Ionizing Bar for Air Nozzle Manifold

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001 ] This application claims the benefit of U.S. Provisional Patent Application No.

61/824.587, entitled 'Ionizing Bar for Air Nozzle Manifold," filed on May 17, 2013, currently pending, and the benefit of U.S. Provisional Patent Application No. 61/887,543, entitled

"Ionizing Bar for Air Nozzle Manifold," filed on October 7, 2013, currently pending, the entire contents of all of which are incorporated by reference herein.

BACKGROUND OF THE INVENTION

(0002J Embodiments of the present invention relate generally to air cleaning and static neutralizing systems, and more particularly, to an ionizing bar mounted into an air nozzle manifold.

[0003] Conventional bottle or can-tilling applications often utilize compressed air to clean the bottles or cans on the assembly line prior to filling. Similarly, it is often desirable to neutralize static electricity which builds up or is otherwise introduced in the bottles or cans during a filling operation. Discrete nozzles were therefore used to blow ionized compressed air into the bottles or cans to accomplish both tasks at once. However, these solutions are costly due to the use of compressed air and the cost for powering the electrical components of the discrete nozzles. Maintenance is also difficult to perform on the discrete nozzles. [000 J Alternatives to compressed air nozzles, such as air manifolds having a series of nozzles, air knives, or the like, may be used to direct air received at an inlet from a blower. It is desirable to provide a cleaning and static neutralizing system that utilizes blown, rather than compressed, air, and which allows for the use of an efficient static neutralizing device that is simple to manage and service as part of the blown air system without compromising the desired effects of the blown air.

BRIEF SUMMARY OF THE INVENTION

f0005] Briefly stated, an embodiment of the present invention comprises a processing system including an air blower and an air manifold including a main body having an inlet coupled to the air blower and a plurality of outlet openings. Each of the outlet openings is coupled to a nozzle. An ionizer bar includes a housing, a power cable contained within the housing, and a plurality of emitter pins electrically coupled to the power cable. A cartridge includes two side plates forming a channel in which the ionizer bar is mounted. The cartridge is removably couplable to an interior of the main body of the air manifold.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

|0006| The foregoing .summary as well as the following detailed description of preferred embodiments of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, (hat the invention is not limited to the precise arrangements and instrumentalities shown.

10007) In the drawings:

(0008) Fig. I is a schematic diagram of a processing system in accordance with a first preferred embodiment ofthe present invention: [00091 Fig. 2 is a front side perspective view of an air manifold in accordance with the first preferred embodiment of the present invention:

[OOIOJ Fig. 3 is a cross-sectional front side elevational view of the air manifold of Fig. 2 with the ionizer bar installed:

(0011 J Fig. 4 is a top plan view of a cartridge for securing the ionizer bar to the air manifold in Fig. 3;

|0012] Fig. 5 is a bottom side perspective view of the cartridge of Fig. 4;

|0013] Fig. 6 is a right side elevational view of the ionizer bar of Fig. 3;

|0014) Fig. 7 is a front side elevational view ofthe ionizer bar of Fig. 3:

(0015| Fig. 8 is a side elevational view of an attachment tool for manufacturing the air manifold of Fig. 3 in accordance with the first preferred embodiment of the present invention;

2 |00J 6] Fig. 9 is a iixxH side perspective view of an air knife in accordance with a second preferred embodiment of the present invention;

| 17| Fig. 1 is a front side perspective view ol an air manifold in accordance with a third preferred embodiment of the present invention: (0018| Fig. 11 a cross-sectional front side elevational view of the air manifold of Fig. 10 with the ionizer bar installed: and

|0019) Fig. 12 side view of a nozzle and elongated cylindrical shaft coupled thereto tor use in the air manifold of Fig. 10.

DETAILED DESCRIPTION OF THE INVENTION

(0020| Certain terminology is used iu the following description for convenience only and is not limiting. The words "right," "left." "lower" and "upper" designate directions in the drawings to which reference is made. The words "inwardly" and "outwardly" refer to directions toward and away from, respectively, the geometric center of the device and designated parts thereof. Unless specifically set forth herein, the terms "a", "an" and "the" are not limited to one element but instead should be read as meaning "at least one". T he terminology includes the words noted above, derivatives thereof and words of similar import.

