U.S. patent application number 13/198047 was filed with the patent office on 2012-06-28 for uv module.
Invention is credited to Michael L. Claeys.
Application Number | 20120162976 13/198047 |
Document ID | / |
Family ID | 39512285 |
Filed Date | 2012-06-28 |
United States Patent
Application |
20120162976 |
Kind Code |
A1 |
Claeys; Michael L. |
June 28, 2012 |
UV MODULE
Abstract
A UV module of this invention has connection block (optional),
connection end cap, shutter, and exhaust end cap assemblies. The
connection block has doweled or tapered bayonets for facilitated
installation and removal of the UV module. It is emphasized that
this abstract is provided to comply with the rules requiring an
abstract that will allow a searcher or other reader to quickly
ascertain the subject matter of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. 37 C.F.R.
.sctn.1.72(b).
Inventors: |
Claeys; Michael L.;
(Broomfield, CO) |
Family ID: |
39512285 |
Appl. No.: |
13/198047 |
Filed: |
August 4, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12001080 |
Dec 7, 2007 |
8038282 |
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13198047 |
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60874212 |
Dec 11, 2006 |
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Current U.S.
Class: |
362/218 ;
29/525.08 |
Current CPC
Class: |
F26B 3/28 20130101; C09D
11/101 20130101; Y10T 29/49464 20150115; B41F 23/0409 20130101;
Y10T 29/49959 20150115 |
Class at
Publication: |
362/218 ;
29/525.08 |
International
Class: |
F21V 29/00 20060101
F21V029/00; B23P 11/00 20060101 B23P011/00 |
Claims
1-46. (canceled)
47. A UV module, comprising: a connection block assembly comprising
a connection block, electrical and coolant connectors attached to
said connection block, and a pair of bayonets extending from said
connection block, each of said bayonets having a first portion
accommodating a latch mechanism and a second tapered portion with a
maximum diameter; means for providing electricity to a UV lamp; and
means for circulating coolant within said module.
48-71. (canceled)
72. The UV module of claim 47, wherein said second tapered portion
of each of said bayonets includes adjacent cylindrical
portions.
73. The UV module of claim 72, wherein said latch mechanism
accommodating first portion is generally cylindrical.
74. The UV module of claim 73, wherein said latch mechanism
accommodating first portion is disposed between two other
cylindrical portions with greater diameters than a diameter of said
latch mechanism.
75. The UV module of claim 47, wherein said second tapered portion
includes two further stepped, cylindrical portions.
76. The UV module of claim 47, wherein said connection block
assembly further includes a poppet valve connection block.
77. The UV module of claim 76, wherein said coolant circulating
means ingresses and egresses coolant through said poppet valve
connection block.
78. The UV module of claim 47, wherein said connection block
assembly further includes an electrical connection subassembly.
79. The UV module of claim 78, wherein said electricity providing
means operably provides an electrical current to said electrical
connection assembly.
80. A method of manufacturing a connection block assembly for a UV
module, said method comprising: attaching a pair of bayonets to a
connection block, wherein each of said bayonets includes a latch
mating surface and precision dowel surface; and installing an
electrical connection subassembly and a poppet valve connection
block within said connection block.
81. The method of claim 80, wherein said latch mating surface of
each of said installed bayonets is cylindrical.
82. The method of claim 81, wherein said latch mating surface of
each of said installed bayonets is disposed between two flanking
cylindrical portions, each of said flanking cylindrical portions
having a greater diameter than said latch mating surface.
83. The method of claim 80, wherein said precision dowel surface
includes a tapered portion.
84. The method of claim 80, wherein said precision dowel surface
includes a stepped portion with a plurality of diameters.
85. A method of attaching a connection block assembly to a UV
module, the connection block including a connection block, a pair
of bayonets extending from said connection block, and a poppet
valve connection block and an electrical connection subassembly
disposed within said connection block, said method comprising:
extending said pair of bayonets into said UV module; and providing
coolant to said poppet valve connection block and an electrical
current to said electrical connection subassembly.
86. The method of claim 85, wherein each of said bayonets
accommodates a latch mechanism disposed within said UV module when
said bayonets are extended into said UV module.
87. The method of claim 85, wherein each of said bayonets are
guided into a position to connect the electrical connection
subassembly and the poppet valve connection block to the UV module
by a precision dowel surface disposed on each of said bayonets.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, and hereby
incorporates by reference, U.S. patent application Ser. No.
12/001,080, filed Dec. 7, 2001, which, in turn, claims priority
under 35 U.S.C. .sctn.119(e) to, and hereby incorporates by
reference, U.S. Provisional Application No. 60/874,212, filed Dec.
11, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the printing industry and, in
particular, this invention relates to devices for curing
ultraviolet sensitive inks printed on substrate.
[0004] 2. Background
[0005] Ultraviolet-sensitive ink is used widely in the printing
industry. One reason for its use is that ultraviolet-sensitive ink
can be quickly cured by being irradiated with ultraviolet light.
Such irradiation is accomplished by directing a light beam,
containing high proportions of ultraviolet light, at the printed
substrate.
[0006] Lamps used to generate light for this purpose also generate
considerable amounts of other energy in the form of heat. This heat
is usually of little consequence when a printing press is
operating, because the light and heat are directed toward the
substrate which is in motion during the printing process. However,
if the heat and light generated by the lamp is directed at a
nonmoving substrate for a sufficient amount of time, the substrate
is damaged, often to the point of the ignition. Additionally, other
nonmoving components of the printing press may be damaged by the
high amount of heat generated from the lamps. When the printing
press operation must be halted, for example to Clear obstructions
or replenish ink supplies, the light generated by the lamp must be
prevented from impinging the substrate. One way to prevent
irradiating nonmoving substrate is to power down the lamp. However,
considerable time is necessary for the lamp to generate sufficient
irradiation to cure the ultraviolet-sensitive ink when power is
restored. Consequently, preventing irradiation from impinging
nonmoving substrate when a printing press is halted has been
accomplished by housing the lamp in a structure having shutters,
which can be opened to allow irradiation or closed to prevent
irradiation from leaving the structure.
[0007] As stated above, intense heat is generated by the UV lamp
during operation. These high-energy lamps require high-voltage and
fairly high current, some requiring 3000 volts and 17 amps and may
generate temperatures of 1000 degrees Fahrenheit during operation.
Consequently, the structures housing these high-energy lamps are
subjected to periods of the extremely high temperatures. These high
temperatures inescapably cause the metal components of these
structures to expand and warp. One consequence of this expansion
and warpage is failure of these structures to properly operate.
[0008] There is then a need for an ultraviolet module, which can
dependably operate when subjected to the intense heat generated by
high-energy ultraviolet lamps.
SUMMARY OF THE INVENTION
[0009] This invention substantially meets the aforementioned needs
of the industry by providing an ultraviolet module capable of
functioning when components of the module are expanded and warped
by heat generated during operation and which can be readily
adjusted without extensive or undue effort or time expenditure.
[0010] A cassette style shutter drive assembly has been developed,
which operates efficiently when subjected to extremely high heat
generated by high-energy ultraviolet lamps. One embodiment has two
shutter drive assemblies, each incorporating a clutch, drive train,
and other associated components to eliminate problems associated
with shutter warpage, drive train component misalignment, as well
as other tolerance issues.
[0011] Each of a plurality of, e.g., two, shutter drive assemblies
incorporates a clutch as well as a set of features designed to
eliminate problems associated with shutter warpage, drive train
component misalignment, and other malfunctions due to incorrect
tolerances. The shutter drive train operates both shutter drive
assemblies simultaneously.
[0012] A shutter shaft sleeve bearing used as a component of one
embodiment of this invention includes integral internal dynamic
seal glands and integral external static seal glands. The two
external seals are arranged with a coolant drainway therebetween,
working in conjunction with a drain port integral to the connection
end cap to provide a visual leak path and indicator.
[0013] A ball-drive pin engages a slot in the shutter end cap to
drive the shutter. Several degrees of freedom are provided by this
pin and the shutter end cap slot arrangement, thereby allowing the
shutter to warp and change length without inducing undesirable
forces on the drive train components. The shutter arm assembly
contributes thusly to reliable shutter functionality.
[0014] A pair of "indexing" clutches (e.g., one clutch per shutter)
has been designed to prevent drive train binding and subsequent
drive motor overload. Each clutch is bi-directional, having an
adjustable break-point torque to enable automatic re-engagement.
The instant clutch also allows for shutter retiming
(synchronization). Each worm gear may be positively secured to a
shutter shaft using a special two-piece clamp collar and a drive
pin, which engages the worm gear. An angled shoulder on the collar
abuttingly mates to an angled rib on the shutter shaft. These two
features cooperate to function as a circumferential wedge. When the
clamp fasteners are tightened, the worm gear is firmly secured in
place. Loosening the fasteners on both shutter drive assemblies
accordingly allows the gears to be oriented as required to time or
synchronize the shutters to work together properly.
[0015] The worm gear is secured to the shutter shaft in a positive
manner by using a two-piece clamp collar and a drive pin. The
two-piece collar clamps securely to the shutter shaft. The drive
pin protrudes from the collar to engage a slot in the worm gear.
