CA2106029A1 - Powder collection system - Google Patents
Powder collection systemInfo
- Publication number
- CA2106029A1 CA2106029A1 CA002106029A CA2106029A CA2106029A1 CA 2106029 A1 CA2106029 A1 CA 2106029A1 CA 002106029 A CA002106029 A CA 002106029A CA 2106029 A CA2106029 A CA 2106029A CA 2106029 A1 CA2106029 A1 CA 2106029A1
- Authority
- CA
- Canada
- Prior art keywords
- opening
- powder collector
- canopy
- powder
- fan
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B16/00—Spray booths
- B05B16/40—Construction elements specially adapted therefor, e.g. floors, walls or ceilings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B14/00—Arrangements for collecting, re-using or eliminating excess spraying material
- B05B14/40—Arrangements for collecting, re-using or eliminating excess spraying material for use in spray booths
- B05B14/48—Arrangements for collecting, re-using or eliminating excess spraying material for use in spray booths specially adapted for particulate material
Landscapes
- Details Or Accessories Of Spraying Plant Or Apparatus (AREA)
- Electrostatic Spraying Apparatus (AREA)
- Coating Apparatus (AREA)
Abstract
ABSTRACT OF THE INVENTION
Apparatus and methods for aligning a powder spray canopy of a powder coating booth with a fan plenum assembly so that a powder collector can be quickly aligned and effectively sealed to both the powder spray canopy and the fan plenum. The invention also relates to an improved filter cartridge mounting assembly which allows for quick and easy mounting and dismounting of filter cartridges in the powder collector.
Apparatus and methods for aligning a powder spray canopy of a powder coating booth with a fan plenum assembly so that a powder collector can be quickly aligned and effectively sealed to both the powder spray canopy and the fan plenum. The invention also relates to an improved filter cartridge mounting assembly which allows for quick and easy mounting and dismounting of filter cartridges in the powder collector.
Description
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PO~DER COl.L.EC'rION ~; YSTEM
:, ' ~I~LD OF rrHE INV~ITION
This invention relates to the field of powder coating booths and collection systems for electrostatic application of powder coating materials. More particularlv, the in~ention relates to an apparatus to quickly and easily align a powder spray canopy with a fan plenum so that a powder collector can be quickly aligned and effectively sealed to both the powder spray canopy and the fan plenum. The invention also relates to an improved filter cart idge mounting assembly which allows for quick and easy mounting and dismounting of ~ilter , cartridges in the powder collector.
BACRGROUND OF TXE INVEN~ION
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Powder booths for electros~atic application of powder materials to articles typically include a spray booth and a conveyor for carrying the article -to be sprayed through the spray booth. Spray guns mounted in the booth and connected to a source of air entrained ~ ~ 20 powder, such as a powder feed hopper and powder pump, ! : spray electrostatically charged powder material onto the electrically grounded article carried by the conveyor through the booth. An important feature of the powder booths is th~ apparatus for ~ollecting oversprayed ;25~powder, that is the powder which doe~ not adhere to the h~
articles being powder co~ted, and returning this powder to the spray guns. Typically, an ~xhaust system including a fan plen~lm assembly creates a negative pressure i~ the booth and causes oversprayed powder to be drawn into the powder collector where the air is separated from the powder prior to exhausting the cleaned air to atmosphere. The oversprayed powder is typically collected at the bottom of the powder collector where it is recirculated to the powder feed hopper for return to the spray guns.
When the air carries the loose powder from within the spray booth into the powder collector, some of the powder falls and collects at the bottom of the collector while the remainder collects on the outside of the one or more filters~ This latter powder can be removed by techniques including air pulsing, as discussed in U.S.
Patent No. 4,662,309, assigned to Nordson Corp~, the assignee of the present invention, which patent is incorporated in its entirety herein. I
Typically, interchangeable powder collec.toxs are moved into or out of position under or adjacent the spray \ booth to enable the use of a different powder collector \ for each color powder being spr~yed. The powder collectors have an inlet opening adapted to be aligned with and securely sealed against a powder exhaus-t opening in the canopy of the spray booth. An airtight seal is important to prevent the escape of spray powder to the surrounding atmosphere. Further, the powder collectors have an air outlet adapted to be aligned with and sealed against the air inlet opening of an exhaust plenum assembly. The integrity of this seal is also very - ~ ;`-. .'.
PO~DER COl.L.EC'rION ~; YSTEM
:, ' ~I~LD OF rrHE INV~ITION
This invention relates to the field of powder coating booths and collection systems for electrostatic application of powder coating materials. More particularlv, the in~ention relates to an apparatus to quickly and easily align a powder spray canopy with a fan plenum so that a powder collector can be quickly aligned and effectively sealed to both the powder spray canopy and the fan plenum. The invention also relates to an improved filter cart idge mounting assembly which allows for quick and easy mounting and dismounting of ~ilter , cartridges in the powder collector.
BACRGROUND OF TXE INVEN~ION
. . .
Powder booths for electros~atic application of powder materials to articles typically include a spray booth and a conveyor for carrying the article -to be sprayed through the spray booth. Spray guns mounted in the booth and connected to a source of air entrained ~ ~ 20 powder, such as a powder feed hopper and powder pump, ! : spray electrostatically charged powder material onto the electrically grounded article carried by the conveyor through the booth. An important feature of the powder booths is th~ apparatus for ~ollecting oversprayed ;25~powder, that is the powder which doe~ not adhere to the h~
articles being powder co~ted, and returning this powder to the spray guns. Typically, an ~xhaust system including a fan plen~lm assembly creates a negative pressure i~ the booth and causes oversprayed powder to be drawn into the powder collector where the air is separated from the powder prior to exhausting the cleaned air to atmosphere. The oversprayed powder is typically collected at the bottom of the powder collector where it is recirculated to the powder feed hopper for return to the spray guns.
