U.S. patent application number 10/282876 was filed with the patent office on 2003-03-13 for underbooth powder paint collector.
Invention is credited to Burke, Richard D., Cole, David John, Kelly, Charlotte E., O'Ryan, David E..
Application Number | 20030046909 10/282876 |
Document ID | / |
Family ID | 25008521 |
Filed Date | 2003-03-13 |
United States Patent
Application |
20030046909 |
Kind Code |
A1 |
Cole, David John ; et
al. |
March 13, 2003 |
Underbooth powder paint collector
Abstract
A powder paint reclamation collector includes an upper chamber
for collecting powder paint particles from a paint booth and a
lower chamber that receives the particles from the upper chamber. A
vacuum line communicates with the lower chamber retrieving the
particles from the collector and transferring the particles to a
reclamation system. An air chamber receives pressurized air from an
air supply and communicates with the lower chamber through a porous
plate. Air bleeds through the porous plate into lower and upper
chambers for fluidizing the paint particles. The porous plate and
an air chamber floor angle downward from the lower chamber towards
the vacuum line to improve the flow of fluidized paint particles
into the vacuum line.
Inventors: |
Cole, David John; (Canton,
MI) ; Kelly, Charlotte E.; (South Lyon, MI) ;
Burke, Richard D.; (Norwalk, OH) ; O'Ryan, David
E.; (Clarkston, MI) |
Correspondence
Address: |
HOWARD & HOWARD ATTORNEYS, P.C.
THE PINEHURST OFFICE CENTER, SUITE #101
39400 WOODWARD AVENUE
BLOOMFIELD HILLS
MI
48304-5151
US
|
Family ID: |
25008521 |
Appl. No.: |
10/282876 |
Filed: |
October 29, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10282876 |
Oct 29, 2002 |
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09748222 |
Dec 26, 2000 |
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6471737 |
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Current U.S.
Class: |
55/385.1 ;
118/326; 454/50 |
Current CPC
Class: |
Y10S 55/46 20130101;
B05B 14/48 20180201; B01D 50/002 20130101; B01D 50/20 20220101 |
Class at
Publication: |
55/385.1 ;
118/326; 454/50 |
International
Class: |
B01D 050/00 |
Claims
What is claimed is:
1. A powder paint reclamation collector comprising: an upper
chamber for collecting powder paint particles from a paint booth; a
lower chamber communicating with said upper chamber receiving the
paint particles from said upper chamber; a vacuum line
communicating with said lower chamber retrieving the particles from
said collector; an air chamber having a floor and receiving
pressurized air from an air supply, said air chamber communicating
with said lower chamber through a porous plate thereby causing air
to flow into said lower and said upper chambers fluidizing the
paint particles; and said floor and said porous plate angling
downward from said lower chamber towards said vacuum line.
2. A collector as set forth in claim 1 wherein said porous plate
angles downward from said upper chamber substantially parallel to
said floor.
3. A collector as set forth in claim 2 wherein said floor and said
porous plate angle downward of at least four degrees from
horizontal.
4. A collector as set forth in claim 3 wherein said floor includes
a first end and a second end, said first end being positioned above
said second end.
5. A collector as set forth in claim 4 wherein said vacuum line
conmmunicates with said lower chamber at a position lower than said
first end.
6. A collector as set forth in claim 4 wherein said air supply
comprises a single air inlet line.
7. A collector as set forth in claim 6 wherein said air inlet line
is positioned intermediate between said first end and said second
end.
8. A collector as set forth in claim 7 wherein said air inlet line
is positioned below said first end and above said second end.
9. A collector as set forth in claim 8 wherein said air inlet line
directs pressurized air towards said floor.
10. A collector as set forth in claim 9 wherein said porous plate
is affixed to said collector with at least one fastener.
11. A collector as set forth in claim 1 wherein said lower chamber
includes a length to width ratio ranging from ten to twenty.
12. An assembly as set forth in claim 1 wherein the distance
between said porous plate and said floor is less than about 4
inches and said air chamber includes a single inlet from said air
supply.