The collar also features an angled shoulder which mates to an
angled rib integral to the shutter shaft. These two features serve
as a circumferential wedge. As the fasteners securing the two-piece
collar to the shutter shaft are tightened, the worm gear is wedged
toward a bearing-retaining nut. The gear is then tightly clamped
between the clamp collar and the nut. The combination of the
two-piece clamp collar, drive pin, and wedge-induced clamping
action serves to firmly secure the worm gear in place and correctly
positions the worm gear relative to the worm. This arrangement
allows all worm gear teeth remain fully intact and functional so
that the worm gear may rotate fully in accordance to the
requirements for proper clutch operation.
[0016] The shutter shafts and the exhaust shutter pivot shafts
function as bearing surfaces for the shutter end cap bearings as
well as for O-rings and sealing surfaces for the shutter end cap
bearing seals.
[0017] An integral stop is built into the center of the lower end
cap to prevent either of the shutters from over-traveling or
contacting the UV lamp. The stop works equally well for all
contemplated manual and automatic operations.
[0018] A pair of sensors monitors the "open" and "closed" positions
of each shutter. These sensors are activated by a magnet embedded
in the shutter shaft arm and are mounted so as to minimize contact
with hot module components. The sensor/magnet arrangement provides
for a range of sensor sensitivity. Once the sensitivity of the
sensor/magnet arrangement is adjusted as desired, sensitivity is
unaffected by changes in shutter length, shutter axial position,
shutter radial position, or shutter warpage.
[0019] A drain hole in the connection end cap assembly may be
ported outside the instant module, thereby visually indicating the
existence of an internal leak. The drain hole may also direct
leaking coolant away from electrical components to reduce the
likelihood of detrimental high-energy short circuits.
[0020] The water poppet valve may have a double-seal arrangement.
Accordingly, the instant water poppet valve may be essentially
drip-free during module installation, removal, and post-removal.
This high-flow valve fits into a restricted amount of space and
functions in conjunction with a rotating shutter shaft and its
integral coolant passageway.
[0021] Shutter end cap material is matched to the shutter extrusion
material to minimize galvanic and corrosive effects. The shutter
end cap includes a special coolant passageway, which doubles as a
reservoir and cooperates with other features to cool the stem of
the UV lamp, as well as other components.
[0022] The bearing/seal arrangement in the shutter end caps allows
for nominal flexing, thermal expansion/contraction, warpage, and
dimensional variations of the shutter assembly without sacrificing
fluid-tight integrity or inducing adverse forces on seals and
shutter drive train components. The instant bearing features a
narrow, centrally located load-bearing surface that is sealed on
either side by a pair of integral seal glands fitted with O-rings.
The O-rings help to distribute the bearing loads and the outer seal
also serves as a wiper. The bearing arrangement also provides for
important freedom of motion for the shutter assembly relative to
these shutter shafts. The bearing further acts as a heat sink and a
heat transfer element further cooling the stem of the UV lamp and
other components.
[0023] In one embodiment, the lamp connector of this invention is a
two-piece assembly, thereby allowing easier and more reliable
assembly of the high-voltage socket and lead wire. Additional
insulation may be present around the high-voltage wire entryway and
around the socket opening. The increased insulation results in a
longer and a less direct electrical leak path to thereby reduce the
chance of a high-energy short circuit.
[0024] Both lamp connector assemblies may be spring-loaded against
the lamp. This spring-loading encourages higher and more consistent
electrical conductivity, maintains full pin-socket engagement
during aggressive module installations, allows for more relaxed
dimensional tolerances for manufacturing the UV bulb, and minimizes
high-energy short circuits.
[0025] Special non-conductive, screw-ferrules may be used as a
mechanical backup to thereby secure the high voltage pin and socket
connectors into the electrical connection block. The ferrules also
allow for easier pin and socket servicing.
[0026] Coolant plugs with integral sacrificial zinc anodes may be
installed directly in the coolant flow path inside the module to
prevent corrosion in the coolant passage ways. The anodes may be
shaped to reduce flow restrictions.
[0027] The shutter end caps may have a relieved reflector mounting
surface. This feature provides better UV protection for the ring
located in the shutter body/shutter end cap interface and
eliminates the need for custom-fit reflector strips.
[0028] The reflectors may be removed and installed without removing
the shutter end caps and without breaking the fluid-tight integrity
of the shutter assembly. Only the retaining strip needs to be
removed to exchange a reflector.
[0029] The design of the instant module produces a full length,
uninterrupted, properly shaped reflector supporting surface. This
design further provides for quicker reflector replacement and
allows the use of convenient pre-cut reflectors.
[0030] In one embodiment, the original female V-shaped reflector
retainer profile has been modified to include a shallow U-shaped
channel. This helps to prevent shutter-to-shutter binding when the
shutters are closed. The U-shaped channel does not reduce the
effectiveness of how well the closed shutters block light.
[0031] The coolant cross over feature may be incorporated into the
upper module of this invention to facilitate easier and less
expensive manufacturing and assembly. The cross over cavity doubles
as a substantial reservoir to provide better component cooling.
[0032] A slide-out mount for the electrical connection assembly is
located in the connection block and may be easily removed to
provide better and quicker service. Special three-dimensional
locating features provide the precise alignment required for
optimum module performance.
[0033] The dove-tailed edge design of the shutter drive train
access doors allows the doors to be easily removed with a minimum
of module disassembly.
[0034] The stub bayonet shafts act as precision two-dimensional
locating dowel to provide optimum functionality to the poppet
valves and electrical connections.
[0035] The latch rod has locating features at the latch-end and
provides accurate axial positioning of the poppet valve components
and the electrical connections.
[0036] The spring-loaded latch provides precise axial alignment of
the instant module to the connection block of this invention. When
combined with the stub bayonets and the latch rod left, a precise
three-dimensional module-to-module connection block docking is
easily achieved to provide for optimum module performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a top isometric view of one embodiment of the UV
module of this invention.
[0038] FIG. 2 is a bottom view of the UV module of FIG. 1.
[0039] FIG. 3 is a top, isometric view of the connection block of
this invention.
[0040] FIG. 4 is a perspective view of the module of FIG. 1 docked
to the connection block of FIG. 3.
[0041] FIG. 5 is a sectional view depicting portions of the instant
shutter shaft seal arrangement and bearing arrangement.
[0042] FIG. 6 is an oblique sectional view of the UV module of FIG.
1 with the shutters in an open position.
[0043] FIG. 7 is an oblique sectional view of the UV module of FIG.
1 with the shutters in a closed position.
[0044] FIG. 8 is a perspective view of one embodiment of the
instant shutter shaft assembly.
[0045] FIG. 9 is a perspective view of the shutter shaft assembly
of FIG. 8 and a shutter end cap of this invention, shown
disengaged.
[0046] FIG. 10 is a perspective view of one embodiment of the
shutter drive train of this invention.
[0047] FIG. 11 is a partial sectional view of the shutter drive
pin/slot, depicting freedoms of motion thereof.
[0048] FIG. 12 is a perspective view of one embodiment of the
instant clutch, having the shutter arm thereof in phantom view.
[0049] FIG. 13 is an oblique sectional view showing the instant
shutters "out of time" (unsynchronized).
[0050] FIG. 14 is a perspective view of the lower end cap showing
an integral stop of one embodiment of the module of this
invention.
[0051] FIG. 15 is a perspective view depicting shutter position
sensors of this invention as mounted in the instant connection end
cap assembly.
[0052] FIG. 16 is a sectional view of one embodiment of the poppet
valve of this invention, prior to docking.
[0053] FIG. 17 is a sectional view of the poppet valve of FIG. 16
during mid-docking.
[0054] FIG. 18 is a sectional view of a poppet valve of FIG. 16
fully docked.
[0055] FIG. 19 is a sectional view of the connection end of the
shutter end cap bearing/seal arrangement of this invention.
[0056] FIG. 20 is a sectional view of the exhaust end of one
embodiment of the shutter end cap bearing/seal arrangement of this
invention.
[0057] FIG. 21 is an isometric view of one embodiment of the lamp
connector assembly of this invention.
[0058] FIG. 22 is a sectional view of the lamp connector assembly
of FIG. 21.
[0059] FIG. 23 is an isometric view of one embodiment of the
ferrules and high-voltage pin connector of this connection.
[0060] FIG. 24 is a sectional view of the ferrules and high-voltage
pin assembly of FIG. 23.
[0061] FIG. 25 is a perspective view of one embodiment of the
coolant plugs with integral sacrificial anodes of this
invention.
[0062] FIG. 26 is a sectional view of the coolant plugs with
integral sacrificial anodes of FIG. 25.
[0063] FIG. 27 is a perspective view of one embodiment of the
shutter end cap of this invention showing a relieved reflector
mounting surface.
[0064] FIG. 28 is a perspective view of the shutter end cap of FIG.
27 installed in the module of FIG. 1.
[0065] FIG. 29 is a perspective view of one embodiment of the
cross-over location callout of this invention.
[0066] FIG. 30 is a perspective view of one embodiment of the upper
module cover of this invention with cross-over details.