When the air carries the loose powder from within the spray booth into the powder collector, some of the powder falls and collects at the bottom of the collector while the remainder collects on the outside of the one or more filters~ This latter powder can be removed by techniques including air pulsing, as discussed in U.S.
Patent No. 4,662,309, assigned to Nordson Corp~, the assignee of the present invention, which patent is incorporated in its entirety herein. I
Typically, interchangeable powder collec.toxs are moved into or out of position under or adjacent the spray \ booth to enable the use of a different powder collector \ for each color powder being spr~yed. The powder collectors have an inlet opening adapted to be aligned with and securely sealed against a powder exhaus-t opening in the canopy of the spray booth. An airtight seal is important to prevent the escape of spray powder to the surrounding atmosphere. Further, the powder collectors have an air outlet adapted to be aligned with and sealed against the air inlet opening of an exhaust plenum assembly. The integrity of this seal is also very - ~ ;`-. .'.
2 ~ 2 ~
important to insuxe that the negative pressure developed by the exhaust fan in the fan plenum fully acts within the spray booth to efficiently draw all of the oversprayed po~Jder into the powder collector. Also an airtight seal around the opening into the air plenum is important to pre~ent leakage of the cleaning a.ir pulses directed from the plenum into the powder collector to clean the filters. Such leakage would reduce the effective of cleaning of the filters.
In setting up powder booth spray systems in the past with free standing, independently supported fan plenums, such as is shown in U.S. 4,498,913, the spray booth was ~ initially aligned with respect to ~he conveyor line - extending therethrough. Typically the spray booth had a base with six or eight legs, each having an adjustable foot, e.g., a caster. The aligning of the spray booth was labor intensive and time consuming particularly ~here there were irregularities in the worX floor on which the booth rested.
Next, the air inlet port of the exhaust fan plenum had to be aligned with respect to the powder exhaust opening in the spray booth canopy so that when the powder collector was moved lnto place, its inlet opening could be aligned with and sealed against the powder exhaust opening i~ the canopy and its air outlet could simultaneously be aligned with and sealed to the air inlet opening of the exhaust plenum assembly. This typically required time consuming, labor intensive adjustment of the casters on the four legs supporting the ~an plenum. Finally, the casters on the four legs of the powder collector were a.justed to properly seal the :, ' .
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collector against both the booth and the air plenum.
In another type of prior ark booth, as illustrated in U.S. Patent Nos. 4,277,260 and 4,378,728, the fan section is structurally coupled to the spray booth. In this case, since the fan plenum ;.s quite heavy and ii cantilevered from the booth, the spray booth canopy has to be constructed of heavy weight metal to support the fan plenum. This is particularly so because in additio~
to the fan section being heavy, it also generates a great deal of vibration, especially from the valve manifold used to pulse clean the filter cartridges. Besides being expensive, a spray booth canopy of heavy weight metal construction tends to attract the powde~ coating material which then sticks to the booth walls rather than the article which is to be powder coated.
In U.SO Patent No. 4,354,451, the fan unit is positionèd above the top of the spray booth and mounted either directly to the top of the spray booth or mounted independently of the spray booth. In both case~ the system is deficient. First, the powder collector is very tall and is therefore a~Xward to safely maneuver across '~ the plant floor, especially since it is replaced whenever a different color is sprayed. Second, the spray booth would have to be constructed of heavy weight metal in order to support the fan unit~
Another common problem in the prior art relates to the apparatui used to secuxe the air filters within the powder collector. As illustrated in prior art U.S.
4,218,277, air filters can have a central tie rod which ~; 30 lS secured to a hole through a bottom plate by a threaded :
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nut. One reason why this design is deficient is that over time the hole provides a path for unfiltered powder to enter the clean air fan plenum. When particles of powder escape into the clea~ air fan plenum, any downstream filter, specifically the final filter ~hich is designed to filter extremely small sized particles, quickly clogs causing a shutdown of the entire powder coating operation. Further, the filter as designed is difficult to mount in the collector. In many instances, the installation of this filter required two installers, one on the exhaust side and the other on the inlet side of the powder collector.
OBJECTS AP~D ~U~RY O~ ~E I~EN~ION
It is an object of the present invention to align a powder spray canopy with a fan plenum so that a powder collector can be quickly aligned and effectively sealed to both the powder booth canopy and the fan plenum to obviate the problems and limitations of the prior art systems.
It is a further ~bject of the present invention to provide an improved filter cartridge mounting assembly which allows for quic~ and easy mounting and dismounting of filter cartridges in the powder collector.
It is a still further object of the present invention to provide structural components for compression mounting vertically oriented, filter cartridges so that they are easily installed and have a ~ simple and reliable seal.
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It is a ~et further object of the present invention to provide an improved seal between the fan plenum a~d the powder collector.
Yet another ob~ect is to provide an improved booth design wherein the fan plenum i5 supported by the booth in such a way that the booth canopy can be constructed of lightweight, plastic material.
In accordance with the invention, there is provided a powder coating system comprising a hase with a fan o support secured thereto. The fan support is adapted to support a fan plenum assembly having an inlet opening in a bottom wàll thereof. A canopy of a powder spray booth having an exhaust opening in a side wall is secured to the base and to the fan support. A powder collector ` 15 having an inlet opening in a f~ont wall and an exhaust opening in a top plate is ada~ted to be sealed against the canopy and the fan plenum assem~ly whereby the , exhaust opening in the side wall of the canopy seals against the inlet opening of the powder collect~r and the inlet opening of the fan plenum assembly seals against the exhaust opening of the powder collector.
