Systems and methods for coating conduit interior surfaces utilizing a thermal spray gun with extension arm

• US 6,916,502 B2
• Filed: 02/11/2002
• Issued: 07/12/2005
• Est. Priority Date: 02/11/2002
• Status: Expired due to Fees

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Moore, Karen A., Zatorski, Raymond A.
• Primary Examiner(s): Meeks, Timothy
• Assistant Examiner(s): FLETCHER III, WILLIAM P
• Application Number:
  US10/074,355
• Publication Number:
  US 20030161946A1
• Time in Patent Office: 1,247 Days
• Field of Search: 427/230, 427/231, 427/232, 427/233, 427/234, 427/235, 427/236, 427/237, 427/238, 427/239, 427/105, 427/123, 118/DIG.10, 118/55, 118/317, 118/318
• US Class Current: 427/236
• CPC Class Codes: B05B 14/10 the excess material being particulate for spray booths B05B14/48
• CPC Class Codes: B05B 7/201 downstream of the nozzle
• CPC Class Codes: B05B 7/222 using an arc
• CPC Class Codes: B05D 1/02 performed by spraying
• CPC Class Codes: B05D 2254/04 Applying the material on the interior of the tube
• CPC Class Codes: B05D 3/0426 Cooling with air

Abstract

Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Claims

1. A method of forming at least one conductive trace within an interior of a pipe, comprising:

disposing a movable spray gun within an interior of a pipe;

generating a reduced air pressure zone proximate the spray gun wherein the reduced air pressure zone is movable with the spray gun;

spraying, via the movable spray gun, a conductive material toward an interior surface of the pipe while moving the movable spray gun in relation thereto and generating the reduced air pressure zone proximate the spray gun to form at least one conductive trace.

2. The method according to claim 1, further comprising spraying, via the movable spray gun, an insulative material toward the interior surface of the pipe while moving the movable spray gun in relation thereto and generating the reduced air pressure zone proximate the spray gun to form an insulating layer upon the interior surface of the pipe prior to spraying the conductive material.

3. The method according to claim 2, wherein spraying the insulating material comprises:

mounting the movable spray gun to an extension arm; and

inserting the extension arm at least partially into the interior of the pipe.

4. The method according to claim 3, Wherein generating the zone of reduced air pressure adjacent the spray gun comprises drawing overspray of the insulating material in a direction generally opposite to a direction of spraying.

5. The method according to claim 3, wherein generating the zone of reduced air pressure adjacent the spray gun comprises transporting overspray through the extension arm.

6. The method according to claim 3, wherein providing the spray gun comprises providing a thermal spray gun.

7. The method according to claim 6, further comprising cooling the thermal spray gun.

8. The method according to claim 7, further comprising cooling the extension arm separately from the thermal spray gun.

9. The method according to claim 3, further comprising rotating the pipe while spraying the insulative material.

10. The method according to claim 3, further comprising measuring a position of the spray gun in relation to the interior surface of the pipe with a sensor while spraying the insulative material.

11. The method according to claim 10, further comprising controlling the position of the spray gun in relation to the interior surface of the pipe responsive to measuring the position.

12. The method according to claim 3, further comprising measuring a thickness of the insulative layer with a sensor while spraying the insulative material.

13. The method according to claim 2, wherein spraying the conductive material toward the interior surface of the pipe to form the at least one conductive trace comprises spraying the conductive material toward the interior surface of the pipe to form a plurality of conductive traces.

14. The method according to claim 13, wherein spraying the conductive material toward the interior surface of the pipe to form the plurality of conductive traces comprises forming each of the plurality of conductive traces upon the insulative layer.

15. The method according to claim 13, wherein:

forming the insulative layer comprises forming a plurality of separate insulative layer segments; and

spraying the conductive material toward the interior surface of the pipe to form the plurality of conductive traces comprises forming a respective one of the plurality of conductive traces onto each of the plurality of separate insulative layer segments.

16. The method according to claim 1, wherein spraying the conductive material comprises:

mounting the movable spray gun; and

inserting the extension arm at least partially into the interior of the pipe.

17. The method according to claim 16, wherein generating a the zone of reduced air pressure adjacent the spray gun comprises drawing overspray of the conductive material in a direction generally opposite to a direction of spraying.

18. The method according to claim 17, wherein generating the zone of reduced air pressure adjacent the spray gun comprises transporting overspray through the extension arm.

19. The method according to claim 16, wherein providing the spray gun comprises providing a thermal spray gun.

20. The method according to claim 19, further comprising cooling the thermal spray gun.

21. The method according to claim 20, further comprising cooling the extension arm separately from the thermal spray gun.

22. The method according to claim 16, further comprising rotating the pipe while spraying the conductive material.

23. The method according to claim 16, further comprising utilizing a sensor to measure a position of the spray gun in relation to the interior surface of the pipe while spraying the conductive material.

24. The method according to claim 16, further comprising utilizing a sensor to measure a thickness of the conductive material while spraying the conductive material.

25. The method according to claim 16, further comprising spraying an insulative layer over the at least one conductive trace.

26. The method according to claim 1, further comprising flushing the interior of the pipe with cooling air.

27. The method according to claim 26, further comprising directing the cooling air into the interior of the pipe from at least one cooling air outlet disposed on the extension arm.

28. The method according to claim 26, further comprising directing the cooling air into the interior of the pipe from an open end of the pipe.

29. The method according to claim 26, wherein flushing the interior of the pipe with cooling air comprises introducing atomized water into the interior of the pipe, the atomized water carried by the cooling air.