[0067] FIG. 31 is a perspective view of one embodiment of the UV
module of this invention showing slide-out mount detail.
[0068] FIG. 32 is a perspective view of one embodiment of the
slide-out mount of this invention shown removed from one embodiment
of the connection block of this invention.
[0069] FIG. 33 is a perspective view of the slide-out mount of FIG.
31.
[0070] FIG. 34 is a perspective view of one embodiment of the UV
module of this invention, with an access door location.
[0071] FIG. 35 is a perspective view of the UV module embodiment of
FIG. 34, the access door thereof depicted as positioned for
removal.
[0072] FIG. 36 is a perspective view of one embodiment of an access
door of this invention.
[0073] FIG. 37 is a sectional view of one embodiment of the
connection cap assembly with the access door of this invention
removed.
[0074] FIG. 38 is a perspective view of one embodiment of the stub
bayonet of this invention.
[0075] FIG. 39 is a sectional view of one embodiment of a
three-axis module docking/locating feature of this invention.
[0076] FIG. 40 is a perspective view of one embodiment of a
latch/latch-rod assembly of this invention.
[0077] FIG. 41 is a perspective view of a latch side of one
embodiment of the connection end cap assembly of this
invention.
[0078] FIG. 42 is a sectional view of one embodiment of a
spring-loaded lamp connector of this invention, biased against a
lamp.
[0079] FIG. 43 is a sectional view of one embodiment of a high
voltage pin/socket arrangement of this invention.
[0080] FIG. 44 is a side view of the UV module of this invention
depicting another embodiment of the positive and negative retaining
strips of this invention.
[0081] FIG. 45 is a sectional view along line A-A of FIG. 44.
[0082] FIG. 46 is a sectional view along line B-B of FIG. 44.
[0083] FIG. 47 is a cross-section of the clutch arm of this
invention depicting the ball spring plungers engaged to shutter
shaft grooves.
[0084] FIG. 48 is a cross-section of the clutch arm of this
invention depicting the ball spring plungers disengaged to the
shutter shaft grooves.
[0085] It is understood that the above-described figures are only
illustrative of the present invention and are not contemplated to
limit the scope thereof.
DETAILED DESCRIPTION
[0086] Unless otherwise defined, all technical terms used herein
have the same meaning as commonly understood by one of ordinary
skill in the art to which this invention belongs. Although methods
and materials similar or equivalent to those described herein can
be used to practice the invention, suitable methods and materials
are described below.
[0087] Any references to such relative terms as front and back,
right and left, top and bottom, upper and lower, horizontal and
vertical, or the like, are intended for convenience of description
and are not intended to limit the present invention or its
components to any one positional or spatial orientation.
[0088] Each of the additional features and methods disclosed herein
may be utilized separately or in conjunction with other features
and methods to provide improved devices of this invention and
methods for making and using the same. Representative examples of
the teachings of the present invention, which examples utilize many
of these additional features and methods in conjunction, will now
be described in detail with reference to the drawings. This
detailed description is merely intended to teach a person of skill
in the art further details for practicing preferred aspects of the
present teachings and is not intended to limit the scope of the
invention. Therefore, combinations of features and methods
disclosed in the following detailed description may not be
necessary to practice the invention in the broadest sense, and are
instead taught merely to particularly describe representative and
preferred embodiments of the invention.
[0089] One embodiment of the ultraviolet (UV) module of this
invention is shown in FIGS. 1 and 2, and particularly in FIG. 4, at
100 and includes an optional connection block assembly 102, a
connection end cap assembly 104, a shutter assembly 106, and an
exhaust end cap assembly 108.
[0090] Referring now to FIGS. 3, 31, 32, and 33, the connection
block assembly 102 has a connection block 120, a slide-out mount
122, an electrical (or socket) connection subassembly 124, a poppet
valve connection block 126, and stub bayonets 130, 132.
[0091] As best seen in FIG. 32, the connection block 120 defines a
stepped opening 140, with horizontal surfaces 142, 144 facing
vertical surfaces 146, 148 (not shown) and a lower horizontal
surface 150. Locating structures such as extensions 152, 154 from
the horizontal surfaces 142, 144 and extensions 156, 158 (not
shown) from the vertical surfaces 146, 148 may be present.
[0092] Referring to FIGS. 3 and 31, an optional attachment block
160 is depicted. The attachment block 160, in the embodiment shown,
has fluid attachment features (e.g., fittings) 162, 164 and an
electrical attachment fixture 166. One of the fluid attachment
fixtures 162, 164 connects to a source of ingressing fluids to cool
the instant UV module during use and the other of the fluid
attachment fixtures 162, 164 serves as a conduit for egressing
coolant fluids therefrom. When attached to the connection block
assembly 102, the attachment block 160 provides for electrical and
fluid supply to the UV module of this invention. While shown
oriented generally horizontally to the instant UV module, a person
of ordinary skill in the art will readily recognize that the
coolant and electrical attachment fittings 162, 164, 166 may be
vertically oriented as well, due to space constraints and the like.
Moreover, a person of ordinary skill in the art will readily
recognize that fluids and electricity may be supplied to the UV
module of this invention by other means as well. A person of
ordinary skill in the art would further recognize that UV modules
without a system or assembly for circulating coolant are also
within the scope of this invention, for example, if sources of UV
radiation are used which do not generate appreciable amounts of
heat. One example of such a UV source is an LED emitter.
[0093] As seen in FIG. 33, the slide-out mount 122 includes an
upper member 172 and unitary (or otherwise integral) extensions
174, 176 extending from the upper member 172. An electrical
connection assembly mounting face 178 is defined by the extensions
174, 176 and a lower portion of the upper member 172. Locating
features are functionally defined as slots 180, 182, each defined
in a lower portion of the upper member 172 adjacent each extension
174, 176. Further locating features include slots 184, 186 (slot
186 not shown) defined in outboard surfaces of the extensions 174,
176. Threaded apertures 188, 190, 192, 194 are present in the
extensions 174, 176.
[0094] The instant slide-out mount for electrical connection
assembly, located in the connection block docking with the module,
may be conveniently attached to and removed from the attachment
block 160 to facilitate assembly and disassembly. Due to the
facilitated attachment and removal, the slide-out mount also
significantly reduces servicing time. Locating features in this
slide-out mount provide the precise three-dimensional alignment
required for optimum module-to-connection block interface
performance (FIGS. 31, 32, 33).
[0095] As viewed in FIGS. 3, 15, 33 39, 42, and 43, and especially
in FIGS. 32 and 43, the socket connection block subassembly 124 has
a housing 200, which encloses sockets 202, 204 and ferrules 206,
208. In one embodiment, the ferrules 206, 208 are made from a
non-conductive material and are threaded into openings in the
connection block housing 200, thereby securing the sockets 202, 204
within the housing 200. The sockets 202, 204 are accessed by means
of openings 210, 212 in the housing 200. The socket connection
block 124 is secured to the slide-out mount 122 by threading
fasteners through apertures 214, 216, 218, 220 present in the
housing 200 and into the apertures 188, 190, 192, 194 (present in
the slide-out mount extensions 174, 176). While two sockets 202,
204 are depicted and described, a person of ordinary skill in the
art would readily recognize that more sockets may be present, e.g.,
to accommodate other voltages. As seen in FIG. 43, at least one,
e.g., a pair of elastomeric elements, such as O-rings 228. are
optionally disposed between the electrical connection block
subassembly 124 and the slide out mount 122 when the electrical
connection block subassembly 124 is attached to the slide out block
122 using fasteners, such as shoulder screws 230. While O-rings 228
are depicted as being secured by each of the shoulder screws 230,
this may not be the case in other embodiments of this invention.
For example, one or more of the 0 228-rings may be secured in a
pair of diagonal or opposing corners. The elasticity of the O-rings
enables the connection block subassembly 124 to move slightly
during docking. Consequently, the elastomeric characteristics of
the O-rings, when present, maintain the electrical connection
subassembly 124, hence the connection block assembly 102, in a
position such that the sockets are centered or positioned to
receive the pins when connecting the connection block assembly 102
to the remainder of the instant UV module. as more fully described
below. Upon engagement of the connection block assembly to the
remainder of the module, the elasticity of the O-rings 228 ensures
that the electrical connection pins can slide into their respective
sockets without misalignment due to the ability of the electrical
connection subassembly 124 to displace within the limits of the
elasticity of the O-rings 228. Accordingly, initial misalignments
of the sockets and pins are corrected during connection or docking
or whenever the connection block assembly 102 is not completely
engaged to the remainder of the UV module. In UV modules of the
prior art, the absence of the elastically enabled or
self-correcting alignment sometimes resulted in misalignment of
pins and sockets when connecting the connection block assembly to
the remainder of the UV module. Consequently, the pins were not
completely seated in the sockets and the electrical connections
were incomplete and arcing sometimes occurred between the
misaligned sockets and pins. Additionally, the sockets and/or pins
were bent or damaged due to the misalignment. In other embodiments
of the prior art, the connection assembly was spring mounted,
thereby resulting in an attenuated ability to maintain the desired
centered position. Consequently, the pins were sometimes ejected
from their mounts when engaging the sockets. Ejection of pins often
caused mechanical damage to the pins or sockets, arcing, and
occasionally fires from the arcing. The foregoing self-centering
feature of the instant electrical connection subassembly functions
in conjunction with the precision dowel feature of the stub
bayonets (described below) of the UV module of this invention to
ensure that connecting elements of the connection block assembly
104 are properly aligned with corresponding elements of the
remainder of the instant UV module.