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Also in accordance with the invention, a leveling ~,~ means is provided on the base to simultaneously level the fan plenum assembly and the booth canopy. A leveling means on the powder collector simultaneously levels the powder collector ~ith respect to the fan plenum assembly and the canopy, whereby the inlet opening of the powder collector is aligned for sealing to the exhaust opening , of the canopy and the exhaust opening of the powder collector is aligned for sealing against the inlet i: .
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opening of the fan plenum assembly.
The base incl~des two substantially parallel beams having legs at each end and a substantially rectangular table secured to the beams. The table has a central section secured to the parallel beams and opposite firsk and second end sections extending from opposite ends of the central section cantilevered outward from the parallel beams. The canopy is secured on the parallel beams whereby a portion of the bea~s project outward from one side of the table and have the fan support secured thereto.
In accordance with the invention, seal means between - the fan plenum asse~bly and the powder collector seals the exhaust opening of the powder collector against the inlet opening of the fan plenum assembly. The seal means includes a bracket and a pneumatic seal member securely gripped therein. The seal member is constructed of an elastomeric material wlth a cross section including a top surface, two side walls, a bottom surface with an upstanding rib and a hollow inner chamber wherein -the seal member is normally in a collapsed, d~lated state " where the upstanding rib is in a first position closer to the top surface, and wherein the seal member can be expanded to an inflated state where the upstandiny rib is 25 in a second position further away from the top surface than in the first position. The seal means helps to secure the powder collector in position. Also, a second seal means between the fan support and the powder collector seals an opening through a wall in the fan ; 30 support to the inlet opening in the powder collector.
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In ~ccordance with the i.nvention, a method of sealing a powder collector against both a canopy of a spray boo-th and against a fan plen~m assembly, comprises the following steps. A base is provided which is secnred to hoth a canopy having an exhaust opening and a fan plenum assembly having an inlet opening. The base is aligned with the conveyor and leveled ~hereby the exhaust opening of the canopy and the inlet opening of the fan plenum assembly are automatically, simultaneously leveled. A powder collector having an inlet opening and an exhaust openin~ is then leveled with respect to the base whereby the inlet opening of the powder collec~or is automatically aligned for sealing to the exhaust opening of the canopy and the exhaust opening of the powder collector is simultaneously aligned with the inlet op~ning in the fan plenum assembly. Next, the exhaust opening of the canopy is sealed to the inlet opening of the powder collector and the inlet opening OI the fan plenum assembly is pneumatically sealed to ~he exhaust opening o-E the powder collector.
Further in accordance with the invention, a cartridge mount assembly comprises a hollow cartridge having a bottom plate with an internally threaded boss secured to the inside wall of the bottom end OI the cartridge. A tie rod extending through the cartridge is threadably engaged at one end to the threaded boss and at an opposite end to a support assembly. The support assembly i5 adapted to be supported in an opening within a powder collector whereby the cartridge is secured against a top plate of the powder collector. A handle ~: extends through the tie rod to initially thread the tie rod into the threaded boss before the cartridge is . 8 .
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mounted into the collector. A spider assembly has a center bushing and a plurality of truss arms affixed thereto and projecting radially outward therefrom. The outer ends of the truss arms are notched out to rest against the periphery of the opening in the top plate of the powder collector to support the cartridge therefrom.
Notches in the top plate engage the truss arms and prevent rotational movement of the spider assembly. A
centering bracket on the tie rod engages the interior wall of the cartridge and maintains a centerline of the tie rod coincident with the centerline khrough the cartridge to protect ~he threaded boss from torque caused by a misaligned tie rod, particularly during installation. The handle is used to pllll thP tie rod up 15 through the center bushing so that a nut can be threaded onto tne uppe~ end of the tie rod to mount the cartridge in the collector. A roll pin extends through the tie rod to engage the b~shing and prevent the tie rod from being unthreaded from the boss when the cartridge is removed from the powder collector. A single installer can both install and remove the cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
~, The structure, operation, and advantages of the presently preferred embodiment of the invention will become further apparent upon consideration of the following description taken in conjunction wikh the accompanying drawings, wherein:
~ IG. 1 is a perspective view of a base structure supporting a fan plenum and a spray booth in alignment with each other and the conveyor, and showing a powder collector prior to being positioned and sealed against : , :
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the spray booth and the fan plenum, in accordance with the invention;
FIG. 2 is a perspective view of a base structure supporting a fan plenum and a spray booth in alignment with each other and a powder collector positioned and sealed against the spray booth and the fan plenum;
FIG. 3 is a perspective view of the base for the spray booth and fan plenum of the powder coating system illustrated in FIG. 1;
FIG. 4 is a perspective view of the base illustrated in FIG. 3 with the fan plenum support structure mounted thereto;
FIG. 5 is a perspective view of the base and fan plenum support structure, as illustrated in FIG. 2, with the fan plenum mounted to the fan assem~ly support structure;
FI~. 6 is a perspective view uf the base with a fan plenum support structure supporting the fan plenum, as illustrated in FlG. 5, and the canopy located on the base assembly in alignment with the fan plenum;
FIG. 7 is a view taken along line 7-7 of FIG. 5 illustrating the retractable seal assembly;
FIG. ~ is a view taken along line 8-8 of FIG~ 7 illustrating the seal assembly in its normal deflated, retracted position;
FIG. 9 is a view taken along line 9~9 of FIG. 2 illustrating the seal assembly in the inflated, expanded : position between the powder collector and the fan plenum;
:~ FIG. 10 is a view taken along line lO-10 of FIG. 1 illustrating the inlet opening to the powder collector;
: FIG. ll:is a top view of a cartridge filter assembly resting on the top of the powder collector;
` FIG. 12 is view taken along line 12-12 of FIG. ll ~:, 10 :: :
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illustrating the cartridge fil~er and mounting assembly;
FIG. 12A is an enlarged section of F~G. 12; and FIG. 12B is a view taken along line 12B-123 of FIG
12A.