(0021 ( Referring to the drawings, wherein the same reference numerals are used to designate the same components throughout the several figures, there is show n in Fig. I a processing system 10 that includes an air supply source 12 configured to deliver a fluid (e.g.. air) to air manifolds 14 A and 14B along a flow path 1 . In the illustrated embodiment, the How path 16 i cludes fluid conduits 20, 2, 6, and 38. a filter 24. and a di ider 32.

[0022] The air supply source 12 may include a high flow centrifugal blower ("air blower* ^' ) which, in some embodiments, may include a supercharger and motor configuration. In one embodiment, the operating characteristics of the air blower 12 may provide an air (low having a pressure of between approximately 1-10 pounds per square inch (psij and having a flow rate of between approximately 50-2000 cubic feet per minute (CFM) or more specifically, between approximately 150 to 1 0 CF . In some embodiments, the air blower 12 may be housed within an enclosure. The air blower 12 may be separated from the air manifolds 14A and 14B by

3 a distance of 10, 20, 30, 40, 50, 100, or 200 feet or more. As such, the flow part) 16 is configured to provide a path through which air provided by the air blower 12 may be routed and ultimately delivered to the air manifolds l4A and I4B.

|0023| The air blower 12 may include an outlet 18 coupled (o (he fluid conduit 20 that defines a first portion of the fl w path 16. The fluid conduit 20 may be a hose, such as a flexible hose, a pipe, such as a stainless steel pipe or a polyvinyl chloride (i'VC) pipe, ductwork, or the like. Adapters (not shown) may be used in the How path 16 to provide an interface for coupling dissimilar conduit materials, uch as a hose and a pipe. A filter 24 is preferably disposed downstream of the air blower 12. As shown in Fig. 1. the filter 24 i.s interposed between the conduits 20. 22. Operation of the filter 24 will be described in further detail below.

| 24| The flow path 1 continues to the distal etui of the conduit 22, which may be coupled to an inlet 30 of a flow divider 32 that receives the air flow. The flow divider 32 may be configured to distribute or split the air flow to multiple outlets 33 and 34. Additional fluid conduits 36 and $ may respectively couple the outlets 33 and 34 to the air manifolds 14A and 14B. respectively. In the illustrated embodiment, the air manifolds 14A and 14B may each include an inlet f 40A and 40B) configured for a hose connection, and the fluid conduits 36 and 38 may thus be provided as hoses, such as flexible hoses or the like. In other embodiments, a pipe may be disposed between the divider 32 and one of the air manifolds Ι Λ or 14B. whereby adapters (not shown) are coupled to each end of the pipe to facilitate a fluid connection he! ween hoses extending from an outlet (e.g.. 33 or 34) of the divider 32 and from an mlet (e.g., 40A or 40B) of one of the air manifolds (e.g.. Ι4Λ or 14B). In some embodiments, the system 10 may include only a single air manifold (e.g., 14A) and thus may not include a divider 32. In such embodiments, the fluid conduit 22 may be coupled directly to the air manifold 14A.

( II25J As shown in Fig. I , the air flow 44 exiting the air manifolds 14 A and 14B may be directed towards applications 48 and 50. respectively, of the processing system 10. For example, the applications 48. 50 may be transported through the system 10 along u conveyor belt 52 or other suitable type of transport mechanism. As will be appreciated, the system 10 may utilize the air flow 44 provided by tlie air manifolds 14A and I4B. respectively, for a variety of functions, including but not limited to drying products, removing dust or debris, coating control, cooling.

4 leak detection, surface impregnation, corrosion prevention, and (he like. For example in certain embodiments, the system 10 may be used for drying food or beverage containers, such as cans or bottles, or may be a system tor removing dust and other debris from sensitive electronic products, such as printed circuit boards ( PCBs) or the like. In addition, some embodiments of the system 10 may also utilize the air flow 44 to clean and/or remove debris from the conveyer bell 52.