[0096] Referring to FIGS. 32, 33 the rear surface of the electrical
connection subassembly 124 contacts the electrical connection
assembly mounting face 178 of the slide-out mount 122. The modular
slide-out mount 122 is attached to the connection block 120 by
disposing the slide-out mount 122 into the opening 140, such that
extensions 152, 154 are disposed in slots 180, 182 and such that
extensions 156, 158 are located in slots 184, 186. When the
slide-out mount 122 is disposed in the opening 140 as described,
apertures 188, 190 in the slide-out mount 122 are aligned with
threaded apertures 224, 226 (defined from surfaces 142, 144 of the
connection block 120). Accordingly, the slide out mount 122 can be
secured in place by threading fasteners through the foregoing
aligned apertures. While the connection block of this invention is
depicted as having electrical connection sockets, it should be
appreciated that electrical pins could be present in place of the
sockets, so that electrical connection pins shown below as present
in the pin connector assembly could be replaced by sockets.
[0097] As seen in FIG. 32, the poppet valve connection block 126
includes high flow water poppet valves 240, 242, which are housed
in the connection block 120. Referring now to FIGS. 16, 17, and 18,
each of the poppet valves 240, 242 (poppet valve 240 shown) has a
water stem 243 axially retained within a water sleeve 244. A water
stem seal 245 is disposed about an inner surface of the water
sleeve 244. An exterior seal 246 is disposed about a central
portion of the water sleeve 206. A spring (not shown), also present
within the water sleeve 206, urges the water sleeve 244 to the
right (from the perspective of FIG. 12).
[0098] The water poppet valve of this invention has a double seal
arrangement provided by seals 245, 246 (FIGS. 3, 5, 16-18). The
double seal provides a virtually drip-free connection during module
installation, as well as a drip-free connection when the instant
module is undocked. Stated otherwise, all components are closed
during initial module engagement to the connection block and again
closed prior to final disengagement from the connection block.
Accordingly, very little, or no, fluid escapes the valve when the
instant module is being installed or removed. The instant poppet
valve, in contrast to other known poppet valves, functions in
conjunction with a rotating shutter shaft, the rotating shutter
shaft doubling as a coolant passage way.
[0099] FIGS. 3, 32, and 38 depict the present stub bayonets 130,
132, which may unitarily (or otherwise integrally) have six
cylindrical portions. A first cylindrical portion 250 adjoins a
second cylindrical portion 252, the second cylindrical portion 252
with a greater diameter. A third cylindrical portion 254 has a
smaller diameter than either of flanking portions 252, 256. The
increased diameter of the cylindrical portion 256 produces a
tapered (or stepped) "precision dowel surface," as more fully
explained below. A diameter of the stub bayonets 130, 132 continues
to decrease (taper) at cylindrical portions 258, 260. A latch
mating surface 262 is defined by facing surfaces 264, 266 (surface
266 not shown) and 268. The function of the latch mating surface
262 is more fully described below. The cylindrical portion 260 is
secured within the connection block 120, as depicted in FIG. 3.
[0100] The two stub bayonet shafts guide, support and dock the
connection block assembly as it is attached to, and functions with,
the remainder of the instant UV module. Due to the close concentric
tolerances required for optimum functionality of the water poppet
valves and the electrical connections, a short section of the stub
bayonets is slightly increased in diameter to act as a pair of
precision locating dowel pins. This feature accurately docks the
module to the connection block. The two-dimensional (up/down and
side-to-side) mating precision resulting from this dowel effect
enables increased flow through the water poppet valves and
eliminates the pin and socket ejection problems associated with
misalignment. When the precision dowel locating effect is combined
with the axial (in/out) positional control gained from the instant
latch rod and the instant spring-loaded docking latch (as more
fully explained below), optimum functionality of the poppet valves
and the electrical connections are achieved (FIGS. 3, 38-41).
[0101] Referring to FIGS. 1, 2, 4, 5, 10 and 16, the connection end
cap assembly 104 is enclosed in a housing 280 and includes a
shutter drive train assembly 282, a connection end cap valve
assembly 283, an end cap electrical assembly 284, and an end cap
latch assembly 286.
[0102] As best viewed in FIG. 10, the shutter drive train
(assembly) 282 includes a connection end cap 290 (as seen in FIG.
14), a drive gear motor 292, first and second spur gears 294, 296,
a worm shaft 298, and left and right shutter drive subassemblies
300, 302. However, in some embodiments, the instant drive train may
be considered to include connection shutter end caps 570, 172
(discussed below). The drive gear motor 292 rotates the spur gear
294 which, in turn, rotates the spur gear 296. The spur gear 296 is
attached to, and rotates, the worm shaft 298. The worm shaft 298
has respective left and right hand segments 304, 306, which, in
turn, rotate the shutter drive subassemblies 300, 302, as more
fully explained below. However, a person of ordinary skill in the
art will recognize that the shutter shafts 332 may be directly
rotated by the motor 292 or that other combinations of gears to
comprise the instant drive train are within the scope of this
invention. As seen in FIG. 15, also included in each of the left
and right shutter drive subassemblies 300, 302 are sensor mounts
308, 309 and a pair of sensors 310.
[0103] Within the instant connection end cap assembly is a geared
drive motor. Via a set of spur gears, this geared drive motor turns
a worm shaft having left-hand and right-hand thread segments. Each
of these worm shaft segments turns a worm gear secured to a shutter
shaft. The gear motor spins the worm to open or close both shutters
simultaneously.
[0104] As seen in FIGS. 8, 9, 10, 11, 12, 40, and 41, respective
left and right shutter drive subassemblies 300, 302 are rotatably
attached to the shutter shafts 332 and have clutch pin drive
assemblies 316, 318, and worm gears 324, 326, as well as
substantially identical (or similar) shutter shafts 332, collars
334, (hex) nuts 336, ball bearings 338, and worm gear drive pins
340. The left and right clutch pin drive assemblies 316 are
rotatably attached to each end of the shutter shafts 332 and 318
respectively include shutter arms 350, 352 and shutter arm
extensions 354, 356, the other components described below being
substantially identical or similar. Referring now to FIGS. 8, 9,
11, 12, 40, and 41, a ball headed drive pin 358 axially extends
from each of the shutter arm extensions 354, 356. Each of the ball
headed drive pins 358 has a shank 360 with a longitudinal axis 361
and terminating in a head 362. A cross sectional dimension, such as
a diameter 364 of the head 362 is greater than a cross sectional
dimension such as a diameter 366 of the shank 360.
[0105] A sensor magnet 372 is housed in each of the shutter arms
352, 354 generally opposite the shutter arm extensions 354, 356. At
least one or a plurality of, e.g., four, adjustable ball spring
plungers 374 are disposed in each of the shutter arms 350, 352. A
plurality, e.g., pair, of shutter position sensors 376, 378 are
also attached to each of the shutter arms 350, 352, the shutter
position sensor 376 attached so as to be aligned with a sensor
magnet 372, thereby detecting when the shutters are in an open or
closed position. The shutter position sensor 378 is attached
approximately radially midway between the shutter position sensor
376 and one of the shutter arm extensions 354, 356, to thereby
detect when the shutters are in a closed position. The two pairs of
sensors (one pair for each shutter) monitor the open and closed
position of each shutter. The sensors may be reed switches
activated by a magnetic field and are mounted so as to minimize
contact with module components directly exposed to high
temperatures found in the instant UV module. The magnets are
stronger than those previously used to ensure sensor activation. A
variety of magnet lengths (thus, a variety of magnetic field
strengths) may be used to finely adjust shutter sensor sensitivity.
The magnets are present in the shutter shaft arms which are, in
turn, mounted on the shutter shafts. Accordingly, the sensitivity
of the shutter position sensors is unaffected by shutter warpage,
changes in shutter length, or changes in the axial positioning of
the shutter assemblies relative to the module body of this
invention. The sensors themselves may be also micro-positioned
within their mounting brackets to more finely adjust sensor
sensitivity (FIGS. 8, 10, 11).
[0106] Referring more particularly to FIGS. 47 and 48, each of the
ball spring plungers 374 includes a slotted cap 380, which closes a
threaded housing 382. A spring 384 is disposed within the housing
382 and a ball 386 partially protrudes from the housing 382, the
spring 384 biasing the ball 386 away from the slotted cap 380.