DETAII,ED DESCRIPTION OF TXE INVENTION
Re~erxing to FIGs. 1 and 2, a powder coating system 10, intended for use as a powder coating booth 12 for applying powder coating ~aterial on a production line basis, includes provision for automatic recovery and recirculation of the oversprayed powder in the syst~m.
The booth itself is of a generally conventional design and includes a canopy 14 having entry and exit vestibules ; 16 and 18, respectively, at each end thereof through which the ar~icle or part 20 to be coated can ~e transporterd. Typically in such equipment, the article 20 to be coated is hung by a hook 21 from a conveyor system 22 to move slowly through the spray booth so that the part is sprayed with one or more spray guns thro~gh an s opening (not shown) in the side of the canopy o~poslte , 20 the collector.
'~ ~ A powder collector 24 as illustrated in FIGS. l, 2 and 10 is mounted on wheels 26. The wheels 26 include leveling means 27, which are preferably vertically adjustable casters, to level the powder collector as required for the particular floor conditions. The collector, during operation of system 10, is located adjacent an exhaust opening 28 in a side wall of canopy 14. The powder collector, best shown in FIG~ 10, has an inlet opening 30 in a side wall thereof with a seal 32, ;30 preferably "D" shaped in cross section thereabout. The : ~ .
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, inlet op~ning 30 is adapted to mate with canopy exhaust opening 28, as discussed below. A top plate 34 of the collector (see FIG. 1) has an exhaust opening 36 which fits under a fan plenum assembly 38 and is sealed against a bottom wall portion 40 of fan plenum 38, as illustrated in FIG. 9, disposed about an inlet opening 42, as discussed in more detail below.
A principle feat~re of this invention is the construction of a base 44 which enables the canopy 14 to 10 be automatically properly aligned with respect to the ~an plenum assembly 38i so that a powder collector 24 can be moved into and out of position and quickly aligned and effectively sealed to both the exhaust opening ~S of powder spray canopy 14 and inlet opening 42 of the fan plenum 38. The ~ase 44, as illustrated in FIG. 3, includes a rectan~ular table 46 having a central section 48 and opposite end sections 50 and 52 cantilevered outward from opposite ends of the central section 48.
The table is supported on t~o substantially parallel beams 54 and 56 which extend transversely to the length of the table and have leg elements 58 at each end. Beams 54 and 56, which are positioned un~er the intersections of the central section 48 and the opposite end sections 50 and 52, are secured to the table by means such as ~elding. The triangular braces 60, secured to the bottom of the table and to the beams, provide additional support. The parallel beams 54 and 56 project outward from one side 62 of table 46 and form a base to which a fan support 64 (See FIG. 4) is secured.
Leveling means 72 are provided on base 44 to simultaneously level the fan plenum assembly 38 and ::
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2 1 ~ 3 canopy 14, as discussed in more detail below. Theleveling means includes vertically adjustable feet 72 at the bottom of legs 580 The fan support 64, as illustrated in FIG. 4, has a front wall 80 with an openiny 82 adapted to mate with the exhaust ope~ing 28 (see FIG. l) of canopy 14. A
rectangular frame 84 around opening 82 provides a smooth surface against which the ~IDi~ shaped seal 32 of the powder colleotor is sealed, as discussed below. A plate 86, secured along the bottom edge of opening 82, is level with the table 46 which forms the inner floor of spray booth 12. Plate 86 extends into the inlet opening 30 of collector 24 so that any powder which bui3.ds up on the inner booth floor 46 can be easily swept into the collector. The fan support 64 includes two parallel side walls 88 and 90 secured to and extending substantially normal to front wall 80. The lower surfaces of ~he side walls are secured, by means such as welding or bolts, to the upper surface of the portions of the parallei beams 54 and 56 which project outward from side 52 of table 46.
The upper sur*aces of side walls 80 and 90 are perpendicular to the frame 84 and provide a support surface on which the bottom of the fan plenum assembly 38 can be attached by means such as nuts and bolts, as illustrated in FIG. 6.
An important feature of this invention relates to the ability of the fan support 64 to maintain a : perpendicular relationship between the opening 82 through : the front wall 80 of fan support 64 and the inlet opening ; 30 42 of the fan plenum assembly 38. This relationship is critical to enablè both the inlet opening 30 and the .
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exhaust opening 36 of powder collector 24, which are perpendicular to one another, to be quicXly and ~asily aligned with and properly sealed to both the opening 82 through the front wall 80 of fan ~upport 64 and the inlet opening 42 of the fan plenum asse~lbly 38. Once the canopy 1~ is securely mounted on table 46, the side wall of the canopy can be secured to the front wall 80 of the fan support so that the exhaust opening 28 is immovably aligned with the opening 82. Since the inlet opening of fan plenum assembly 38 is securely mounted to the top surface of sidewalls 88 and 90, which in turn are perpendicular to the fronk wall 80, the inl t opening of fan plenum assembly 38 is automatically aliyned to be perpendicular with the opening 82 in the side wall o-f fan 15 support 64.
By establishing a perpendicular relationship between the inlet opening 42 of the fan plenum and the opening 82 of the front wall of the fan support, the powder collector 24 can be rolled into position, as illustrated in FIG. 2, and simultaneously aligned with respect to the canopy and the fan plenum assembly so that an e~:Eective air tight seal can be achieved. That is, both inlet and exhaust openings 30 and 36, respectively, of powder collector 24 are located against fan support opening 82 and fan plenum inlet opening 42, respectively, so that an air tight seal can be ~uickly and easily achieved, as discussed in more detail below. An air tight seal is very important to the proper functioning of the powder coating system 10 because it enables more air entrained po~der to be removed from powder coating booth 12, and prevents escape of the powder from the booth into the plant en~ironment and from the collector into the fan ~: 14 .
