Electrostatic spray gun with self-contained miniaturized power pack integral therewith
阅读：318发布：2023-03-21
专利汇可以提供Electrostatic spray gun with self-contained miniaturized power pack integral therewith专利检索，专利查询，专利分析的服务。并且An electrostatic spray gun having physically integral therewith a power pack for transforming low voltage supplied to the gun to high voltage for application to the gun electrode. The power pack is contained completely within the gun, and includes a combined oscillator and transformer which converts low voltage d.c., e.g., 11 volts, supplied to the gun via a low voltage cable to an intermediate voltage at high frequency, e.g., 6,000 volts peakto-peak at 45 KHz; and a voltage multiplier circuit which transforms the high frequency 6,000 volt peak-to-peak power to 72,000 volts d.c. for application to the gun electrode.，下面是Electrostatic spray gun with self-contained miniaturized power pack integral therewith专利的具体信息内容。
1. An electrostatic coating spray system which generates and applies high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage comprising: a spray gun having a nozzle from which coating material is emitted, an electrode mounted to said gun to electrostatically charge emitted coating material when said electrode is energized with high voltage electrical energy, and a booster supply having minimal capacitive electrical energy storage at coating charging potentials mounted to said gun for converting low voltage electrical energy supplied to said gun to high voltage electrical energy for energization of said electrode, said booster supply including: a. an oscillator circuit responsive to said low voltage energy for transforming said low voltage energy to electrical energy at high frequency, and b. a voltage multiplier responsive to said high frequency energy and including interconnected diodes and capacitors for multiplying the voltage of said high frequency electrical energy to high voltage energy for application to said electrode, said high frequency multiplier having minimal capacitive electrical energy storage to reduce the shock and ignition hazards associated with capacitive electrical energy discharge in an explosive environment and/or to an operator.
2. The system of claim 1 further including an electrical cable interconnecting said oscillator circuit and a source of low voltage energy remote from said gun, said cable being electrically insulated sufficiently for safe operation at low voltages and insufficiently for safe operation at high voltages.
3. The system of claim 2 wherein said low voltage source is an inverter circuit for transforming 60 Hz. a.c. current to low voltage unidirectional current.
4. The system of claim 1 further including a ferrite core transformer connected to said oscillator and to said voltage multiplier for stepping up said low voltage energy input to said oscillator to intermediate voltage energy at high frequency for input to said voltage multiplier.
5. The system of claim 4 further including an electrical cable interconnecting said oscillator circuit and a source of low voltage energy remote from said Gun, said cable being electrically insulated sufficiently for safe operation at low voltages and insufficiently for safe operation at high voltages.
6. The system of claim 1 wherein said gun includes an elongated barrel terminating at said nozzle and electrode, said barrel having a cavity therein with an end adjacent said nozzle and electrode which is liquid sealed with respect thereto, said cavity having an opening remote from said nozzle and electrode to facilitate insertion of said multiplier circuit into said cavity.
7. The system of claim 1 wherein said multiplier capacitors are disc-shaped with a periphery and with opposed substantially parallel surfaces each having an electrical terminal thereat, at least some of said capacitors being arranged in at least one stack in which the peripheries of said stacked capacitors are aligned and adjacent terminals of adjacent stacked capacitors are in electrical contact.
8. The system of claim 7 wherein there are at least two stacks of capacitors, wherein said two stacks are disposed in spaced, substantially parallel relation, and wherein said diodes of said multiplier have two terminals each connected to a capacitor of a different stack.
9. The system of claim 4 wherein said ferrite core transformer includes two opposed cup-shaped ferrite core sections each having a central stub, and at least two windings wound on said stubs, a first one of said windings having relatively few turns and being connected in the input circuit of said oscillator and responsive to said low voltage and a second one of said windings having relatively many turns and connected in the output circuit of said oscillator, said windings having a turns ratio to step up said low voltage to an intermediate a.c. voltage in the range of 2, 000-10,000 volts peak-to-peak.
10. The system of claim 9 further including dielectric potting material between said windings and the interior of said cup-core sections for insulating said second winding and said core, said potting material having a dielectric constant equal or lower than approximately 3.6 and a dissipation factor equal or lower than approximately 0.02 for minimizing stray capacitance and providing efficient power transformation at oscillator frequencies above approximately 10 KHz.
11. The system of claim 9 wherein said oscillator includes a transistor having an emitter-collector path in which said first winding is connected and having a base, a third winding wound on said ferrite core stubs, said third winding being connected to said transistor base and of opposite polarity to said first winding for producing oscillation of said transistor.