[0107] As seen in FIGS. 11 and 12, each of the shutter shafts 332
has at least one or a plurality of, e.g., six, axial bores 390 and
an angled rib 392 is circumferentially and integrally formed from
an exterior surface thereof. A plurality of axially aligned grooves
(slots) 394 are formed on the exterior of the shutter shafts 332 so
as to coincide with the position of the shutter arms 350, 352. The
shutter shaft of this invention has been extended to extend through
the connection block and the associated seal arrangement has been
designed to greatly reduce the chance of a coolant leak. If a leak
were to occur, a tale-tale weep hole ported to the atmosphere, not
only indicates the existence of a leak, but directs any leaking
coolant away from the internal spaces of the connection block and
module and, in particular, any coolant leakage is directed away
from electrical connections and components, thereby minimizing
chances of any coolant-induced electrical shortages and any damages
to the instant module therefrom.
[0108] A pair of "indexing" clutches (one per shutter) prevents
drive train binding and subsequent drive overload (FIGS. 8-12,
47-48). Within the clutch of this invention, a plurality of ball
spring plungers are mounted within the shutter shaft arm and may be
adjusted as required to produce the desired "breakpoint" torque,
the amount of torque required to disengage the clutch as seen in
FIG. 47 and during normal operation with each shutter clutch
engaged, the spring plunger balls 386 are forced into the grooves
394 formed in the shutter shaft 332, thereby effectively "locking"
the shutters to the drive train. The optimum "breakpoint" allows
the clutch to disengage before the drive motor draws sufficient
heat-producing current to be damaged, yet still operates the
shutters during normal operation. As shown in FIG. 48, when
disengaged, the balls 386 are no longer seated in the grooves 394
of the shutter shaft 332. When properly adjusted, the present
clutch in the "disengaged" mode allows the shutter drive train to
continue operating in a powered-up condition for an unlimited
amount of time without damaging drive train components. While under
power and disengaged, the clutch can "free wheel" in a manner
somewhat similar to a spring-loaded pawl and ratchet arrangement.
The clutch will always automatically reengage by virtue of the
"indexing" configuration integral to the shutter shaft, shutter
shaft arms, and spring plungers. Stated otherwise, regardless of
the position of the shutters, a disengaged clutch of this invention
will always attempt to reengage. The clutch arrangement of this
invention also allows the shutters to be individually repositioned
by hand. Suitable ball spring plungers are available in several
ranges of spring force values. These devices may have threaded
bodies allowing them to be threaded into or out of the shutter
shaft arm to respectively increase or decrease the torque required
to reach the "breakpoint" of the clutch. The combination of the
spring forces and the extent to which the threaded bodies are
threaded into the clutch allows the clutch "breakpoint" to be thus
readily adjustable. Due to the action of the springs, a disengaged
clutch will continually attempt to reengage and will reengage
automatically as soon as the applied torque in the shutter drive
train system falls below the "breakpoint" torque, or as soon as the
drive motor is deenergized. When a shutter is repositioned by hand,
the clutch will reengage as soon as the shutter is released. The
design of the clutch components is such that the clutch is
bidirectional and will disengage at approximately the same
"breakpoint" torque value regardless of whether the shutters are
being opened or closed. The clutch operates silently when fully
engaged. When operating under power in the "disengaged" mode, the
clutch admits a series of subdued clicking sounds to thereby alert
personnel that the clutch is disengaged and is attempting to
reengage.
[0109] The instant clutch also facilitates shutter synchronization.
During module assembly the two shutters may be moved to their fully
open positions and synchronized to mate the positive and negative
reflector retaining strips. In any condition in which either or
both of the shutter clutches undergo disengagement, loss of shutter
timing may occur. To re-synchronize the shutters, the condition
causing the clutches to disengage must often be first corrected.
The shutters may then automatically reacquire the correct shutter
synchronization when they are moved, either manually or via the
drive motor to their fully open positions. In this situation, the
module body extrusion acts as a hard stop for both shutters. When
both shutters have been moved to their fully opened positions (and
the drive motor, if in use, has been deenergized), both shutter
clutches will automatically reengage and the shutters will again be
properly timed and engaged to their respective shutter shafts
(FIGS. 6, 7, 13).
[0110] As shown in FIGS. 8, 9, and 11, the worm gears 324, 326 are
secured to the shutter shafts 332 using the two piece clamp collar
334 and the drive pin 340. Individual pieces (396, 400) of the
clamp collar 334 clamp securely to the shutter shaft 332 and the
drive pin 340 protrudes from the collar 334 to engage a slot (not
shown) in each of the worm gears 324, 326. When thusly secured, an
angled shoulder 400 of the collar 334 abuts the angled rib 392 of
the shutter shaft 332. As fasteners 402 secure the two-piece collar
334 to the shutter shaft 332, one of the worm gears 324, 326 is
wedged toward the bearing-retaining nut 336. Each of the worm gears
324, 326 is then tightly clamped in place between the clamp collar
334 and the hex nut 336 and is positioned to fully mesh with the
left and right hand segments 304, 306 of the worm shaft 298.
[0111] As best seen in FIG. 15, the sensor mounts 308 are mounted
to the connection end cap 290 secure shutter position sensors 310
in place.
[0112] Referring to FIGS. 14 and 15, a lower end cap 406 includes
an optionally integral (or unitary) hard integral stop 408 in one
embodiment of this invention. The integral stop is positioned at
the center of the lower end cap cover to prevent either of the
shutters from over traveling and contacting the UV lamp. In the
event of clutch disengagement, the shutter may be forced past the
normal "shutter closed" position. In this event, the shutter shaft
arm will contact the integral stop before any portion of the
shutter assembly can move sufficiently to contact the lamp. Thus,
this integral stop prevents UV lamp contact whether the shutters
are overdriven via the drive motor or by manual manipulation and
will prevent lamp-to-shutter contact, regardless of the axial
position of the shutter relative to the module body (FIGS.
13-15).
[0113] As can be seen in FIGS. 5, 16, 17, and 18, a second bearing
420 may be used in conjunction with a ball bearing 422 to support
the shutter shafts 332. In one embodiment, the second bearing 420
is a bronze, flanged, sleeve bushing. However, other suitable
materials may be used for other embodiments. The bearing 420 may
include integral internal dynamic seal glands 430, 432 and integral
external static seal glands 434, 436. These glands may be outfitted
to accommodate seals, such as O-rings 440, 442, 446, 448 to provide
fluid-tight integrity. The two external seals 446, 448 have a
coolant drainway 452 therebetween. The coolant drainway 452 drains
to a drain port 454, which is integral to the connection end cap
290, to provide a path for coolant leakage. For each of the two
shutter drive assemblies, the second bearing (e.g., bronze,
flanged, sleeve bushing type) is used in conjunction with a single
ball bearing to provide full and solid support to the shutter
shaft. The sleeve bearing may include integral internal dynamic
seal glands and integral external static seal glands. These glands
accommodate seals, e.g., O-rings, to provide a high degree of
fluid-tight integrity. The two external seals are arranged with a
coolant drainway therebetween and function in conjunction with a
drain port integral to the connection end cap to provide a telltale
leak path in the event of a failed primary static bearing seal.
[0114] Referring to FIGS. 16, 17, and 18, one embodiment of the
connection end cap valve assembly of this invention 283 has a
striker plate 456, a valve disc 457, a sleeve 458 with a plurality
of outboard slots 459, and a compression (coil) spring 460 (spring
460 not shown). The striker plate 456 accommodates internal O-rings
461, 462 about a fluid passageway 463 and an inboard O-ring 464 to
seal the junction between the connection end cap valve assembly 283
and the bearing 596 (more fully described below). An open volume
465 is defined in an inboard portion of the striker plate 456 and
is also bounded by the sleeve 458 and the bearing 596. The spring
460 is disposed in the sleeve 458 and biases the valve disc 457
toward the left (as viewed from the perspective of FIG. 16) such
that the valve disc 457 is in a fluid tight engagement with the
O-ring 462, thereby preventing fluid egress from the valve assembly
283. FIG. 16 depicts what may be considered as a first stage of
docking the connection block assembly 102 to the connection end cap
assembly 104, wherein the connection block poppet valve 240 and the
connection end cap valve assembly 283 are both closed to fluid
egress. As seen in FIG. 17, the opening 463 of the striker plate
snugly accommodates a positive end 466 of the water sleeve 244,
such that the O-rings 461, 462 sealingly contact said positive end
466. As the cooperation between the connection block poppet valve
240 and the connection end cap valve assembly 283 progresses toward
the disposition depicted in FIG. 18, the positive end 466 of the
water sleeve 244 abuts and displaces the valve disc 457 (to the
right as viewed from the perspective of FIGS. 17 and 18), thereby
compressing the spring 460. As viewed in FIG. 18, the valve disc
457 is fully displaced, no longer in a sealing position, thereby
allowing fluid to flow through the poppet about 240 and into the
valve assembly 283. Coolant thusly flows around the valve this 457,
though the slots 459 and sleeve 458 in two the shutter shaft 332. A
person of ordinary skill in the art will readily recognize that
when undocking the connection block assembly 102 from the
connection end cap assembly 104, the connection block poppet valve
240 and the connection end cap valve assembly 283 are sealed to
prevent fluid egress by events essentially the reverse of the
foregoing description.