(002 1 Figs. 2 and 3 show a preferred embodiment of the air manifold 14 tor use in the system 10 of Fig. 1. The air manifold 14 includes a main body or housing 56 which includes an axial length (e.g.. measured along the longitudinal axis L) preferably between approximately 0.5 feet to 4 feel (e.g., 0.5. 1. 1.5, 2, .5. 3. 3.5, or 4 feet), although other axial lengths of the main body 56 may be used as well. For example, in some embodiments, the length may also be greater than 4 feet (e.g., 5.6, 7. 8 feet, or the like).

|0U27| The main body 56 in the depicted embodiment is generally cylindrical in shape (e.g.. having a generally circular cross section). In other embodiments, the main body 56 may have an oval-shaped cross-section, a diamond-shaped cross-section, a triangular-shaped cross-section, a square or rectangular-shaped cross-section, or the like. A first end of the main body 56 is open and forms the inlet 40. As described abov e, air supplied by the air source 12 may be routed to the air manifold 14 through the inlet 40 and discharged via a plurality of nozzles 42A-42F. For example, the inlet 40 may be coupled to a fluid conduit (e.g., conduit 36). A second end (a scaled end) of the main body 56 that is opposite the inlet 40 may be seated by an end cap 58. In certain embodiments, the end cap 5 may have a shape ihat is generally the same as the cross- sectional shape of (he main body 56 (e.g., circular). The end cap 58 may be joined to the main body 56 by welding (e.g., tungsten inert gas (TIG) welding), fastened to the main body 56 using one or more screws, bolts, or any other suitable type of fastener, adhesive, or the like. |0028) In some embodiments, the main body 56 of the air manifold ! 4 may include one or more mounting brackets 60 for mounting of the air manifold 14 to an assembly line. The mounting brackets 60 arc preferably welded to the main body 56. although other methods of connection, such as adhesive, mechanical fasteners, or the like may be used to secure the brackets 60 to the main body 56. In the embodiment shown, the mounting brackets 60 are each

5 formed by a plate 61 extending radially outwardly from the main body 56. and each includes a plurality of through-holes 62 for receiving mounting screws (not shown) or like mechanical fasteners for .securing the plate 61 to a support (not shown). Other types of mounting brackets 60. including those allowing movement of the main body 56 with respect to the support, including rotational movement, sliding movement, or the like, may also be used.

{0 291 The inlet 40 and the main body 56 are depicted in Figs. 2 and 3 as having respective diameters that are preferably equal, in one embodiment, the diameters of the inlet 40 and the main body 56 are between appioximately 1 to 0 inches. In other embodiments, the diameters of the inlet 40 and the main body 56 may be different sizes. Further, in some embodiments, the diameter of the main body 56 may vary along the length L thereof. For example, the diameter of the main body 56 may progressively decrease or increase from the inlet 40 end to the sealed end (e.g., having the end cap 58).

{0030| The nozzles 42A-42F extend radially outwardly from the main body 56. Hie main body 56 includes a plurality of openings 70A-70F (Fig. 3), each of which corresponds to a respecti e one of the nozzles 42A-42P. Inlet ends of the nozzles 42A-42 F may be welded to the main body 56 via TIG welding or a like attachment process such that air flowing into the main body 56 of the air manifold 14 via the inlet 40 may flow through the openings 70A-70F of the main body 56 and into the respective nozzles 42A- 2F. That is, each nozzle 42A-42F and its respective opening 70A-70F on the main body 56 defines a flow path by which air within the main Ixxly 56 may be discharged f om the air manifold 14.

(00311 While the depicted embodiment of Figs. 2 and 3 includes si,\ nozzles (42A-42F), it should be appreciated that various embodiments may provide any suitable number of nozzles. For example, certain embodiments may include 2 to 20 nozzles or more. The nozzles 42A-42F may be axially spaced apait along the length L of the main body 56, such that each nozzle 42Λ- 42F is separated in the axial direction. The distances between adjacent nozzles 42A-42F may be identical or may vary, as shown in Fig. 2, and are preferably each between about I to 12 inches.