12. The system of claim 7 further including disc-shaped resistors mechanically and electrically connected between said stacked capacitors for dissipating electrical energy stored in said multiplier circuit capacitors should said electrode become grounded.
13. The system of claim 11 wherein said intermediate voltage is approximately 6,000 volts peak-to-peak and said first, second and third windings have turns in the ratio of approximately 1:3:600, respectively.
14. A method of electrostatic coating with a spray gun having an interconnected particle-charging high voltage electrode and a voltage multiplier circuit, including interconnected rectifiers and capacitors, mounted thereon, which method involves the application of high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage, said method comprising the steps of: supplying a low voltage to said gun from a remote source via an electrical cable, converting in said gun said input low voltage to an intermediate voltage at a high frequency, multiplying in said gun said high frequency intermediate voltage using said gun-mounted rectifier-capacitor multiplier circuit, said circuit having minimal capacitive electrical energy storage at coating charging potentials, applying the muLtiplied voltage output from said multiplier circuit to said high voltage electrode while emitting coating particles from said gun in the vicinity of said electrode, to thereby charge said particles, and directing said charged particles toward an article to be coated while maintaining said article at an electrical potential different from that of said electrode.
15. The method of claim 14 wherein said converting step includes driving an oscillator circuit in said gun with said low voltage to generate high frequency oscillatory voltage and by transformer action in said gun stepping up said high frequency oscillatory voltage to an intermediate voltage of the same frequency.
16. A method of electrostatic coating with a spray gun having an interconnected particle-charging high voltage electrode and voltage multiplier circuit, including interconnected rectifiers and capacitors, mounted thereon, which method involves the application of high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage, said method comprising the steps of: supplying a low voltage to said gun from a remote source via an electrical cable insulated for use safely at low voltages and unsafely at high voltages necessary for particle charging, driving an oscillator circuit in said gun with said low voltage to generate a high frequency oscillatory voltage, stepping up said oscillatory voltage to an intermediate voltage of the same frequency with a ferrite cup-core transformer, multiplying in said gun said high frequency intermediate voltage using said gun-mounted rectifier-capacitor multiplier circuit, said circuit having minimal capacitive electrical energy storage at coating charging potentials, applying the multiplied voltage output from said multiplier circuit to said high voltage electrode while emitting coating particles from said gun in the vicinity of said electrode, to thereby charge said particles, and directing said charged particles toward an article to be coated while maintaining said article at an electrical potential different from that of said electrode.
17. The system of claim 1 wherein said gun includes an elongated barrel terminating at said nozzle and electrode, and said multiplier circuit has a high voltage output terminal and is mounted to said barrel with said terminal proximate said electrode.
18. The system of claim 2 wherein said cable has capaci-tive electrical energy storage not substantially greater than zero.
19. The system of claim 2 wherein said cable has insufficient resistance to dissipate without ignition electrical energy in an amount equal to that stored in an identical cable carrying a high d.c. voltage.
20. The system of claim 1 further including an electrical cable interconnecting said oscillator circuit and a source of low voltage energy remote from said gun, said cable having insufficient resistance to dissipate without ignition electrical energy in an amount equal to that stored in an identical cable carrying a high d.c. voltage.
21. The system of claim 1 wherein said multiplier circuit has a capacitance substantially below 900 picofarads.
22. The system of claim 2 wherein said cable stores substantially less electrical energy in capacitive form than a similar cable carrying a high d.c. voltage.
23. The system of claim 1 wherein said multiplier circuit has a capacitance per stage which provides, at the operating frequency, a total multiplier capacitance sufficient to produce a smooth unidirectional voltage output.
24. The system of claim 1 wherein said multiplier circuit includes multiple multiplying stages, and wherein said multiplier circuit has insufficient resistance to dissipate without ignition electrical energy in an amount equal to that stored in an equivalent multiplier circuit of approximately the same per stage voltage operating at low frequency.
25. The system of claim 1 wherein said multiplier has insufficient resiStance to dissipate without ignition electrical energy in an amount equal to that stored in an equivalent multiplier circuit of approximately the same total multiplier voltage operating at low frequency.
26. The system of claim 1 wherein said multiplier circuit has a total capacitance approximately equal to a 12-stage multiplier operating at 45 KHz with an average per stage voltage gradient of 6,000 v.
27. The system of claim 1 wherein said multiplier circuit has a total capacitance approximately equal to that of a 12-stage multiplier operating at 45 KHz having a total voltage thereacross of 72 Kv.