13. A booth assembly for painting a product with powder paint
comprising: a paint application chamber wherein powder paint is
applied to the product; a plurality of reclamation collectors
spaced beneath said application chamber receiving paint particles
from said application chamber; each of said reclamation collectors
having: an upper chamber for collecting powder paint particles from
said paint booth; a lower chamber connected with said upper chamber
receiving the particles from said upper chamber; a vacuum line
connected to said lower chamber retrieving the particles from said
collector; an air chamber having a floor and receiving pressurized
air from an air supply, said air chamber communicating with said
lower chamber through a porous plate thereby causing air to flow
into said lower and said upper chambers from said air chamber
through said porous plate fluidizing the paint particles; and said
floor and said porous plate angling downward from said lower
chamber towards said vacuum line.
14. An assembly as set forth in claim 13 wherein said porous plate
angles downward from said lower chamber substantially parallel to
said floor.
15. An assembly as set forth in claim 14 wherein said floor and
said porous plate angle downward at least four degrees from
horizontal.
16. An assembly as set forth in claim 15 wherein said floor
includes a first end and a second end, said first end being
positioned above said second end.
17. An assembly as set forth in claim 16 wherein said vacuum line
connects with said lower chamber at a position lower than said
first end.
18. An assembly as set forth in claim 17 wherein said air supply
comprises a single air inlet line
19. An assembly as set forth in claim 18 wherein said air inlet
line is positioned intermediate between said first end and said
second end.
20. An assembly as set forth in claim 19 wherein said air inlet
line is positioned below said first end and above said second
end.
21. An assembly as set forth in claim 20 wherein said air inlet
line directs pressurized air towards said floor.
22. An assembly as set forth in claim 21 wherein said porous plate
is affixed to said collector with at least one fastener.
23. An assembly as set forth in claim 22 wherein said lower chamber
includes a length to width ratio ranging from ten to twenty.
24. A powder paint reclamation collector, comprising: an upper
chamber for collecting powder paint particles from a paint booth; a
lower chamber communicating with said upper chamber receiving paint
particles from said upper chamber having an inclined bottom wall;
an inclined porous plate in said lower chamber spaced from said
inclined bottom wall extending generally parallel to said inclined
bottom wall and defining a pressure chamber between said inclined
bottom wall and said porous plate, said inclined porous plate
having openings therethrough of a diameter substantially less than
the particle size of said powder paint particles permitting air to
pass therethrough; an air pressure inlet line directing air under
pressure into said pressure chamber toward said inclined bottom
wall, suspending paint particles received on said inclined porous
plate; and a vacuum paint particle return line communicating with
said lower chamber above said porous plate adjacent the lower
extent of said inclined porous plate.
25. The powder paint reclamation collector as defined in claim 24,
wherein said lower chamber inclined bottom wall and said inclined
porous plate are angled downwardly toward said vacuum paint
particle return line at an angle of five degrees from horizontal or
greater.
26. The powder paint reclamation collector defined in claim 25,
wherein said air pressure line is positioned approximately at the
center of said pressure chamber.
27. The powder paint reclamation collector as defined in claim 24,
wherein the length of said inclined bottom wall of said lower
chamber is at least six feet and the length to width ratio of said
inclined bottom wall is between ten and twenty.
Description
BACKGROUND OF THE INVENTION
[0001] The subject invention relates generally to an improved
powder paint reclamation collector for use with a production powder
paint application booth.
[0002] The application of powder paint has become an increasingly
utilized method of painting mass production products, such as
automobiles, to reduce volatile organic compound emissions from a
production paint facility. A typical powder paint booth includes
powder paint reclamation system that increases the paint usage
efficiency upwards of ninety five percent. This type of reclamation
system includes a reclamation collector positioned beneath each
section of the paint booth. A typical reclamation collector
includes an upper chamber for separation of process air and powder
paint particles from a paint booth and a lower chamber that
receives the particles from the upper chamber. A vacuum line is
connected with the collector for transferring the particles from
the collector to a powder paint reclamation system. To effectively
retrieve the particles from the collector, the particles must be
maintained in a fluidized or suspended state. Otherwise, the
particles will agglomerate, build up in areas not having sufficient
fluidization, and ultimately result in paint defects on the painted
products.