(00321 Referring to Figs. 3, 6. and 7. an ionizer bar 100 is provided for insertion into the main body 56 to generate ions that enter the air flow 44 directed toward the applications 48, 0. The ionizer bar 1 0 preferably include a housing 102 made from an insulative material. preferably * lyictnil1uorocihylcne (PTFIr.), reinforced plastic, or the like. The housing 102 preferably contains at least one hollow channel 104 extending along a length of the ionizer bar 100. The hollow channel 1 A is sized and shaped to receive a power cable 106 coupled to a high voltage direct current (DC) or alternating current (AC) power supply (not shown) that provides power to the ionizer bar 100. The power cable 106 is preferably an insulated cable with a conductive core and preferably supplies a voltage in the range of 8- 12 kV or higher.

|0033) The housing 102 of the ionizer bar 100 also preferably includes, in a bottom surface thereof, a pin slot 108 that extends along and accesses the hollow channel 104. A plurality of pins 1 10 are electrically coupled to the power cable 106 and extend into the pin slot 1 8. T he pins 110 may be directly connected, resisti vely connected, or capacitively connected to the high voltage power supply via the power cable 106. In the embodiment shown in the drawings, the pins 1 1 penetrate the insulation of the power cable 106 to establish a physical and electrical connection to the conductive core. However, in other embodiments, the pins 1 10 may be coupled to the power cable 106 via terminals, conductive traces, or the like. The pins 1 1 are preferably spaced apart in a regular pattern along the length of the housing 102 of the ionizer bar 100 in order to provide an even distribution of ions. For example, the pins 110 may be placed an inch apart from each other along the power cable 1 6. The pins 11 are preferably formed from a metal or semiconductor material, such as copper, aluminum, tungsten, titanium, stainless steel, silicon, silicon carbide, or the like. |0034| The ionizer bar 1 0 is preferably mounted in the main body 56 of the air manifold 14 with the ive end of the power cable 106 located proximate the end cap 58. To prevent a short circuit by inadvertent contact of the power cable 106 or one of the pins 1 10 with the main body 56. an end portion 1 12 of the housing 102 of the ionizer bar 100 is preferably tilled with an inert or non-conducti e material 114. which is preferably a polyolctin-based hot melt adhesive.

Alternatively, the inert or non-conductive material 1 14 may be an epoxy. polyuivthanc, silicon- based compound, or the like.

|0035| Referring to Figs. 3-5, the ionizer bar 100 is preferably mounted within the main body 56 of die air manifold 14 by a cartridge 80. The cartridge 80 may be permanently connected to the main body 56, uch as by welding or the like, but it is preferred that the cartridge 80 is rclcasably attached to the main body 56 instead to facilitate easier access to the ionizer bar 100 for service and or replacement. Accordingly, (he cartridge 80 may be attached to the main body 56 by way of bolts 82 or other mechanical fasteners that extend from (he exterior of the main body 56 and into the cartridge 80. However, other methods of releasable attachment of the cartridge 80, such as latches, hook-and-loop fasteners, or the like may also be used. It is preferred that the cartridge 80 is attached firmly to the main body 56 (o avoid movement of the cartridge 80 and ionizer bar 100 as a result of (he force of the air flowing through the main body 56.

10036) The cartridge 80 is preferably in the shape of a hollow bar having two side plates 84. 85 arranged to extend parallel (o one another and along a length L of the main body 56 of the air manifold 14 when installed, ^' he side plates 84, 5 are spaced apart from one another to fonn a channel 86 therebetween which is preferably sized and shaped to retain the ionizer bar KM). A bottom surface of each of the plates 84, 85 also preferably includes a lip 88 extending perpendicularly to (he plates 84. 85 and toward (he channel 86. The lips 88 are utilized to support the ionizer bar 1 0. For example, the lips 88 may abut a bottom surface of the housing 102 of the ionizer bar 100 and allow the pins 110 to extend through a slot 90 formed by the lips 88. However, it is preferred that the lips 88 engage respective grooves 1 16 extending along the housing 102 of (he ionizer bar 100 (Fig. 6). In this way (he corona discharge of the pins 110 will not be impeded by the cartridge 80. This airangement allows for convenient insertion and removal of (he ionizer bar 1 0 in the cartridge 80 by way of sliding the ionizer bar 100 into (he channel 86. However, other methods of insertion and removal for the cartridge 80, such as clips or other mechanical fasteners, may be used as well.