[0115] As may be viewed in FIGS. 15, 21, 22, 23, 24 and 42, the end
cap electrical assembly 284 includes a UV lamp 468, a lamp
connector 470, a pin connector assembly 472, and a board 474. The
UV lamp 468 fits into, and is secured in place by, the lamp
connector 470. Referring to FIGS. 21 and 22, the lamp connector
470, in turn, has a high-voltage cable 480, a two-piece housing
482, a fastener mechanism 484, an insulating membrane 486, and
socket 488. The two-piece housing 482 depicted in this embodiment
may include two housing components 492, 494, which house the high
voltage socket 488, the insulating membrane 486 and a ring terminal
496. As best shown in FIG. 22, a plurality of connectors, e.g.,
two, sex bolts 498 attach and secure the high voltage cable 480 to
the ring terminal 496. As seen in FIG. 15, the conductors within
the high voltage cable 480 (not shown) may be connected directly to
the pin connector 472, or connected to the pin connector 472 via
the connector board 474. When the lamp connector 470 is secured in
place, a spring 502 (as best shown in FIG. 42) biases the lamp
connector 470 toward the lamp 468.
[0116] As best viewed in FIGS. 15, 23, 24, and 42, the pin
connector assembly 472, in the embodiment shown, includes an
electrical connection block 510, ferrules 512, 514, and high
voltage connection pins 516, 518. The nonconductive ferrules 512,
514 threadably secure and connect conductors to the high voltage
pins 516, 518 when disposed in openings 520, 522 of the connection
block 510. As best shown in FIG. 42, additional high voltage pins
(and sockets), such as high-voltage connection pin 524 may be
present, e.g., to accommodate three phase electrical current.
However, a person of ordinary skill in the art will readily
recognize that any number of the present high voltage connection
pins (as well as sockets 202, 204) may be present. The instant
two-piece socket housing allows easier, more consistent, and more
reliable assembly of the high-voltage socket and lead wire; and the
lamp socket housing is designed to provide better electrical
insulating properties. These better insulating properties are
accomplished by providing more insulating material around the
high-voltage wire entry way and by adding an additional partial
membrane around the socket opening. With a UV lamp installed in the
instant module, this membrane creates a longer, more tortuous path
to reduce the likelihood of a high-energy short circuit between the
lamp connection and the surrounding housing.
[0117] Both lamp connectors (a lamp connector in each of the
connection and exhaust ends) are substantially identical in one
embodiment of this invention. Additionally, both are spring-loaded
against the UV lamp (FIG. 42). The spring action thus encourages
higher electrical conductivity through the lamp, socket-pin
connections by maintaining full pin-two-socket engagement; prevents
the lamp pin from becoming unseated from the socket during
aggressive module installation; allows more relaxed dimensional
tolerances for manufacturing the UV bulb; and reduces the
likelihood of arcing between the pin-to-socket connections and the
surrounding end caps.
[0118] Special non-conductive screw-in type ferrules are used as a
mechanical back-up to maintain the high-voltage pin and socket
connectors better secured in their respective electrical blocks.
The pin and socket connectors, normally depending solely on a
press-fit into the connection blocks, have, in the past, become
unseated or ejected during aggressive module installations. The
instant ferrules also permit easier pin and socket replacement in
the instance that a conductor is damaged (FIGS. 23, 24, 43).
[0119] Referring now to FIGS. 38, 39, 40, and 41, one embodiment of
the latch assembly of this invention 286 includes a latch 530 and
torsion spring 532 axially secured to a latch rod 534 by retaining
rings 536. The latch 530 defines a retaining groove 538, within
which one arm 540 of the torsion spring 532 is disposed. When
secured to the stub bayonets 130, 132, the latch 530 is disposed in
the latch mating surface 262, as described above. When the latch
536 is thusly secured, the bayonets 130, 132, hence connection
block assembly 102, are secured in place. Pressing the latch 530
inwardly (as seen in FIG. 41) displaces the latch from the latch
mating surface 262 of each of the stub bayonets 130, 132 and allows
removal of the connection block assembly 102.
[0120] The latch rod 534 of this invention has retaining clip
grooves 542 at the latch end thereof, rather than at the handle
end. With the instant module docked to the connection block of this
invention, the retaining clips provide more accurate axial
positioning of the water poppet valve components and the electrical
connections. As stated above, optimum axial positioning of the
water poppet valves provides for maximum coolant flow through the
module. Optimum axial positioning of the electrical connections
further ensures reliable current flow and minimizes chances for
electrical arcing (FIGS. 38-41).
[0121] The spring-loaded docking latch has been widened to transmit
more easily over the small gaps between bayonet junctions. The
latch features an integral, linear groove designed to retain one
leg of the latch torsion spring, thereby providing more consistent
assembly and latch operation. Accordingly, the instant latch
provides precise axial alignment of the module of this invention to
the instant connection block. When utilized with the instant stub
bayonets and the instant latch rod, the overall result of the
cooperation of these mechanical features results in a precision
three-dimensional module-to-connection docking arrangement
necessary for optimum module performance (FIGS. 3, 38-41).
[0122] As can be seen in FIGS. 15 and 39, lateral connection end
cap passageways 546, 548 are laterally defined in the connection
end cap 290 and accommodate the stub bayonets 130, 132. The
increased diameter of the tapering portion 256 of each of the stub
bayonets 130, 132 is snugly accommodated within the passageways
546, 548. However, the more distal portions, e.g., 254, 252, of the
stub bayonets 130, 132 have a smaller diameter and, thus, slide
easily into the connection passageways 546, 548. Consequently, the
stub bayonets 130, 132 are easily placed within the passageways
546, 548 but are laterally secured therewithin due to the quite
close tolerance between the diameter of the bayonet sections 256
and the diameter of, and distance between, the passageways 546,
548.
[0123] One embodiment of the shutter assembly 106 of this invention
includes left and right connection shutter end caps 570, 572, (FIG.
10), left and right exhaust shutter end caps 574, 576 (FIG. 25), a
module body 578 (FIG. 6), left and right shutters (extrusions) 580,
582 (FIG. 6), negative and positive retainers 584, 586 (FIG. 6), a
crossover module 588 and cover 590 (FIGS. 29, 30, and 31), an
access door 592 (FIGS. 34 and 35), and connection end and exhaust
end bearings 596, 598 (FIGS. 16 and 20).
[0124] Perspectives of the shutter end caps of this invention may
be viewed in FIGS. 10, 25, 27, and 28 and are either identical or
are mirror images. Consequently, the right connection shutter end
cap 572 will be further explained, corresponding features in the
other shutter end caps being either identical or in mirror image.
Referring now to FIG. 9, the exterior of the shutter end cap 572 is
shaped to receive and secure in place the shutter 582. An exterior
opening 612 is defined, and extends from, an exterior surface of
the shutter end cap 572. The opening 612 is dimensioned and
disposed to receive a bearing 596, which will be more fully
described below. The bearing, in turn, snugly receives the shutter
shaft 332 therewithin. A drive pin slot 614, with a longitudinal
axis 615, is also defined in a lower outboard portion of the
shutter end cap 572. As can be seen in FIG. 11, the drive pin slot
614 is dimensioned to snugly accommodate the drive pin head 362, as
will be more fully explained below. Accordingly, on each of the two
cassette-style shutter drive assemblies, a ball headed drive pin is
mounted to a shutter shaft arm at the connection end of the module.
During operation, the head of this pin engages a drive pin slot in
the shutter end cap to rotate each shutter. The ball diameter is
larger than the shank diameter of the pin to prevent the shank from
contacting any portion of the slot. As shown in FIG. 11, several
degrees of freedom are therefore provided by the interface of this
pin and the shutter end cap slot to allow the shutter to warp and
change length without inducing undesired, adverse forces on drive
train components. The slot and pin are configured to provide
minimal backlash throughout the normal radial swing of the shutter
arm and drive pin. Additionally, the slot/pin arrangement of this
invention provides for these freedoms of motion: the pin may rotate
df1 along its axis inside the slot 614; the pin may slide df2 into
the slot at various depths; the pin may tilt df3 relative to the
centerline of the pin; and the drive pin may contact virtually any
portion of the walls of the slot without loss of functionality
while nonetheless rotating the shutters. Stated otherwise, the
pin-and-slot configuration of this invention allows the shutter end
cap to "wobble" and slide along the pin as the shutter assembly
warps, expands, and contracts in length. Consequently, binding
problems in the drive train components due to imperfect shutter
configurations are eliminated or greatly reduced. The variable
orientation of the slot relative to the drive pin also relaxes a
variety of dimensional and tolerance requirements for pertinent
components. This design further prevents damage from occurring to
the drive train during rough handling of the instant module, for
example, when being lifted or carried by the shutters. The instant
drive-pin configuration functions in conjunction with the shutter
shaft, exhaust shutter pivot shafts, and shutter end cap bearings
to accomplish this functionality.
[0125] Referring now to FIGS. 16, 17, and 18, the opening 612
extends into a reservoir 616. As seen in FIG. 19, the reservoir 616
opens into a vertical passageway 618 which, in turn, opens into a
horizontal passageway 620. Accordingly, coolant flowing from the
shutter shaft 332 flows horizontally into the reservoir 616, then
flows vertically through the vertical passageway 618, then flows
horizontally through the horizontal passageway 620. From the
horizontal passageway 620, the coolant flows through a passageway
in each of the shutters, as will be described more fully below.
