Power feeding apparatus having an adjustable feed width

• US 6,197,114 B1
• Filed: 11/05/1998
• Issued: 03/06/2001
• Est. Priority Date: 11/05/1998
• Status: Expired due to Fees

• Current Assignee: Material Sciences Corporation (New Star Metals Holdings LLC)
• Original Assignee: Material Sciences Corporation (New Star Metals Holdings LLC)
• Inventors: Rodenberger, Phillip
• Primary Examiner(s): EDWARDS, LAURA ESTELLE
• Application Number:
  US09/186,466
• Time in Patent Office: 852 Days
• Field of Search: 118/308, 118/300, 118/623, 118/629, 118/627, 118/260, 118/DIG.16, 239/700, 239/223, 239/224, 239/675, 239/679, 239/680, 239/665, 239/655, 239/124, 239/127, 222/370, 222/368
• US Class Current: 118/623
• CPC Class Codes: B05B 3/02 with rotating elements electric spraying discharge apparatus characterised by having rotary outlet or deflecting elements B05B5/04
• CPC Class Codes: B05B 5/04 characterised by having rotary outlet or deflecting elements , i.e. spraying being also effected by centrifugal forces
• CPC Class Codes: B05B 5/057 Arrangements for discharging liquids or other fluent material without using a gun or nozzle
• CPC Class Codes: B05B 5/14 specially adapted for coating continuously moving elongated bodies, e.g. wires, strips, pipes
• CPC Class Codes: B05B 5/1683 specially adapted for particulate materials
• CPC Class Codes: Y10S 118/16 Slinger type

Abstract

A method and system are provided for adjusting a discharge width of a powder feeder. The system includes a supply hopper that is spaced from the powder feeder. The powder feeder includes a receiving opening and a discharge opening and at least one adjustable wall. Preferably, two adjustable walls are provided. Movement of the two adjustable walls provides variations in the width of the discharge opening and therefore facilitates use of the powder feeder on target volumes or target areas having different widths. A rotatable auger brush is in communication with the supply hopper for causing powder withdrawn from the supply hopper to be transported to the powder feeder and disposed uniformly across the receiving opening of the powder feeder. The brush is immersed within the powder and extends across the receiving opening of the powder feeder, and maintains a filled level powder feeder. The powder feeder is particularly well-suited for use in a coating apparatus, as well as a dual-side coating apparatus.

Claims

1. A powder feeder and discharging system for feeding powder from a powder supply to a powder discharging device, comprising:

a powder receptacle having an inlet, a discharge for directing powder toward a powder discharging device, a stationary wall portion and at least one adjustable wall which is movable with respect to the stationary wall portion to adjust a width of the discharge;

a powder discharge device in communication with the discharge for directing powder toward an object to be coated; and

a rotatable auger brush in communication with the powder supply and extending along the inlet of the powder receptacle, for withdrawing powder from the powder supply and transporting the powder through the inlet of the powder feeder.

2. The powder feeder and discharging system of claim 1, further comprising a drive mechanism operatively connected to the rotatable auger brush so as to rotate the rotatable auger brush.

3. The powder feeder and discharging system of claim 2, wherein the rotatable auger brush is driven by the drive mechanism using a rotational speed which causes the powder to be dispensed uniformly across the powder receptacle.

4. The powder feeder and discharging system of claim 1, wherein the rotatable auger brush is horizontally arranged in the powder receptacle.

5. The powder feeder and discharging system of claim 1, wherein said at least one adjustable wall includes a powder flow tube in communication with the powder receptacle and extending away from the powder receptacle, from an outside surface of said at least one adjustable wall, the rotatable auger brush being arranged so as to extend through the powder flow tube and transport powder therethrough.

6. The powder feeder and discharging system of claim 5, wherein the powder flow tube is fixed to said at least one adjustable wall for movement therewith.

7. The powder feeder and discharging system of claim 6, further comprising a stationary feed tube arranged so that the powder flow tube is telescopically movable along a portion of the stationary feed tube, the stationary feed tube being disposed around a portion of the rotatable auger brush so that the rotatable auger brush transports powder through the stationary feed tube.

8. The powder feeder and discharging system of claim 7, wherein the stationary feed tube and the powder flow tube extend toward the powder supply and together define a telescopic powder feed path of adjustable length which compensates for movement of said at least one adjustable wall.

9. The powder feeder and discharging system of claim 7, wherein the stationary feed tube and the powder flow tube extend generally away from the powder supply toward a powder reclamation apparatus and together define a telescopic powder reclamation path of adjustable length which compensates for movement of said at least one adjustable wall.