10037) Preferably (he slot 90 does not extend die entire length of the cartridge 80. but rather stops short of an edge of (he cartridge 80 adjacent (he inlet 40 of (he air manifold 1 in the installed position. The lips 88 preferably converge at (his location o (he cartridge 80 to form part of a spacer 92. A top portion of each plate 84, 85 also preferably converges at this location (o form another part of the spacer 92. The spacer 92 also preferably includes an end cap 1. The spacer 92 seals off the end of the cartridge 80 proximate (he inlet 40 of the air manifold 14 to prevent air from accessing the power cord 106 of (he ionizer bar 100.

8 | 038} Specifically, the pow r cord 106 is preferably gripped by a fitting 69 and inserted into the air manifold 14 through a cord opening 68 at a top f the main body 56 proximate the inlet 40. The channel 36 of the cartridge 80 is aligned with the cord opening 68 such that when the fitting 69 is secured in the cord opening 68, the power cord 106 is immediately received in the channel 86 of the cartridge 80 and is not exposed to pressurized air entering the main body 56 through the inlet 40. However, the fitting 6° and cord opening 68 may be positioned at other locations of the air manifold 1 .

|0039| A plurality of nut plates 72 are preferably provided on the top portion of the cartridge 80, each of which is welded or otherwise mechanically fastened to the plates 84, 85. Each nut plate 72 preferably includes a threaded hole 74 extending at least partially therethrough. The threaded holes 74 arc preferably spaced on the cartridge 80 to align with corresponding bolt holes 75 lbrmed in a top of the main body 56. The bolts 82 are placed through the bolt holes 75 and are threaded into the threaded holes 74 of the nut plates 72 to secure the cartridge 80 to the main body 56 of the air manifold 14 as shown m Fig. 3. |0040| Referring to Fig. 8, in some embodiments, the main body 56 of the air manifold 1 includes a cylindrical spacer 76 welded above the bolt holes 75 to compensate for the joining of two incompatible surfaces (e.g.. the curved interior of the main body 56 and the flat nut plates 72 of the cartridge 80). In order to properly align the cylindrical spacer 76 during welding, an attachment tool 77 may be used. Hie tool 77 includes a spring clip 77a. a sleeve 77b. and a long bolt 77c. In use, a bottom portion of the spring clip 77a abuts a surface of the main body 56 of the air manifold while the Long bolt 77c extends through the sleeve 77b. through the cylindrical spacer 76, through the bolt hole 75, and into the nut plate 72 of the cartridge 80. When the cartridge 80 is secured in the desired location and lightness, the cylindrical spacer 76 may be welded in place to the main body 56. The sleeve 77b is preferably made from aluminum to avoid welding of the sleeve 77b to the cylindrical spacer 76. Once welding is completed, the tool 77 may be removed and the regular bolts 82 are used to attach the cartridge 80 for use.

(0041 j It is preferred that at least the cartridge 80, and also preferably the main body 56 of the air manifold 1 . be formed from a conductive material such as stainless steel and the housing 1 2 of the ionizer bar 1 0 be made of non-cwiducti ve material. In this way, the cartridge 80

9 and'Or the main body 56 of the air manilbld function as th reference (ground) electrode for the ionizing bar i 00, as opposed to the housing 102 of the ionizer bar 100 itself, or a reference electrode embedded in the housing 1 2, which arc more commonly known airangements for ion generation. Surprisingly, this configuration outperformed arrangements having ail or portions of the air manifold 14 made from a non-conductor such as plastic in removing charge from a line of cans. However, other more conventional arrangements of the ionizer bar 100 and an insulative main body 56 and cartridge 80 may also be used.