Referring now to FIG. 27, the interior surface of the shutter end
cap 572 defines an O-ring gland 622 surrounding the opening of the
horizontal passageway 620 and a relieved surface 624. The relieved
surface (slot) 624 accommodates and secures reflectors in
place.
[0126] The shutter end caps include a relieved reflector mounting
surface. This feature provides better UV protection for the O-ring
located in the shutter body-shutter end cap interface. This feature
further allows the length tolerances of the replaceable reflector
strips to be less critical. By using the instant shutter end caps,
reflectors may now be removed and installed without removing the
shutter end cap and without breaking the fluid-tight integrity of
the shutter assembly. Only the retaining strip needs to be removed
to exchange a reflector. In-situ, carefully made reflector fitment
is no longer necessary because convenient pre-cut reflectors may be
used. With the end caps of this invention assembled to the shutter
extrusion, the relieved surfaces of the end caps fit flush to the
inner surface of the shutter extrusion to produce an uninterrupted,
full length, properly shaped reflector supporting surface (FIGS.
27, 28). Accordingly, printing press down time may be greatly
reduced, due to the advantages of the quick change feature present
in the reflectors of this invention. Using the instant reflectors
may also be an important factor of the efficiency of the UV curing
process. It has been reported that, with the use of clean and
properly shaped reflectors, somewhere between 60% and 80% of the UV
light striking the substrate is reflected light.
[0127] The present shutter end caps are made from aluminum, rather
than stainless steel previously used. Accordingly, the instant
shutter caps minimize galvanic and corrosive action occurring when
the instant shutter end caps are mounted to the extruded aluminum
shutter body. Shutter end caps are further fabricated from a single
piece of material, rather than the multiple pieces previously used.
Fashioning the instant shutter end caps eliminates several
intricate welding operations previously necessary. The shutter end
caps of this invention are fabricated using custom made tools to
produce a special coolant passageway. This passageway includes an
integral reservoir, which helps cool the stem of the UV lamp. The
stem of the UV lamp must be maintained several hundred degrees
cooler than the main body of the lamp (FIGS. 18, 27).
[0128] As seen in FIGS. 1, 2, 4, 6, 7, and 13, the module body 578
unitarily, or otherwise integrally, defines an upper member 630 and
lateral members 632, 634, which depend from the upper member 630.
The lateral members 632, 634 respectively define module body
lateral passageways 636, 638, which are continuous with the
respective passageways 546, 548 of the connection end cap assembly
102 and which accommodate the stub bayonets 130, 132 therein (FIG.
15). As seen in FIG. 39, defined in a central portion of the module
body 578 are coolant passageways 640, 642. Referring again to FIGS.
6 and 7, the upper portion of the module body 578 defines a
crossover module opening 644, which accommodates the crossover
module 588 as more fully explained below.
[0129] As best viewed in FIGS. 6, 7, and 13, the shutters 580 and
582 attach to the end caps and have therewithin coolant passageways
650, 652. The coolant passageways 650, 652 align with, and receive
coolant from, the horizontal passageways 620 of the instant shutter
end caps. Attached to lower edges of the shutters 580, 582 are
respective negative (female) and positive (male) reflector
retainers 584, 586. The negative reflector retainer 584 terminates
in extensions 650, 652, thereby defining a gap 654. The positive
reflector retainer 586 terminates in a beveled tip 660. Reflector
mounts 662, 664, are formed at the inboard ends of the shutters
580, 582 and reflector mounts 666, 668 are formed at the outboard
ends of the retainers 584,586. These mounts secure The reflectors
utilized during operation by securing the edges of the reflectors
therewithin. To replace these reflectors, the retainers 584, 586
are removed by removing the fasteners used to secure them in place,
the reflectors are then removed from the mounts 662, 664,
replacement reflectors are installed, and the retainers are then
secured in place as shown by the fasteners.
[0130] Previously, each shutter assembly was outfitted with either
a "male" or "female" reflector retainer strip mounted to the outer
edge of the shutter extrusion. When the shutters were closed, the
male and female profiles of the retainer strips mated together to
effectively block the direct path of light out of the module. In
the design of this invention, the original female V-shaped
(negative) reflector retainer profile is modified to define a
shallow U-shaped channel. This new shape prevents
shutter-to-shutter binding when closed shutters are warped from
heat or from other causes of shutter-to-shutter misalignment (FIGS.
6, 7). The male, V-shaped "positive" reflector retainer profile
retains its original profile. Consequently, when the shutters are
closed and the shutter retainer profiles are mated together, the
U-shaped channel does not affect the ability of the closed shutters
to block light.
[0131] Referring now to FIGS. 29 and 30, the crossover module 588
defines a coolant reservoir 670 opening into coolant ports 672,
674. Lateral portions of the crossover module 588 define
passageways 676, 678, which are continuous with the module body
passageways 636, 638 in assembly end cap passageways 546, 548 to
thereby accommodate the stub bayonets 130, 132. The horizontal,
planar portion 682 of the crossover module 588 defines a plurality
of, e.g., eight threaded apertures 680. Operationally, the
crossover module 588 is disposed within the crossover module
opening 644 of the module body 578. The module body cover 590
conforms to the shape of the horizontal planar portion 682 of the
crossover module 588 and defines a plurality of, e.g., eight
apertures 686. The apertures 686 align with the apertures 680
present in the crossover module 588. Accordingly, the module body
cover 590 is secured in place by extending fasteners through the
apertures 686 and threading the fasteners into the apertures
680.
[0132] The coolant crossover feature is incorporated into the upper
module cover to ease manufacturing and assembly issues. The
crossover cavity features a substantial reservoir to better cool
the lamp seal, shutter sensors, lamp socket assembly and shutter
assemblies (FIGS. 29, 30).
[0133] FIGS. 34, 35, and 36 show an access 690 and access door 592
of this invention. The access 690 is defined at lower portions of
each lateral side of the connection end cap assembly 104. The
access door includes respective upper and lower dovetailed edges
694, 696, which terminate about midway at 698, 700. A worm shaft
access hole 702 is defined in the access door 592 as well.
Proximate upper and lower peripheries of the access 690 are
complementary, slotted portions 704, 706. The dovetailed edges 694,
696 are accommodated, and slide within, the slotted portions 704,
706.
[0134] The shutter drive train access doors have been designed to
allow them to be removed with a minimum of module disassembly. A
portion of the upper and lower dove tail edges of the access doors
has been removed, thereby allowing the doors to be removed after
being slid a short distance. Accordingly, the only component
necessary for removal prior to access door removal is the module
bottom cover in one embodiment. Once the doors are removed, the
shutter drive assemblies may be "timed" (synchronized) as required
without further disassembly of other module components (FIGS.
34-37). The fasteners securing the two-piece collar to the shaft
are easily accessible. Initial timing of the shutters may be
quickly accomplished with the shutter drive assembly in place and
without extensive disassembly of module components. After removing
the access doors, an Allen wrench inserted through access holes can
quickly loosen and retighten the fasteners on the collars or worm
shaft to provide quick and easy shutter timing adjustments. Each of
the two shutter drive assemblies may be independently adjusted in
this manner to help simplify and finely adjust shutter timing
adjustments as desired (FIGS. 8, 34-37).
[0135] As shown in FIG. 9, the bearing 596 is disposed in the
opening 612 of the connection and exhaust shutter end cap shown of
this invention. FIG. 19 depicts the bearing 596 disposed in the
right connection shutter end cap 572 and FIG. 20 shows the bearing
596 disposed in the right exhaust shutter end cap 576. The
orientation of the bearing 596 in the right exhaust shutter end cap
576 is rotated 180 degrees from the orientation of the bearing 596
in the right connection shutter end cap 572. In either case, the
bearing 596 has a housing 710 defining respective outer and inner
glands 712, 714 and a bearing surface 716 therebetween. Respective
outer and inner seals 718, 720 are accommodated within the outer
and inner glands 712, 714. In the case of the left and right
connection shutter end cap shown 570, 572 each of the bearings 596
receives one of the shutter shafts 332 to achieve a fluid tight
connection as the connection end caps are rotated during
operation.
[0136] The bearing arrangement of this invention provides for
nominal flexing, thermal expansion/contraction, warpage, and
dimensional variations of the shutter assembly without sacrificing
fluid-integrity or inducing undesired forces on seals and shutter
drive train components. The instant bearing features a narrow,
centrally located load-bearing surface that is sealed on either
side by a pair of integral seal glands fitted with O-rings. By
virtue of their elasticity, these O-rings also provide a mechanical
means to distribute the bearing loads. The outer O-ring 718 also
serves as a wiper to prevent debris from entering the bearing and
seal areas.
[0137] The shutter shafts and the exhaust shutter pivot shafts
function as bearing surfaces for the shutter end cap bearings and
as O-ring sealing surfaces for the shutter end cap bearing seals.
In both cases, the shutter end cap shown may be displaced with
several degrees of freedom.