[0003] To overcome these difficulties, presently available
collectors include an air chamber that receive pressurized air from
an air supply. The air chamber communicates with the lower chamber
through a porous plate that dissipates the pressurize air. The
pores in the porous plate, or plate density, are sized to prevent
paint particles from entering the air chamber while allowing air to
exit the air chamber. The porous plate is oriented generally
horizontally and parallel to the floor of the air chamber.
[0004] While the vacuum line is typically located in the lowermost
position of the lower chamber, the entirety of the porous plate is
positioned below the vacuum line due to the plate's horizontal
orientation. To provide a sufficient amount of fluidizing air
pressure, several air inlet lines feed pressurized air into the air
chamber. The additional air inlet lines are required to prevent an
agglomeration of paint particles in areas that are distant from the
vacuum line and otherwise would not receive adequate
fluidization.
[0005] Thus, it would be desirable to reorient the porous plate and
the air chamber floor to improve the transfer of fluidized paint
particles to the vacuum line for preventing the buildup of paint
particles in the lower chamber.
SUMMARY OF THE INVENTION AND ADVANTAGES
[0006] The subject invention is a powder paint reclamation
collector that has been modified to improve the flow of fluidized
paint particles into a vacuum line for transfer to a paint
reclamation system. The collector includes an upper chamber for
collecting powder paint particles from a paint booth. The upper
chamber funnels fluidized paint particles to a lower chamber. A
vacuum line is connected to the lower chamber retrieving the
fluidized particles from the collector and transferring the
particles to the reclamation system to be reintroduced to paint
application equipment in the paint booth.
[0007] An air chamber receives pressurized air preferably from a
single air inlet line directed downwardly toward the air chamber
floor and is separated from the lower chamber by a porous or
semipermeable plate. The porous plate allows air to flow into the
lower and upper chambers for fluidizing the paint particles and
prevents the particles from entering the air chamber. Thus, the
porous plate has pores or openings therethrough which are smaller
than the diameter or particle size of the powdered paint, but large
enough to transmit air therethrough. An air chamber floor and the
porous plate angle downward, generally in parallel relation, from
the lower chamber towards the vacuum line.
[0008] Angling the porous plate and the air chamber floor downward
towards the vacuum line facilitates the transfer of paint particles
from the collector to the vacuum line. Because the vacuum line is
positioned below a substantial portion of the porous plate,
gravitational forces will assist the flow of paint particles into
the vacuum lines as opposed to contributing to the build up of
particles in areas that don't receive adequate fluidizing air
turbulence. In the preferred embodiment, the air chamber floor and
porous plate are parallel and are angled toward the vacuum outlet
at an angle of greater than four degrees. It has been found that it
is possible to obtain uniform distribution of air and, therefore,
uniform suspension of the powder with one inlet and clean, dry
pressurized air pressure (60-80 psi) where the distance between the
porous plate and the bottom wall is about 3 inches or less.
Further, the orientation of the porous plate in this manner allows
for the reduction of the number of air inlet lines necessary to
adequately fluidize the paint particles for an efficient transfer
through the vacuum line to the reclamation system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other advantages of the present invention will be readily
appreciated as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0010] FIG. 1 is a cross-sectional elevation of the paint booth
assembly showing the collector of the subject invention;
[0011] FIG. 2 is a top view of the collector of the subject
invention;
[0012] FIG. 3 is a side view of the collector showing the inventive
floor;
[0013] FIG. 4 is a front view of the collector of the subject
invention;
[0014] FIG. 5 is partial sectional view of the collector showing
the vacuum line and fastener used to secure the porous plate;
[0015] FIG. 6 is a front sectional view showing the lower chamber
with the fluidized particles and showing the flow of air through
the porous plate; and
[0016] FIG. 7 is a partial side view of the booth assembly showing
the inventive collectors positioned along the entire length of the
assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to FIG. 1, a cross-section of a booth assembly for
applying powder paint is generally shown at 10. The booth includes
a paint application chamber 12 wherein the powder paint is applied
to a vehicle body 14 or other product. The chamber 12 forms an
elongated room into which the bodies 14 are conveyed for painting.