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plenum.
Another aspect of the invention relates to the fan plenum assembly being supported by the base 44 instead of the canopy, as was often the case in the prior art. This enables the c~nopy to be constructed of a lightweight, non-metallic material, such as for example a plastic like polypropylene. One advantage of a plastic canopy is that the powder coating material does not have an electrical attraction to the plastic and will not tend to stick to the sides of the canopy as with a metal canopy. This is particularly important when the color is changed and the system has to be cleaned before a new color of powder is sprayed. Further t the canopy can be made of a translucent material which provides improved lighting inside the spray booth to better enable a system operator to monitor the system. Further, the plasti~ is light weight which is more manageable to assemble and lower in cost.
Referring to FIG. 10, there is illl~strated the front of po~der collector 24 which has inlet opening 30. A
seal means 32, typically comprising an elastomeric seal " with a "D" shaped cross section, is disposed around inlet openlng 30. When the powder collector is in place, as illustrated in FIG. 2, conventional latches, not shown, attached to fan support 64 pull collector 24 against the front wall 80 of fan support 64 and tightly compresses seal 32 against the frame 84 to form an air tight seal between the rear wall of the canopy and th~ inlet opening 30 of powder collector 24.
Another important feature of the present invention ' 2 ~ 2 3 relates to a seal means 99 including a seal assembly 100 disposed about the inlet opening 42 in bottom 40 of the fan plenum assembly 38, as illustrated in FIGS. 7, 8 and The seal assembly 100 includes a retractable, pneumatic seal member 102 secured in a bracket or extrusion 104. Extrusion 104 has an upper ~all 105 which is secured to bottom wall 40 by any means suoh as spot welding. Oppositely disposed, bracket side walls 106 and 108, extending dow~ward from upper wall 105, converge inward toward each other and then turn outward to form oppositely disposed cur~ed recesses 110 and 112 whi.ch grip the top edges of seal member 102. The seal member 102 is preferably constructed of an elastomeric material and has a normal deflated, retracted shape, the cross section of which is illustrated in FIG. 8, including an upper surface 114, two side walls 116 and 118 which project downward`from the upper surface 114 and initially converye inward to form shoulders 120 and 122 and then diverge outward to form inwardly curved troughs and lower, outwardly rounded corners 124 and 126 which intersect at rib 128 haviny a jagged, outwardly facing surface 130. The seal member 102 also has a hollow inner chamber 132.
As illustrated in FIG. 9, after the powder collector 24 is in place under fan plenum 38, seal member 102 is inflated with air into its expanded condition so that the hollow inner chamber forms a substantially circular cross section forcing rib 128 outward away from bottom surface 114. In this position, the surface 130 of rib 128 compresses against the top plate 34 of collector 2~ and forms an air tight seal around powder collector exhaust opening 36 and fan plenum inlet opening 42.
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When the seal assembly loo is in the retracted - position of FIG. 8, powder collector 24 can be moved in or out from under fan plenAm 38 to replace the collector when a new color is be~ng sprayed or the cartridge filters need replacing. That is, when the powder collector is rolled under the fan plenum assembl.y, the seal 102 is in the retracted position and does no~
interfere with the collector being moved into position.
After the collector is positioned so that both its inlet and exhaust openings 30 and 36, respectively, are aligned with fan support opening 82 and fan plenum assembly inlet opening 42, respectively, collector 24 is secured in place with a latch mechanism, as previously discussed, to pxovide an air tight seal ~etween the rear wall of canopy 14 ~nd the inlet opening 30 into powder collector 2~.
The seal assembly 100 is then inflated into the expanded position of FIG. 9 to compress seal 102 against the collector's upper plate 34 and form an air tight seal between exhaust opening 36 and air plenum inlet openin~
42. The pneumatic seal exerts a downward force on collector 24 and thus additionally functions to secure the collector 24 in position. Thus, even if collector 2.
is inadvertently unlatched, it is still secured with ; ' respect to the fan plenum because of the downward force from seal assembly lO0. When collector 24 is to be moved : out from under fan plenum 38, the seal is simply deflated and it contracts to its normal deflated condition, as illustrated in FIG. 8, so as not to interfere with the movement of the collector.
A further advantage of inflatable seal 100 is that it can account to some deyree for cases where the top : of the collector 24 is not completely level with respect :
to the bottom of fan plenum 38. That is, even where these two components are not completely level with respect to one another, an effeckive seal will be made between collector 24 and fan plenum 38 by means of pneumatic seal 100, because pneumatic seal 100, being resilient, can correct to some degree for misalignment between collector 24 and fan plenum 38. This ls yet another way in which the presenk invention facilitates the quick and easy leveli.ng and sealing of collector 2 with respect to fan plenum 38 and booth canopy 14.
Anoth~r important feature of the present i.nvention relates to the mounting of hollow, cartridge filters 120 to the top plate 34 of the powder co]lector 24, as generally illustrated in FIG. 1. The filters 120 are suspended from a support assembly 12 , as explained in detail below. The cartridge filters 120, as illustrated in ~IGS. 11 and 12, include an elongated hollow member 124. formed of a filter media, such as a cylindrically shaped, filtering wall with a pleated outer surface and a hollow interior disposed about a longitudinal centerline 125. The cartridge filter 120 has a closed bottom end cap 126 with an internally threaded boss 128 secured to the ~ottom end thereof and an open top end cap 130 secured to the top end thereof.
