent of the substantially flat surface of the apertured means.

5. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 2, wherein the axis of the orifice for projecting the entrained powder, the axis of the means for deflecting the powder outwardly and the axis of the aperture of the apertured means are substantially coincident.

6. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 2, including means for providing the powder with swirling gas to assist in conveying the powder radially outward and to the article to be coated.

7. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 6, wherein the means for providing swirling gas includes a chamber having apertured side walls that introduce jets of gas into the chamber substantially tangential to the side walls of the chamber.

8. An electrostatic apparatus for coating an article maintained at a particle attracting potential with particles of powder entrained in a gas including means having an orifice adapted to receive and project powder entrained in a gas, means spaced from the orifice and in the path of powder flow from the orifice for deflecting outwardly the powder projected from the orifice, a non-rotating surface adjacent the means for deflecting the powder and having a sharp edge, the deflected powder traveling across the non-rotating surface and passing in close proximity to the edge, the edge being adapted to be connected to a voltage source to provide a high voltage gradient at the edge for charging powder adjacent the edge, and apertured means adjacent the non-rotating surface across which the powder is traveling allowing gas to be aspirated through the apertured means to provide an additional volume of gas to assist in conveying the charged powder radially outwardly from the edge and to the article to be coated with sufficient momentum to carrying substantially all of the charged powder to the vicinity of the article.

9. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 8, wherein the surface is provided by a disk-like member and the powder particles are projected from the edge of the disk in a plane substantially parallel to the plane of an electrostatic field between the edge of The disk-like member and the article being coated.

10. The apparatus for coating an article with particles of powder entrained in a gas as claimed in claim 8, further including means for reclaiming the powder not deposited on the article.

11. An electrostatic powder spraying apparatus including a non-rotating disk-like member having a sharp edge, the member adapted to be connected to a high voltage source to provide a high field gradient at the sharp edge for charging powder particles adjacent the edge, means defining a passage adapted to be connected to powder entrained in air for providing entrained powder to the non-rotating disk-like member, a first deflector deflecting powder radially outwardly along the surface of the disk-like member, a chamber adjacent the first deflector providing air to the radially deflected powder and an apertured second deflector spaced from the disk-like member, the movement of entrained powder outwardly along the surface of the disk aspirating air through the aperture so that the powder has sufficient momentum to be ejected from the edge of the disk to the vicinity of an article at a powder attracting potential.

12. The electrostatic powder spraying apparatus as claimed in claim 11, wherein the first and second deflectors are substantially disk-like.

13. The electrostatic powder spraying apparatus as claimed in claim 12, wherein the apertured disk-like second deflector has a substantially flat surface in close proximity with the disk-like member.

14. The electrostatic powder spraying apparatus as claimed in claim 13, including means for adjusting the distance between the flat surface of the second deflector and the surface of the disk-like member.

15. Means for coating an article with particles of powder comprising a non-rotating apparatus for providing a spray of powder, the apparatus having an interior portion and an opening to permit flow from its interior portion, first means to deliver a flow of entrained powder to the interior portion of the apparatus, second means to deliver a jet of air to the interior portion of the apparatus to effect a more uniform flow of powder from the opening of the apparatus, third means to permit a flow of atmosphere to be induced into the interior portion of the apparatus by the flow of powder and air through the opening, and to be added to the flow of powder and air from the opening means to form the flowing powder and air into a radially expanding spray and electrostatic means to charge the powder spray to effect its deposition on the article to be coated.

16. Means as set forth in claim 15, the interior portion of the powder spraying apparatus including a chamber joined with the opening to permit flow from the chamber to the opening, the first means delivering the flow of powder to the chamber, the second means delivering the jet of air to the chamber and directing it to effect a more uniform distribution of powder in the chamber, and the third means adjoining the chamber and adding the induced flow of atmosphere to the flow of powder and air from the chamber.

17. Means as set forth in claim 15 in which the means to form the flowing powder and air into a radially expanding spray includes a substantially flat, radially extending disk-like member and the flow of powder, air and atmosphere from the interior portion of the apparatus is directed across a disk-like surface of the member.