10. The powder feeder and discharging system of claim 1, wherein the powder receptacle has an elongated shape of substantially constant cross section over a length thereof, said at least one adjustable wall being disposed near a first longitudinal end of the powder feeder, for selective movement linearly toward an opposite longitudinal end of the powder feeder to thereby selectively adjust the width of the discharge.

11. The powder feeder and discharging system of claim 10, wherein said at least one adjustable wall includes a powder flow tube in communication with the powder receptacle and extending away from the powder receptacle, from an outside surface of said at least one adjustable wall, the rotatable auger brush being arranged so as to extend through the powder flow tube and transport powder therethrough.

12. The powder feeder and discharging system of claim 11, wherein the powder flow tube is fixed to said at least one adjustable wall for movement therewith.

13. The powder feeder and discharging system of claim 12, further comprising a stationary feed tube arranged so that the powder flow tube is telescopically movable along a portion of the stationary feed tube, the stationary feed tube being disposed around a portion of the rotatable auger brush so that the rotatable auger brush transports powder through the stationary feed tube.

14. The powder feeder and discharging system of claim 13, wherein the stationary feed tube and the powder flow tube extend toward the powder supply and together define a telescopic powder feed path of adjustable length which compensates for movement of said at least one adjustable wall.

15. The powder feeder and discharging system of claim 13, wherein the stationary feed tube and the powder flow tube extend generally away from the powder supply toward a powder reclamation apparatus and together define a telescopic powder reclamation path of adjustable length which compensates for movement of said at least one adjustable wall.

16. The powder feeder and discharging system of claim 11, wherein the powder flow tube has a first end fixed to said at least one adjustable wall, the powder feeder further comprising a slidable bulkhead fixed to a portion of the powder flow tube other than the first end for supporting that portion of the powder flow tube.

17. The powder feeder and discharging system of claim 16, further comprising:

at least one control rod connected to the slidable bulkhead so that actuation of said at least one control rod in a first direction moves the powder flow tube and said at least one adjustable wall inwardly to decrease the width of the discharge and actuation of said at least one control rod in a second, opposite direction moves the powder flow tube and said at least one adjustable wall outwardly to increase the width of the discharge.

18. The powder feeder and discharging system of claim 17, further comprising first and second end walls located at the first longitudinal end and the opposite longitudinal end, respectively, for delimiting a powder containment area, one of the first and second end walls having at least one aperture through which said at least one control rod extends.

19. The powder feeder and discharging system of claim 1, further comprising:

at least one control rod connected at least indirectly to said at least one adjustable wall so that actuation of said at least one control rod in a first direction moves said at least one adjustable wall inwardly to decrease the width of the discharge and actuation of said at least one control rod in a second, opposite direction moves said at least one adjustable wall outwardly to increase the width of the discharge.

20. The powder feeder and discharging system of claim 1, further comprising a metering brush rotatably mounted at the discharge, for feeding powder out through the discharge at an adjustable rate, the rate being adjustable by selectively adjusting a rotational speed of the metering brush.

21. The powder feeder and discharging system of claim 20, wherein the metering brush is substantially parallel to the rotatable auger brush.

22. The powder feeder and discharging system of claim 20, wherein:

the powder receptacle has an elongated shape of substantially constant cross section over a length thereof, said at least one adjustable wall being disposed near a first longitudinal end of the powder feeder, for selective movement linearly toward an opposite longitudinal end of the powder feeder to thereby selectively adjust the width of the discharge;

said at least one adjustable wall includes a powder flow tube in communication with the powder receptacle, fixed to said at least one adjustable wall for movement therewith, and extending away from the powder receptacle, from an outside surface of said at least one adjustable wall, the rotatable auger brush being arranged so as to extend through the powder flow tube and transport powder therethrough; and

the powder feeder further comprises a stationary feed tube arranged so that the powder flow tube is telescopically movable along a portion of the stationary feed tube, the stationary feed tube being disposed around a portion of the rotatable auger brush so that the rotatable auger brush transports powder through the stationary feed tube.

23. The powder feeder and discharging system of claim 22, wherein the stationary feed tube and the powder flow tube extend toward the powder supply and together define a telescopic powder feed path of adjustable length which compensates for movement of said at least one adjustable wall.

24. The powder feeder and discharging system of claim 22, wherein the stationary feed tube and the powder flow tube extend generally away from the powder supply toward a powder reclamation apparatus and together define a telescopic powder reclamation path of adjustable length which compensates for movement of said at least one adjustable wall.

25. The powder feeder and discharging system of claim 22, wherein the discharging device includes an atomizing brush rotatably mounted adjacent to and substantially parallel to the metering brush, for receiving the powder from the metering brush and propelling the powder in a substantially uniformly distributed manner towards a target volume.