As illustrated in FIG. 12, a tie rod 132 is threaded at both ends 134 and 136 and extends through the hollow interior of cartridge filter 120. Tie rod 132 is threadably engaged at end 134 to threaded boss 128 and at the opposite end 136 to support assembly 122. Between : 30 ends 134 and 136 is a handle 138 extending transverse to ~ a centerline 140 through the tie rod. In the preferred :: :
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embodiment, the handle is secured in a bore 1~2 through rod 132. The handle enables an assembler to easily rotate the tie rod and thread or unthread it from the ; ~oss 128. A roll pin 144, located near the threaded portion of end 136, extends transversely to centerline 140 through the tie rod and is preferably secured in and extends outward from both sid~s of a bore 146 through rod 132 (See FIGS. 12A & 12B). The roll pin 144 engages a slot 148 in a bushing 150 to prevent the rotation of tie lo rod 13~ when the cartridge i~ being disassembled from the support 1~2, as discussed below. Note that roll pin 144 is located adjacent the shoulder 152 formed at the intersection of the threaded and unthreaded sections of tie rod 132. While a single roll pin is illustrated, an additional roll pin can be installed in bore 153 if desired.
A tie rod centering bracket 154, as seen in ~IGS. 11 and 12, is formed of a circular plate 156 having a hole 158 through its center to freely xeceive the tie rod 132.
A plurality of radial extending arms 159, preferably four, are each attached at one end to the plate 156 and have an upstanding leg 160 at the other end. The radial '~ arms 159 are spaced at substantially 90 degrees with respect to each other. The ups-tanding leys 160 abut against the inner surface o~ the cartridge and prevent radial movement of the bracket. The free ends of -the legs are bent to form a stop 162 which rests against the top end 130 of the cartridge to hold bracXet 154 in place. Bracket 154 functions to center the tie rod within ~iIter 120. That is, bracket 15~ insures that the centerline 140 of the tie rod essentially coincides with . ~
the centerline 125 of cartridge 120. This alignment .
?~ 7, 9 prevents the tie rod 132 from moving out of alignment with the centexline 125 of caxtridge 120 during installation or removal of cartridge 120 which would tend to break the boss 128 or deform end cap 126.
Support assembly 122 is adapted to support the fi.lter cartridges 120 below openings 36 in the ~op plate 34 of powder collector 24 whereby the cartridge is secured with a tight seal against the bottom side 172 of top plate 34. Support assembly 122 includes a spider assembly 174 comprised of center bushing 150 and a plurality of trl~ss arms 176, 178 and 180 affixed thereto and projecting radially outwar~ at an angle of about 120 degrees with respect to each other. The outer ends of the truss arms are notched out so that an inner upstanding surface rests in a notch 181 e~tending radially outward from the periphery of opening 36, as seen in FIG. 11, to prevent rotational or radial movement of spider 174. The radial extending surface of the notch in khe truss arms rests on the top surface of plate 34 and supports the cartridge within powder collec~or 24.
To assemble a cartridge 120 into the powder collector 24, tie rod 140 is threaded into the internal threaded boss 128, centering bracket 154 is inser.ed onto the rod 140 in cartridge 120, and cartridge 120 is placed in the powder collector through the inlet opening 30.
The perforated baffles shown in FIG. 10 are removed during this step so that the interior of collector 2~ is completely open. Support assembly 122 is then secured across opening 36. The assembler then reaches into the opening 36 through the top plate 34 and ho-ding handle 138 pulls up cartridge 120 so that the upper threaded end :::
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. ' ", " , ", i . . . ; . `' t ' ' i' ' ' ' , , i,, ' ' ' ' of rod 132 passes through bushing 150, with roll pin 144 inserted into slot 148 of bushing 150. The assembler pulls up on h~ndle 138 until seal 182 of cartridge 120 rests against the bottom surface 1'72 of plate 34. Next, a nut 183 is threaded onto the upper ~hreaded end of tie rod 132 and tightened to compress gasket 182 and seal cartridge 1~0 around inlet hole 360 When the cartridge is to be removed from the powder collector, the nut 183 is unthreaded. As the nu~ is turned in the counterclockwise direction to unthread i-t, roll pin 144 engages slot 148 in bushing 150 to prevent tie rod 132 from turning and being unthreaded from the threaded boss 128.
The patents listed herein are intended to be incorporated by reference in their entireties, It is apparent that there has been provided in accordance with this invention apparatus and methods for sealing a powder collector assembly against a spray booth and a fan plenum assembly and a cartridge mount assembly that satisfy the objects, means and advantages set forth hereinbefore. According to the invention, a powder spray canopy is aligned with a fan plenum assembly by a fan support bracket which is itself supported by the base which supports the canopy so that a powder collector can be quickly aligned and effectively sealed to both the powder spray canopy and the fan assembly. A pneumatic seal is provided between the fan plenum and collector to facilitate this operation. A support assembly is provide : ~ for the filter cartridges which enables an assembler to ; '0 easily and quickly install and remove the filter , , :
211 ~6~
cartridge as needed from the powder collector.
While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing teachings. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
,~
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important to insuxe that the negative pressure developed by the exhaust fan in the fan plenum fully acts within the spray booth to efficiently draw all of the oversprayed po~Jder into the powder collector. Also an airtight seal around the opening into the air plenum is important to pre~ent leakage of the cleaning a.ir pulses directed from the plenum into the powder collector to clean the filters. Such leakage would reduce the effective of cleaning of the filters.
In setting up powder booth spray systems in the past with free standing, independently supported fan plenums, such as is shown in U.S. 4,498,913, the spray booth was ~ initially aligned with respect to ~he conveyor line - extending therethrough. Typically the spray booth had a base with six or eight legs, each having an adjustable foot, e.g., a caster. The aligning of the spray booth was labor intensive and time consuming particularly ~here there were irregularities in the worX floor on which the booth rested.