18. The means as set forth in claim 15 wherein the first means includes an orifice that directs the flow of powder into the interior portion of the apparatus but not toward the opening and the second means directs the jet of air into the interior portion of the apparatus with a velocity to move the entrained powder from the orifice toward the opening.

19. The means as set forth in claim 15 wherein the interior portion includes a chamber connected with the opening permitting flow from the chamber to the opening, the first means delivers the flow of powder to the chamber, the second means delivers the jet of air to the chamber and directs it to effect a more uniform distribution of powder in the chamber, and the third means is connected with the chamber and adds the induced flow of atmosphere to the flow of powder and air from the chamber to the opening.

20. The means as set forth in claim 15 wherein the interior portion defines an annular opening between the interior portion and the opening through which the powder and air flow, and the second means includes an orifice to direct the jet of air into the interior portion between the first means and the annular opening.

21. The means as set forth in claim 20 wherein the third means directs the induced flow of atmosphere toward the annular opening of the interior portion to combine with the flow of powder and air through annular opening to the opening.

22. The means as set forth in claim 20 wherein the third means includes a deflector opposite the annular opening with an aperture near its center.

23. The means as set forth in claim 20 wherein the annular opening is formed by a first deflector that is provided in the interior portion of the apparatus and located opposite the first means.

24. The means as set forth in claim 23 wherein the third means includes a second deflector opposite the annular opening with an aperture to permit passage of an induced flow of air, the first deflector being interposed between the first means and aperture, and the second means delivers the jet of air into the interior portion of the apparatus with a velocity component that is tangential to the flow entrained powder from the first means.

25. The means as set forth in claim 23 wherein the first means includes an orifice and directs the flow of entrained powder at the third means, the second means forms a chamber and includes a plurality of orifices to deliver a plurality of air jets into the chamber tangential to the flow of entrained powder from the orifice of the first means, the first deflector being located to intercept the flow of entrained powder from the orifice of the first means and the entrained powder being moved by the action of the plurality of jets through the annular opening in the direction of the opening, the third means includes a second deflector located opposite the annular opening and including a central aperture so that atmosphere is induced to flow through the aperture to be directed by the deflectors in the direction of annular opening and the opening and to be added to the flow of entrained powder and air from said opening.

26. The means as set forth in claim 15 wherein a deflector is provided in the interior portion of the apparatus opposite the first means to deliver a flow of entrained powder to the interior portion and the deflector cooperates with the second means to form an annular opening from the interior portion.

27. The means as set forth in claim 26 wherein the interior portion includes a chamber formed by the second means, the deflector and the third means, and the opening is formed by the third means and a radially extending disk-like surface that carries the electrostatic means to charge the powder spray, said opening, third means and radially extending disk-like surface forming the means to form the flow powder and air into a radially expanding spray.

28. The means as set forth in claim 27 wherein the third means is adjustably fixed to the appparatus so that the opening between deflector and the radially extending surface may be varied.

29. Means for coating an article with particles of powder comprising a non-rotating apparatus for providing a spray of powder, the apparatus having an interior portion and an opening to permit flow from its interior portion, first means to deliver a flow of entrained powder to the interior portion of the apparatus, second means to deliver a jet of air to the interior portion of the apparatus to effect a more uniform flow of powder from the opening of the apparatus, third means to permit a flow of atmosphere to be induced into the interior portion of the apparatus by the flow of powder and air through the opening, and to be added to the flow of powder and air from the opening in forming a powder spray from apparatus, a substantially flat, radially extending disk-like surface and the flow of powder, air and atmosphere from the interior portion of the apparatus is directed across the disk-like surface to be dispersed as a radially expanding spray, and electrostatic means to charge the powder spray to effect its deposition on the article to be coated.

30. Means as set forth in claim 29, the interior portion of the powder spraying apparatus including a chamber joined with the opening to permit flow from the chamber to the opening, the first means delivering the flow of powder to the chamber, the second means delivering the jet of air to the chamber and directing it to effect a more uniform distribution of powder in the chamber, and the third means adjoining the chamber and adding the induced flow of atmosphere to the flow of powder and air from the chamber.

31. The means as set forth in claim 17 wherein the radially extending disk-like member carries the electrostatic means to charge the powder spray.

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