|0042) Referring again to Fig- I · the filter 24 prevents debris in the airstreani from entering and contaminating the applications 48, 50. The tiller 24 also prevents debris build-up on the pins 1 10 of the ionizer bar 100. thereby maximizing the ionization efficiency of the pins 1 10 for an extended period of time. The filter 24 also prevents contamination and/or damage in the event of upstream failures. For example, air blowers 1 will often have aluminum impellers, which in a catastrophic failure resulting in aluminum on aluminum contact can produce shavings that may enter the airstream. but will be caught by the filter 24. (0043) The filter 24 preferably has a housing made from stainless steel or a like corrosion- resistant material. Further, the filter 24 may include media (not sh w ) meeting the High- efficiency particulate air (HKPAj standard (i.e.. 99.97% of particles greater than 0.3 micrometers are removed). However, it has been found that a media with 99.99% efficiency at 0.5 micrometers (nominal) allows for better air flow (e.g.. with only 10% of the pressure drop experienced when using HEPA fillers), ami is more than adequate for food and beverage container applications 48, 0. The filter 24 may further include a gauge (not shown; which notifies the user when replacement is necessary.

{0044| While only one filter 24 is shown in Fig. 1 placed between the air blower 12 and the divider 32. one or more additional filters 24 may alternatively or additionally be placed between the divider 32 and the air manifolds 40A, 40B. This configuration would be useful in. tor example, systems 1 having very high pressure air How. A filter 24 may also be placed at an inlet ( not shown) of the air blower 12.

(004SJ In an alternate embodiment of the invention, the air manifold 14 may be replaced by an air knife 14', as shown in Fig. 9. The air knife 14' is constructed similarly to the air manifold 14. including the use of an inlet 40' that receives blown air from the air supply 12, but. in place of the n zzles 42A-42F of the air manifold 14. the air knife 14' includes a discharge slot 42' thai extends along a substantial portion of the length of the main body 56' thereof. The main body 56' includes tapered portions 57" to force (he air through the discharge slot 42'. An ionizer bar 100 may be mounted within the air knife 14 ^* using a cartridge 80 in a similar to fashion as described above.

|0046) Figs. 10-12 show another embodiment of the invention specifically designed for use in cleaning bottles (not shown), which typically have small openings. The air manifold of Figs. 10-12 is similar to the embodiment shown in Figs. 1 -8. and like numerals have been used for like elements, except the 200 series numerals have been used for the embodiment shown in Figs. 10- 12. Accordingly, a complete description of the embodiment ofFigs. 10-12 has been omitted, with only the differences being described.

|0O47| As can be seen in Figs. 1 1 and 12, an elongated cylindrical shaft 24} having a constant inner diameter di may be connected to an outlet of each of the nozzles 242A-242IJ. The elongated cylindrical shaft 243 does not further compress the air How through the respective nozzle 242A-242H. but rather maintains the pressure of the air flow 44 at a relative constant. The elongated cylindrical shaft 243 is used to guide (he air How 44 to the small opening of a bottle, for example. The outer diameter do of the elongated cylindrical shaft 243 is also pj eterably constant along a length thereof. It is particularly preferable in the bottle cleaning application that the inner diameter dj be maximized for air delivery into the bottle while the outer diameter d(.i is minimized so that air leaving the bottle opening can escape past the elongated cylindrical shall 24?. In a preferred embodiment, the inner diameter d _t is about 5 16 of an inch while the outer diameter do is about 3/8 of an inch.

|0048) The elongated cylindrical shaft 243 is preferably friction fit and/or welded to (he corresponding air nozzle 242A-242H. However, other methods of attachment, such as adhesive, mechanical fasteners, or the like may be used as well. The elongated cylindrical shaft 243 may also be removable i r replacement and/or use of the nozzles 242Λ-242Η without the shafts 243.

(0049| Figs. 10 and 11 also show an alternati e arrangement l r attaching the power cable 206 to the air manifold 214. Rather than being located at a top or radial surface of (he main body 256, the cord opening 268 is provided at the sealed end of the main body 256 opposite to the inlet 240. Fig. 10 also shows a slightly different arrangement of the brackets 260. As previously described, these changes may be made to accommodate the mounting requirements of the air manifold 14. 214 and are not limited by the invention.

(0050J ft will be appreci ted by those skilled in the art that changes could be made to the embodiment described above without departing from the broad, inventive concept thereof, ft is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but. it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.

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