26. The powder feeder and discharging system of claim 20, wherein the discharging device includes including an atomizing brush rotatably mounted adjacent to and substantially parallel to the metering brush, for receiving the powder from the metering brush and propelling the powder in a substantially uniformly distributed manner towards a target volume.

27. A powder feeder and discharging system for feeding powder from a powder supply to a powder discharging device, comprising:

a powder receptacle having an inlet, a discharge for directing powder to a powder discharging device, a stationary wall portion and two adjustable walls disposed on opposite ends of the powder receptacle, each of the two adjustable walls being movable with respect to the stationary wall portion to adjust a width of the discharge;

a powder discharge device in communication with the discharge for directing powder toward an object to be coated; and

a rotatable auger brush in communication with the powder supply and extending along the inlet of the powder receptacle, for withdrawing powder from the powder supply and transporting the powder through the inlet of the powder feeder.

28. A powder supply and dispersing system comprising:

a powder supply hopper for holding a supply of powder;

a powder discharging device for dispersing the powder in a substantially uniform manner across a target volume; and

a powder feeder connecting the powder supply hopper to the powder discharging device, for feeding powder from the powder supply hopper to the powder discharging device, wherein the powder feeder includes;

a powder receptacle having an inlet, a discharge to which the powder is directed by the powder discharging device, a stationary wall portion and at least one adjustable wall which is movable with respect to the stationary wall portion to adjust a width of the discharge; and

a rotatable auger brush in communication with the powder supply hopper and extending along the inlet of the powder receptacle, for withdrawing powder from the powder supply hopper and transporting the powder through the inlet of the powder feeder.

29. A powder supply and dispersing system comprising:

a powder supply hopper for holding a supply of powder;

a powder discharging device for dispersing the powder in a substantially uniform manner across a target volume; and

a powder feeder connecting the powder supply hopper to the powder discharging device, for feeding powder from the powder supply hopper to the powder discharging device, wherein the powder feeder includes;

a powder receptacle having an inlet, a discharge to which the powder is directed by the powder discharging device, a stationary wall portion and two adjustable walls disposed on opposite ends of the powder receptacle, each of the two adjustable walls being movable with respect to the stationary wall portion to adjust a width of the discharge; and

a rotatable auger brush in communication with the powder supply hopper and extending along the inlet of the powder receptacle, for withdrawing powder from the powder supply hopper and transporting the powder through the inlet of the powder feeder.

30. A coating apparatus for applying a uniform coating on a target web, the coating apparatus comprising:

a powder supply hopper for holding a supply of powder;

a powder discharging device for dispersing the powder in a substantially uniform manner across a target volume;

an electrostatic coater in the target volume for electrostatically coating the target web in a substantially uniform manner using the powder which is dispersed by the powder discharging device; and

a powder feeder connecting the powder supply hopper to the powder discharging device, for feeding powder from the powder supply hopper to the powder discharging device, wherein the powder feeder includes;

a powder receptacle having an inlet, a discharge to which the powder is directed by the powder discharging device, a stationary wall portion and at least one adjustable wall which is movable with respect to the stationary wall portion to adjust a width of the discharge; and

a rotatable auger brush in communication with the powder supply hopper and extending along the inlet of the powder receptacle, for withdrawing powder from the powder supply hopper and transporting the powder through the inlet of the powder feeder.

31. A coating apparatus for applying a uniform coating on a target web, the coating apparatus comprising:

a powder supply hopper for holding a supply of powder;

a powder discharging device for dispersing the powder in a substantially uniform manner across a target volume near the target web;

an electrostatic coater in the target volume for electrostatically coating the target web in a substantially uniform manner using the powder which is dispersed by the powder discharging device; and

a powder feeder connecting the powder supply hopper to the powder discharging device, for feeding powder from the powder supply hopper to the powder discharging device, wherein the powder feeder includes;

a powder receptacle having an inlet, a discharge to which the powder is directed by the powder discharging device, a stationary wall portion and two adjustable walls disposed on opposite ends of the powder receptacle, each of the two adjustable walls being movable with respect to the stationary wall portion to adjust a width of the discharge; and

a rotatable auger brush in communication with the powder supply hopper and extending along the inlet of the powder receptacle, for withdrawing powder from the powder supply hopper and transporting the powder through the inlet of the powder feeder.