Next, the air inlet port of the exhaust fan plenum had to be aligned with respect to the powder exhaust opening in the spray booth canopy so that when the powder collector was moved lnto place, its inlet opening could be aligned with and sealed against the powder exhaust opening i~ the canopy and its air outlet could simultaneously be aligned with and sealed to the air inlet opening of the exhaust plenum assembly. This typically required time consuming, labor intensive adjustment of the casters on the four legs supporting the ~an plenum. Finally, the casters on the four legs of the powder collector were a.justed to properly seal the :, ' .
: ~ :
2 ~ 2 ~
collector against both the booth and the air plenum.
In another type of prior ark booth, as illustrated in U.S. Patent Nos. 4,277,260 and 4,378,728, the fan section is structurally coupled to the spray booth. In this case, since the fan plenum ;.s quite heavy and ii cantilevered from the booth, the spray booth canopy has to be constructed of heavy weight metal to support the fan plenum. This is particularly so because in additio~
to the fan section being heavy, it also generates a great deal of vibration, especially from the valve manifold used to pulse clean the filter cartridges. Besides being expensive, a spray booth canopy of heavy weight metal construction tends to attract the powde~ coating material which then sticks to the booth walls rather than the article which is to be powder coated.
In U.SO Patent No. 4,354,451, the fan unit is positionèd above the top of the spray booth and mounted either directly to the top of the spray booth or mounted independently of the spray booth. In both case~ the system is deficient. First, the powder collector is very tall and is therefore a~Xward to safely maneuver across '~ the plant floor, especially since it is replaced whenever a different color is sprayed. Second, the spray booth would have to be constructed of heavy weight metal in order to support the fan unit~
Another common problem in the prior art relates to the apparatui used to secuxe the air filters within the powder collector. As illustrated in prior art U.S.
4,218,277, air filters can have a central tie rod which ~; 30 lS secured to a hole through a bottom plate by a threaded :
~ 4 .:
nut. One reason why this design is deficient is that over time the hole provides a path for unfiltered powder to enter the clean air fan plenum. When particles of powder escape into the clea~ air fan plenum, any downstream filter, specifically the final filter ~hich is designed to filter extremely small sized particles, quickly clogs causing a shutdown of the entire powder coating operation. Further, the filter as designed is difficult to mount in the collector. In many instances, the installation of this filter required two installers, one on the exhaust side and the other on the inlet side of the powder collector.
OBJECTS AP~D ~U~RY O~ ~E I~EN~ION
It is an object of the present invention to align a powder spray canopy with a fan plenum so that a powder collector can be quickly aligned and effectively sealed to both the powder booth canopy and the fan plenum to obviate the problems and limitations of the prior art systems.
It is a further ~bject of the present invention to provide an improved filter cartridge mounting assembly which allows for quic~ and easy mounting and dismounting of filter cartridges in the powder collector.
It is a still further object of the present invention to provide structural components for compression mounting vertically oriented, filter cartridges so that they are easily installed and have a ~ simple and reliable seal.
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It is a ~et further object of the present invention to provide an improved seal between the fan plenum a~d the powder collector.
Yet another ob~ect is to provide an improved booth design wherein the fan plenum i5 supported by the booth in such a way that the booth canopy can be constructed of lightweight, plastic material.
In accordance with the invention, there is provided a powder coating system comprising a hase with a fan o support secured thereto. The fan support is adapted to support a fan plenum assembly having an inlet opening in a bottom wàll thereof. A canopy of a powder spray booth having an exhaust opening in a side wall is secured to the base and to the fan support. A powder collector ` 15 having an inlet opening in a f~ont wall and an exhaust opening in a top plate is ada~ted to be sealed against the canopy and the fan plenum assem~ly whereby the , exhaust opening in the side wall of the canopy seals against the inlet opening of the powder collect~r and the inlet opening of the fan plenum assembly seals against the exhaust opening of the powder collector.
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Also in accordance with the invention, a leveling ~,~ means is provided on the base to simultaneously level the fan plenum assembly and the booth canopy. A leveling means on the powder collector simultaneously levels the powder collector ~ith respect to the fan plenum assembly and the canopy, whereby the inlet opening of the powder collector is aligned for sealing to the exhaust opening , of the canopy and the exhaust opening of the powder collector is aligned for sealing against the inlet i: .
.. . . . .... ... . . . . . ........ . ... .
opening of the fan plenum assembly.
The base incl~des two substantially parallel beams having legs at each end and a substantially rectangular table secured to the beams. The table has a central section secured to the parallel beams and opposite firsk and second end sections extending from opposite ends of the central section cantilevered outward from the parallel beams. The canopy is secured on the parallel beams whereby a portion of the bea~s project outward from one side of the table and have the fan support secured thereto.
In accordance with the invention, seal means between - the fan plenum asse~bly and the powder collector seals the exhaust opening of the powder collector against the inlet opening of the fan plenum assembly. The seal means includes a bracket and a pneumatic seal member securely gripped therein. The seal member is constructed of an elastomeric material wlth a cross section including a top surface, two side walls, a bottom surface with an upstanding rib and a hollow inner chamber wherein -the seal member is normally in a collapsed, d~lated state " where the upstanding rib is in a first position closer to the top surface, and wherein the seal member can be expanded to an inflated state where the upstandiny rib is 25 in a second position further away from the top surface than in the first position. The seal means helps to secure the powder collector in position. Also, a second seal means between the fan support and the powder collector seals an opening through a wall in the fan ; 30 support to the inlet opening in the powder collector.