28. An electrostatic coating spray system which generates and applies high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage comprising: a gun from which coating material is emitted, an electrode to effect electrostatic charging of emitted coating material when said electrode is energized with substantially unidirectional high voltage electrical energy, a source of low voltage electrical energy external to said gun, a frequency conversion circuit responsive to said low voltage electrical energy for converting said low voltage electrical energy to high frequency electrical energy, and a voltage multiplier circuit, including interconnected rectifiers and capacitors, mounted to said gun responsive to the output of said frequency conversion circuit for converting said high frequency electrical energy to substantially unidirectional high voltage electrical energy for energizing said electrode, said voltage multiplier having minimal capacitive electrical energy storage to reduce the shock and ignition hazards associated with capacitive electrical energy discharge in an explosive environment and/or to an operator.
29. An electrostatic coating spray system which generates and applies high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage comprising: a gun from which coating material is emitted, an electrode to effect electrostatic charging of emitted coating material when said electrode is energized with substantially unidirectional high voltage electrical energy, and a voltage multiplier circuit mounted to said gun, including interconnected rectifiers and capacitors, for converting low voltage high frequency electrical energy input thereto to substantially undirectional high voltage electrical energy for energizing said electrode, said voltage multiplier having minimal capacitive electrical energy storage to reduce the shock and ignition hazards associated with capacitive electrical energy discharge in an explosive environment and/or to an operator.
30. An electrostatic coating spray system which generates and applies high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage comprising: a gun from which coating material is emitted, an electrode to effect electrostatic charging of emitted coating material when said electrode is energized with substantially unidirectional high voltage electrical energy, and a voltage multiplier circuit, including interconnected rectifiers and capacitors, mounted to said gun for converting, with an accompanying change to high frequency, low voltage electrical energy input thereto at low frequency to substantially unidirectional high voltage electrical energy for energizing said electrode, said voltage multiplier having minimal capacitive electrical energy storage to reduce the shock and ignition hazards associated with capacitive electrical energy discharge in an explosive environment and/or to an operator.
31. An electrostatic coating spray system which generates and applies high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage comprising: a gun from which coating material is emitted, An electrode to effect electrostatic charging of emitted coating material when said electrode is energized with substantially unidirectional high voltage electrical energy, an electrical energy source, including a source of low voltage electrical energy external to said gun, for providing low voltage electrical energy at high frequency, and a voltage multiplier circuit, including interconnected rectifiers and capacitors, mounted to said gun responsive to said high frequency low voltage electrical energy for conversion thereof to substantially unidirectional high voltage electrical energy for energizing said electrode, said voltage multiplier having minimal capacitive electrical energy storage to reduce the shock and ignition hazards associated with capacitive electrical energy discharge in an explosive environment and/or to an operator.
32. The system of claim 31 further including an electrical cable connected between said external low voltage source and said multiplier circuit, said cable being electrically insulated sufficiently for safe operation at low voltages and insufficiently for safe operation at high voltages.
33. The system of claim 31 wherein said gun includes am elongated barrel terminating at a nozzle from which said coating is emitted and adjacent to which said electrode is mounted, said barrel having a cavity therein with an end adjacent said nozzle and electrode which is liquid sealed with respect thereto, said cavity having an opening remote from said nozzle and electrode to facilitate insertion of said multiplier circuit into said cavity.
34. The system of claim 33 wherein said multiplier includes rectifier and capacitive circuitry, said circuitry being potted and configured to fit in said cavity.
35. The system of claim 34 wherein said multiplier circuit includes capacitors at least some of which are arranged in at least two stacks, said at least two stacks being disposed in spaced, substantially parallel relation, and includes rectifiers at least some of which have two terminals each connected to a capacitor of a different stack.
36. An electrostatic coating spray system which generates and applies high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage comprising: a gun from which coating material is emitted, an electrode to effect electrostatic charging of emitted coating material when said electrode is energized with substantially unidirectional high voltage electrical energy, a source of high frequency electrical energy, including a source of low voltage energy external to said gun, a transformer having at least two windings, a first one of said windings having relatively few turns and responsive to said low voltage source and a second one of said windings having relatively many turns, said windings having a turns ratio to step up said low voltage to an intermediate voltage at high frequency, and a multiplier circuit, including interconnected rectifiers and capacitors, mounted to said gun and responsive to said high frequency intermediate voltage for conversion thereof to substantially unidirectional high voltage electrical energy for energizing said electrode, said multiplier circuit having minimal capacitive electrical energy storage to reduce the shock and ignition hazards associated with capacitive electrical energy discharge in an explosive environment and/or to an operator.