32. A dual-side coating apparatus for applying a uniform coating on opposite first and second sides of a target web, the dual-side coating apparatus comprising:

at least one powder supply hopper for holding a supply of powder;

a first powder discharging device for dispersing the powder in a substantially uniform manner across a first target volume on the first side of the target web;

a first electrostatic coater in the target volume for electrostatically coating the first side of the target web in a substantially uniform manner using the powder which is dispersed by the first powder discharging device;

a first powder feeder connecting said at least one powder supply hopper to the first powder discharging device, for feeding powder from said at least one powder supply hopper to the first powder discharging device;

a second powder discharging device for dispersing the powder in a substantially uniform manner across a second target volume on the second side of the target web;

a second electrostatic coater in the target volume for electrostatically coating the second side of the target web in a substantially uniform manner using the powder which is dispersed by the second powder discharging device;

a second powder feeder connecting said at least one powder supply hopper to the second powder discharging device, for feeding powder from said at least one powder supply hopper to the second powder discharging device;

wherein the first powder feeder includes;

a powder receptacle having an inlet, a discharge to which the powder is directed by the first powder discharging device, a stationary wall portion and at least one adjustable wall which is movable with respect to the stationary wall portion to adjust a width of the discharge; and

a first rotatable auger brush in communication with said at least one powder supply hopper and extending along the inlet of the first powder receptacle, for withdrawing powder from the at least one powder supply hopper and transporting the powder through the inlet of the first powder feeder.

33. A dual-side coating apparatus for applying a uniform coating on opposite first and second sides of a target web, the dual-side coating apparatus comprising:

at least one powder supply hopper for holding a supply of powder;

a first powder discharging device for dispersing the powder in a substantially uniform manner across a first target volume on the first side of the target web;

a first electrostatic coater in the target volume for electrostatically coating the first side of the target web in a substantially uniform manner using the powder which is dispersed by the first powder discharging device;

a first powder feeder connecting said at least one powder supply hopper to the first powder discharging device, for feeding powder from said at least one powder supply hopper to the first powder discharging device;

a second powder discharging device for dispersing the powder in a substantially uniform manner across a second target volume on the second side of the target web;

a second electrostatic coater in the target volume for electrostatically coating the second side of the target web in a substantially uniform manner using the powder which is dispersed by the second powder discharging device;

a second powder feeder connecting said at least one powder supply hopper to the second powder discharging device, for feeding powder from said at least one powder supply hopper to the second powder discharging device;

wherein the first powder feeder includes;

a powder receptacle having an inlet, a discharge to which the powder is directed by the first powder discharging device, a stationary wall portion and two adjustable walls disposed on opposite ends of the first powder receptacle, each of the two adjustable walls being movable with respect to the stationary wall portion to adjust a width of the discharge; and

a first rotatable auger brush in communication with said at least one powder supply hopper and extending along the inlet of the first powder receptacle, for withdrawing powder from the at least one powder supply hopper and transporting the powder through the inlet of the first powder feeder.

34. A powder application system, comprising:

a powder feeder atomizer including a supply hopper, a powder feeder spaced from the supply hopper and having an inlet and a discharge, a rotatable auger brush in communication with the supply hopper and extending across the inlet for causing powder to be withdrawn from the supply hopper and to be transported longitudinally to the powder feeder and to be dispensed level across the powder feeder through the inlet, a drive for rotating the brush, and at least one adjustable wall which is movable to adjust a width of the discharge; and

an application chamber in communication with the powder feeder atomizer, the application chamber having a substrate inlet aligned with a substrate exit, a plurality of charging electrodes arrayed in the chamber for charging powder supplied by the powder feeder atomizer, and a plurality of baffles disposed within the chamber interposed with the electrodes for shaping a dispersion of powder and an electric field resulting from the electrodes so that powder is attracted to and caused to be attached to substrates disposed within the chamber.

35. A powder feeder assembly for feeding powder from a powder supply to a powder discharging device, the powder feeder assembly comprising a powder receptacle having an inlet, a discharge for directing powder toward the powder discharging device, a stationary wall portion, at least one adjustable wall which is movable linearly and horizontally along the stationary wall portion in a direction parallel to the inlet to adjust a width of the discharge, and a powder feeder extending along the inlet for supplying powder to the receptacle, wherein the inlet is coextensive with an operative length of the discharge.

36. A powder feeder assembly for feeding powder from a powder supply to a powder discharging device, the powder feeder assembly comprising a powder receptacle having an inlet, a discharge for directing powder toward the powder discharging device, a stationary wall portion, two adjustable walls which are movable linearly and horizontally along the stationary wall portion in a direction parallel to the inlet to adjust a width of the discharge, and a powder feeder extending along the inlet for supplying powder to the receptacle, wherein the inlet is coextensive with an operative length of the discharge.