A conveying device 16, such as, for example a power and free
conveyor, moves the products through the application chamber
12.
[0018] Paint application equipment 18 is disposed within the
chamber 12 for applying the powder paint as is known in the art of
powder painting. The chamber 12 is enclosed by opposing walls 20,
which separate the chamber 12 from each of the control rooms 22.
The walls 20 are supported from below by a plurality support
members 24 that are arranged end to end along the entire length of
the assembly 10. At least two frame posts 26 are affixed beneath
each of the support members 24 to support the assembly 10 and to
provide distance between the assembly 10 and a base floor 28, the
purpose of which will become more evident below.
[0019] A plurality of horizontal support beams 30 are affixed to
the support members 24 and project outwardly from the assembly 10.
A control room floor 32 is formed over the horizontal support beams
30 for supporting control equipment 34 associated with operating
the assembly 10.
[0020] An air supply plenum 36 is affixed above the assembly 10 to
provide fresh air to the application chamber 12. Filters 38 are
disposed within the plenum 36 to remove impurities from the fresh
air that would otherwise result in paint defects on the car body
14. The fresh air provides a down draft to the chamber 12 to force
over spray powder paint particles 39 downward and out of the
chamber 12.
[0021] A plurality of grates 40 form the floor of the application
chamber 12. The grates 40 are supported on one end by a conveyor
support beam 42 and the other end by the support members 24. The
conveying device 16 operates in a channel 44 between parallel
conveyor support beams 42. The grates 40 allow air from the plenum
38 and paint particles 39 that have not adhered to the body 14 to
pass therethrough and into a plurality of reclamation collectors 46
disposed beneath the chamber 12. FIG. 1 shows a collector 46
disposed beneath each of the grates 40 thereby enclosing the bottom
of the booth assembly 10. Air is drawn through a filter 47 disposed
in each collector and routed through a filter house 49 before being
returned to the plenum 36. The filters 47 are periodically pulsed
to prevent powder paint particles from accumulating and thereby
fouling the filters 47 and to maintain uniformity of the air
through the application chamber.
[0022] Referring to FIGS. 2 through 4, the reclamation collector 46
includes an upper collector chamber 48 for collecting powder paint
particles 39 from the application chamber 14. The upper collector
chamber 48 funnels the paint particles 39 to a lower collector
chamber 50. A vacuum line 52 is operatively connected with the
lower collector chamber 50 retrieving the particles 39 from the
reclamation collector 46. The vacuum line 52 draws the paint
particles 39 from the collector 46 and into a reclamation system
(not shown) as is known in the art of powder paint reclamation.
[0023] The reclamation system filters and re-introduces the paint
particles 39 to the paint application equipment 18. The powder 39
must be maintained in a fluidized state in order to convey the
powder. To maintain the particles 39 in the fluidized state an air
chamber 54 is disposed beneath the lower collector chamber 50 for
providing fluidizing air to the collector 46 as is best shown in
FIG. 6.
[0024] The air chamber 54 receives clean, dry, pressurized air from
an air supply and communicates with the lower collector chamber 50
through a porous plate 56. The porous plate 56 disperses the
fluidizing air providing enough turbulence in the collector 46 to
maintain the particles 39 in a fluidized state. The paint particle
39 size typically ranges from 10 to 30 microns. The air supply
comprises a single air inlet line 58 that injects pressurized air
into the air chamber 54. The air pressure typically ranges from 60
to 80 psi at 10-20 cubic feet per minute, and optimally 15 cubic
feet per minute. The air inlet line 58 is angled downward and
therefore directs pressurized air towards a floor 60 in the air
chamber 54. Deflecting the pressurized air off of the floor 60
dissipates the air throughout the air chamber 54, which improves
the fluidizing properties of the air stream as it passes through
the porous plate 56.
[0025] The porous plate 56 has a plurality of openings or pores
therethrough each having a diameter substantially less than the
diameter of the paint particles which, as set forth above,
typically have a particle size of 10 to 30 microns. Of course, the
plate must also be semi-permeable to permit the air to bubble
through the plate to suspend or fluidize the paint particles as
described. A suitable porous plate for this application is a high
density polyethylene porous plate available from Porex Technologies
of Fairburn, Ga., which has been used for fluidizing powder
coatings and material handling applications.