37. The system of claim 36 wherein said transformer has a ferrite core on which said windings are wound, and wherein said windings have a turns ratio to step up said low voltage to an intermediate a.c. voltage in the approximate range of 2,000- 10, 000 volts peak-to-peak.
38. The system of claim 37 wherein said ferrite core includes two opposed cup-shaped core sections each having a central stub upon which said windings are wound, and wherein said transformer includes dielectric potting material between said windings and the interior of said cUp-core sections for insulating said second winding and said core, said potting material having a dielectric constant equal or lower than approximately 3.6 and a dissipation factor equal or lower than approximately 0.02 for minimizing stray capacitance and providing efficient power transformation at oscillator frequencies above approximately 10 KHz.
39. The system of claim 31 wherein said multiplier circuit includes an input and an output between which are connected multiple rectifier and capacitor stages having associated therewith multiple resistors distributed between said input and output for reducing ignition hazards due to electrical energy capacitively stored in said multiplier circuit.
40. A method of electrostatic coating with a spray gun having an interconnected particle-charging high voltage electrode and a voltage multiplier circuit, including interconnected rectifiers and capacitors, mounted thereon, which method involves the application of high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage, said method comprising the steps of: supplying low voltage electrical energy at high frequency at said gun, including transmitting to said gun via a cable low voltage electrical energy from a supply remote from said gun, multiplying in said gun said high frequency voltage using said gun-mounted multiplier circuit, said circuit having minimal capacitive electrical energy storage at coating charging potentials, applying the multiplied voltage output from said multiplier circuit to said high voltage electrode while emitting coating particles from said gun to thereby charge said particles, and directing said charged particles toward an article to be coated while maintaining said article at an electrical potential different from that of said electrode.
41. A method of electrostatic coating with a spray gun having an interconnected particle-charging high voltage electrode and a voltage multiplier circuit, including interconnected rectifiers and multipliers, mounted thereon, which method involves the application of high voltage charging potentials to coatings with minimal safety hazards due to capacitive electrical energy storage, said method comprising the steps of: supplying low voltage electrical energy at said gun, including transmitting to said gun via a cable low voltage electrical energy from a supply remote from said gun, stepping up in said gun by transformer action said low voltage electrical energy to an intermediate voltage at high frequency, multiplying in said gun said high frequency intermediate voltage using said gun-mounted multiplier circuit, said circuit having minimal capacitive electrical energy storage at coating charging potentials, applying the multiplied voltage output from said multiplier circuit to said high voltage electrode while emitting coating particles from said gun to thereby charge said particles, and directing said charged particles toward an article to be coated while maintaining said article at an electrical potential different from that of said electrode.
42. The system of claim 31 wherein said gun includes an elongated barrel terminating at a nozzle from which said coating material is emitted, wherein said electrode is mounted to said barrel, and wherein said multiplier circuit has a high voltage output terminal and is mounted to said barrel with said high voltage terminal proximate said electrode.
43. The system of claim 31 further including an electrical cable connected between said external low voltage source and said multiplier circuit, said cable when carrying electrical energy having capacitive electrical energy storage not substantially greater than zero.
44. The system of claim 31 further including an electrical cable connected between said external low voltage source and said multiplier, said cable having insufficient resistance to dissipate without ignition electrical energy in aN amount equal to that stored in an identical cable carrying a high d.c. voltage.
45. The system of claim 31 wherein said multiplier circuit has a capacitance substantially below 900 picofarads.
46. The system of claim 31 further including an electrical cable connected between said external low voltage source and said multiplier circuit, said cable when carrying electrical energy storing substantially less electrical energy in capacitive form than a similar cable carrying a high d.c. voltage.
47. The system of claim 31 wherein said multiplier circuit has multiple stages and has a capacitance per stage which provides, at the operating frequency, a total multiplier capacitance sufficient to produce a smooth unidirectional voltage output.
48. The system of claim 31 wherein said multiplier circuit has multiple stages and has insufficient resistance to dissipate without ignition electrical energy in an amount equal to that stored in an equivalent multiplier circuit of approximately the same per stage voltage operating at low frequency.
49. The system of claim 31 wherein said multiplier has insufficient resistance to dissipate without ignition electrical energy in an amount equal to that stored in an equivalent multiplier circuit of approximately the same total multiplier voltage operating at low frequency.
50. The system of claim 31 wherein said multiplier is configured to provide approximately 50 KV per cubic inch of volume.
51. The system of claim 36 wherein said transformer and multiplier provide approximately 7 KV per ounce of weight.
52. The system of claim 36 wherein said transformer and multiplier provide approximately 20 KV per cubic inch of volume.
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