[0138] The instant bearing arrangement provides several degrees of
freedom for the shutter and caps as more fully described above. The
instant bearing also functions as a heat sink and a heat transfer
element, again cooperating with other features to maintain module
components at cooler temperatures (FIGS. 5, 19, 20).
[0139] FIGS. 20, 25, 26, and 28 depict the exhaust end cap assembly
108 of the instant invention, including a lamp connector 730, a
lamp connection assembly 731, an exhaust shutter shaft 732, a fluid
passageway including a sacrificial anode 738, and an end plate 740.
The lamp connector 730 may be substantially identical to the lamp
connector 470 as shown in FIGS. 21 and 22. In FIG. 28, the lamp
connector 730 is shown operably mounted between the exhaust end
caps 574, 576. The exhaust shutter shaft is rotatably disposed
within the bearing 596 of each of the exhaust shutter end caps 574,
576. The exhaust shutter shaft opens into the reservoir of each of
the exhaust shutter end caps 574, 576, as well, then opening into a
vertical passageway 734. The vertical passageway 734 extends
upwardly joining a horizontal passageway 736. The horizontal
passageway 736 opens into one of the module body passageways 640,
642. The sacrificial anode 738 functions as a coolant plug and
threads into a lower portion of the vertical passageway 734.
[0140] In one embodiment, the coolant plugs in the module exhaust
end cap are modified (shortened) sacrificial zinc (or manganese)
anodes to combat corrosion in coolant passageways. The sacrificial
anodes are installed directly in the flow path inside the module
for maximum effectiveness and have a chamfered or radiused end for
maximum exposure to coolant flow (FIGS. 25, 26). The contemplated
coolant utilized in the instant invention, as well as other UV
modules, is either locally available water or water-polyethylene
glycol mixtures. Locally available water is often an electrical
conductor due to concentrations of sodium, calcium, magnesium, and
iron cations. Water-polyethylene glycol mixtures are electrical
conductors as well. Accordingly, galvanic corrosion presents an
ongoing problem by causing corrosion of the coolant conductive
passageways. Moreover, the high temperatures present during
operation accelerate the chemical reactions of galvanic corrosion,
resulting in coolant leakage where corrosion reactions have eroded
coolant passageways. Coolant leakages, especially in proximity to
the UV lamp or electrical connections, can cause extensive damage
due to electrical arcing. Galvanic corrosion occurs when a first
metal contacts a second metal, both exposed to an electrolyte.
Since both the first and second metals are conductors, the first
metal will corrode preferentially if the first metal has a greater
(more negative) galvanic potential than the second metal. In the
case in point, zinc has a greater galvanic potential than aluminum,
the predominant metal exposed to the instant coolant solution.
Therefore, the zinc anode of this invention will corrode
preferentially to any aluminum components of the coolant pathway.
Because the instant zinc anode may be provided in the form of a
threaded plug, the instant zinc anode may be easily and quickly
replaced periodically when sufficiently corroded to ensure that the
predominant aluminum pathways remain intact, uncorroded, and
leakage free.
[0141] In one embodiment, a coolant pathway present in the instant
UV module begins when coolant enters the right fitting 164 and
exits the left fitting 162. However, entry via the left fitting 162
and exit via the right fitting 164 or alternating the foregoing two
alternatives are contemplated to be within the scope of the instant
invention. In any of the foregoing scenarios the coolant pathway
would encounter elements described above, albeit in different
sequences. In the first scenario, the coolant enters the right
fitting 164 (FIG. 4) and flows through the right poppet valve 240
(FIG. 16). From the right poppet valve 240, the coolant flows
through the sleeve bushing 420, then through the right shutter
shaft 332 (FIG. 5). From the right shutter shaft 332, the coolant
then flows through the right connection shutter end cap reservoir
616 (FIG. 16), then through the right connection shutter end cap
vertical and horizontal passageways 618, 620 (FIG. 19), then
through the right shutter passageway 652 (FIG. 6). From the right
shutter passageway 652, the coolant flows through the right exhaust
shutter end cap horizontal and vertical passageways and into the
reservoir thereof (not shown). From the right exhaust shutter end
cap reservoir, the coolant flows through the right exhaust shutter
shaft 732, though the vertical and horizontal passageways 734, 736
(FIG. 26) and into the module body coolant passageway 642 (FIG.
39). After flowing through the module body coolant passageway 642,
the coolant flows through the crossover module 588, though port
674, reservoir 670 and port 672 (FIG. 30) and into the module body
passageway 640 (FIG. 39) to begin a passageway in the left
components of the instant UV module which is essentially a reverse
of the passageway to the right components thereof In this reverse
passageway, the coolant flows through the module body passageway
640 (FIG. 39) and into the left horizontal and vertical passageways
(not shown). While many of the components of the left fluid
passageways are not depicted, these components are substantially
similar or identical to those shown with respect to right fluid
passageways. From the vertical passageway 734, the coolant flows
through the left exhaust shutter shaft and into the left exhaust
shutter end cap, where the coolant flows through the end cap
reservoir and vertical and horizontal passageways. From the left
exhaust shutter end cap horizontal passageway, the coolant then
flows through the left shutter passageway 650 (FIG. 6) and into the
left connection shutter end cap reservoir (not shown). After
flowing through the left connection shutter end cap reservoir, the
coolant then flows through the horizontal and vertical passageways
thereof and into the left shutter shaft 332 (not shown). From the
left shutter shaft 332, the coolant then flows through the sleeve
bushing 420, poppet valve 240, and exits via the left fitting 162
(not shown).
[0142] Referring now to FIGS. 44, 45, 46, and 47, another
embodiment of the instant shutter assembly of this invention is
depicted at 750, having respective negative (female) and positive
(male) retainers 752, 754. The other components of the shutter
assembly 750 may be similar or substantially identical to those
discussed previously. The negative retainers 752 defines a terminal
C-channel or slot 760 in a similar manner to the negative retainer
584 discussed above. However, in contrast to the positive retainer
586, the positive male retainers have a plurality of alternate
respective lower and upper cutouts 762, 764 straddling the tip 766
thereof. As can be seen, the remaining, or non-cutout portions 768,
770 of the positive retainer 754 abut the upper or lower extensions
772, 774 of the negative retainers 752, thereby leaving a gap
between the tip 766 of the positive retainer 754 and the surface of
the C-channel 760 to allow airflow into the interior of the shuttle
assembly from the exterior, to thereby further assist in cooling.
Stated otherwise, the gap between the lower cutout 762 and the
lower extensions 772, 774 may be considered as a lower channel
portion 778; the gap between the positive retainer tip 766 and the
surface of the C-channel 760 may be considered as an intermediate
channel portion 780; and the gap between upper cutout 764 and the
upper extensions 772 may be considered as an upper channel portion
782. The lower, intermediate, and upper channel portions 778, 780,
782 being continuous, a plurality of air channels are thereby
defined to further assist in cooling the interior of the instant UV
module of this invention.
[0143] When a printing press is operating, the shutters of this
invention are rotated to an open position by the shutter drive
train (FIG. 6). The very high energy light (a combination of
visible, infrared, and ultraviolet wavelengths) is generated from a
lamp. A proportion of the light is reflected and another proportion
directly impinges the inked substrate. The shutters are designed
with a special shape to reflect and aim as much light energy toward
the substrate as possible so that the UV wavelengths will "cure"
(dry) the UV-reactive ink.
[0144] Under certain conditions, the shutters must be closed (FIG.
7). The outer edges of each of the shutters are equipped with
either a positive (male) or a negative (female) profile. These
profiles mate together when the shutters are closed to block the
passage of light to the substrate being printed by the press. A
shutter assembly that has stalled in a non-fully-closed position
(usually due to shutter warpage, drive train bind-up, or motor
failure) has been known to allow a powered-up lamp to ignite the
substrate.
[0145] During normal operation, a water or water/glycol coolant
mixture is circulated through the module body and through both
shutter assemblies to remove excess heat and control the amount of
shutter warpage and expansion. The instant module body and shutter
assemblies are made from extruded aluminum with integral coolant
passageways. There are numerous places throughout the module
assembly where static and dynamic O-rings seals may be used to
attempt to prevent the coolant from leakage. In the past, leakage
problems have been fairly common. In the module design of this
invention, the O-ring seal and gland designs eliminate, or greatly
reduce, coolant leakages. However, most coolants are good
conductors of electricity and due to the close proximity of
leakages to the high-voltage electrical connections within the
module of the prior art, these leakages have often caused and
escalated component damage due to electrical arcing.
[0146] The special high-energy UV lamps require high-voltage and
fairly high current, e.g., up to 3000 volts and up to 17 amps. The
electrical connections conducting this electrical current must
retain electrical conduction properties and must be well insulated
from surrounding components (FIGS. 21-24, 42, 43). In the past
coolant leakages, electrical leakages, pin and socket erosion and
pin-to-socket alignment problems between the module and the
connection block have been causes of failure in the electrical
connections.
[0147] Because numerous modifications of this invention may be made
without departing from the spirit thereof, the scope of the
invention is not to be limited to the embodiments illustrated and
described. Rather, the scope of the invention is to be determined
by the appended claims and their equivalents.
* * * * *