[0026] The floor 60 angles downward from the lower collector
chamber 50 at an angle of at least four degrees from horizontal.
Preferably, the floor 60 angles downward at least five degrees from
horizontal. The porous plate 56 angles downward from the lower
collector chamber 50 in a substantially parallel relationship to
the floor 60. Therefore, both the floor 60 and the porous plate 56
angle downward at an angle of at least four degrees and preferably
at least five degrees. Although the minimum downwardly inclined
angle for the porous plate is known from prototype testing, the
maximum angle will depend upon the application, particularly
including the space available for the underbooth collectors,
providing a practical limit. It is believed that a 60.degree.
downwardly inclined angle would be suitable if the space is
available; however, a maximum angle than 45.degree. or less would
be more practical.
[0027] The lower collector chamber 50 and the air chamber 54
together form an elongated cell ranging approximately six to eight
feet in length and approximately five to seven inches in width.
Obviously, the dimensions outside this range can be chosen to meet
the specific requirements of a powder paint application process.
The length to width ratio ranges between 10 and 20. The preferred
ratio is about fifteen.
[0028] The floor 60 includes a first end 62 and a second end 64.
The first end 62 is higher than the second end 64. The vacuum line
52 connects with the lower collector chamber 50 at the second end
64. The transfer of fluidized paint particles 39 into the vacuum
line 52 from the collector 46 is improved when the floor 60 and the
porous plate 56 slant downwardly towards the vacuum line 52.
[0029] The air inlet line 58 is positioned between the first end 62
and the second end 64. Further, the air inlet line 58 is positioned
below the first end 62 and above the second end 64. This angular
relationship along with the chamber volume allows for the use of a
single air inlet line 58. With a flat or horizontal floor and
horizontal porous plate, three, four, or more air inlet lines 58
are required to provide enough fluidizing air pressure to the
collector 46 to effectively recirculate the paint particles 39. As
set forth above, in the preferred embodiment. The distance between
the porous plate 56 and the floor 60 is about 3 inches or less to
obtain uniform suspension of the paint using normally available air
pressure.
[0030] The inventive features included in the collector 46 provides
the ability to increase the length and overall size of the
collector 46 over currently available collectors. Increasing the
size of the collectors 46 reduces the number of collectors required
in a particular assembly 10 thereby reducing the installation costs
of the assembly 10. Further, utilizing a single air inlet line 58
reduces the installation costs of the assembly 10 and reduces the
amount of maintenance required to keep the assembly 10 operational.
By inclining the porous plate 56 and the floor 60 of the collector
downwardly, preferably in parallel relation, and directing the
outlet of the air nozzle 58 downwardly toward the floor 60,
multiple air inlets into the chamber 54 may be eliminated and the
size of the collector may be significantly increased as described
above.
[0031] Referring to FIG. 5 and 6, the porous plate 56 is affixed to
the collector with at least one fastener 66. Preferably, a
plurality of fasteners 66 will be spaced around the length of the
collector 46. The fasteners 66 are inserted through a pair of
flanges 68 that seal to the plate 56 thereby securing the air
chamber 54 and the plate 56 to the collector 46. The fasteners 66
allow for the plate 56 to be removed for maintenance and
cleaning.
[0032] Referring to FIG. 7, a plurality of collectors 46 are
spaced-along the entire length of the assembly 10. Each collector
46, or each series of collectors 46 collect paint particles from
different zones of the assembly 10. For example, three collectors
46 can be positioned beneath a bell zone, four collectors 46 can be
positioned beneath a robot zone, two collectors 46 can be
positioned beneath an observation zone, and each zone can be
separated by single collector 46.
[0033] The invention has been described in an illustrative manner,
and it is to be understood that the terminology which has been used
is intended to be in the nature of words of description rather than
of limitation.
[0034] Obviously, many modifications and variations of the present
invention are possible in light of the above teachings. It is,
therefore, to be understood that within the scope of the appended
claims, wherein reference numerals are merely for convenience and
are not to be in any way limiting, the invention may be practiced
otherwise than as specifically described.
* * * * *