~ 7 ;; . ^
In ~ccordance with the i.nvention, a method of sealing a powder collector against both a canopy of a spray boo-th and against a fan plen~m assembly, comprises the following steps. A base is provided which is secnred to hoth a canopy having an exhaust opening and a fan plenum assembly having an inlet opening. The base is aligned with the conveyor and leveled ~hereby the exhaust opening of the canopy and the inlet opening of the fan plenum assembly are automatically, simultaneously leveled. A powder collector having an inlet opening and an exhaust openin~ is then leveled with respect to the base whereby the inlet opening of the powder collec~or is automatically aligned for sealing to the exhaust opening of the canopy and the exhaust opening of the powder collector is simultaneously aligned with the inlet op~ning in the fan plenum assembly. Next, the exhaust opening of the canopy is sealed to the inlet opening of the powder collector and the inlet opening OI the fan plenum assembly is pneumatically sealed to ~he exhaust opening o-E the powder collector.
Further in accordance with the invention, a cartridge mount assembly comprises a hollow cartridge having a bottom plate with an internally threaded boss secured to the inside wall of the bottom end OI the cartridge. A tie rod extending through the cartridge is threadably engaged at one end to the threaded boss and at an opposite end to a support assembly. The support assembly i5 adapted to be supported in an opening within a powder collector whereby the cartridge is secured against a top plate of the powder collector. A handle ~: extends through the tie rod to initially thread the tie rod into the threaded boss before the cartridge is . 8 .
' , :
2 1~2~
mounted into the collector. A spider assembly has a center bushing and a plurality of truss arms affixed thereto and projecting radially outward therefrom. The outer ends of the truss arms are notched out to rest against the periphery of the opening in the top plate of the powder collector to support the cartridge therefrom.
Notches in the top plate engage the truss arms and prevent rotational movement of the spider assembly. A
centering bracket on the tie rod engages the interior wall of the cartridge and maintains a centerline of the tie rod coincident with the centerline khrough the cartridge to protect ~he threaded boss from torque caused by a misaligned tie rod, particularly during installation. The handle is used to pllll thP tie rod up 15 through the center bushing so that a nut can be threaded onto tne uppe~ end of the tie rod to mount the cartridge in the collector. A roll pin extends through the tie rod to engage the b~shing and prevent the tie rod from being unthreaded from the boss when the cartridge is removed from the powder collector. A single installer can both install and remove the cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
~, The structure, operation, and advantages of the presently preferred embodiment of the invention will become further apparent upon consideration of the following description taken in conjunction wikh the accompanying drawings, wherein:
~ IG. 1 is a perspective view of a base structure supporting a fan plenum and a spray booth in alignment with each other and the conveyor, and showing a powder collector prior to being positioned and sealed against : , :
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,, .. . , .,, , : , 2 ~
the spray booth and the fan plenum, in accordance with the invention;
FIG. 2 is a perspective view of a base structure supporting a fan plenum and a spray booth in alignment with each other and a powder collector positioned and sealed against the spray booth and the fan plenum;
FIG. 3 is a perspective view of the base for the spray booth and fan plenum of the powder coating system illustrated in FIG. 1;
FIG. 4 is a perspective view of the base illustrated in FIG. 3 with the fan plenum support structure mounted thereto;
FIG. 5 is a perspective view of the base and fan plenum support structure, as illustrated in FIG. 2, with the fan plenum mounted to the fan assem~ly support structure;
FI~. 6 is a perspective view uf the base with a fan plenum support structure supporting the fan plenum, as illustrated in FlG. 5, and the canopy located on the base assembly in alignment with the fan plenum;
FIG. 7 is a view taken along line 7-7 of FIG. 5 illustrating the retractable seal assembly;
FIG. ~ is a view taken along line 8-8 of FIG~ 7 illustrating the seal assembly in its normal deflated, retracted position;
FIG. 9 is a view taken along line 9~9 of FIG. 2 illustrating the seal assembly in the inflated, expanded : position between the powder collector and the fan plenum;
:~ FIG. 10 is a view taken along line lO-10 of FIG. 1 illustrating the inlet opening to the powder collector;
: FIG. ll:is a top view of a cartridge filter assembly resting on the top of the powder collector;
` FIG. 12 is view taken along line 12-12 of FIG. ll ~:, 10 :: :
C~ a 2 ~
illustrating the cartridge fil~er and mounting assembly;
FIG. 12A is an enlarged section of F~G. 12; and FIG. 12B is a view taken along line 12B-123 of FIG
12A.
DETAII,ED DESCRIPTION OF TXE INVENTION
Re~erxing to FIGs. 1 and 2, a powder coating system 10, intended for use as a powder coating booth 12 for applying powder coating ~aterial on a production line basis, includes provision for automatic recovery and recirculation of the oversprayed powder in the syst~m.
The booth itself is of a generally conventional design and includes a canopy 14 having entry and exit vestibules ; 16 and 18, respectively, at each end thereof through which the ar~icle or part 20 to be coated can ~e transporterd. Typically in such equipment, the article 20 to be coated is hung by a hook 21 from a conveyor system 22 to move slowly through the spray booth so that the part is sprayed with one or more spray guns thro~gh an s opening (not shown) in the side of the canopy o~poslte , 20 the collector.
'~ ~ A powder collector 24 as illustrated in FIGS. l, 2 and 10 is mounted on wheels 26. The wheels 26 include leveling means 27, which are preferably vertically adjustable casters, to level the powder collector as required for the particular floor conditions. The collector, during operation of system 10, is located adjacent an exhaust opening 28 in a side wall of canopy 14. The powder collector, best shown in FIG~ 10, has an inlet opening 30 in a side wall thereof with a seal 32, ;30 preferably "D" shaped in cross section thereabout. The : ~ .
~ ~ : ~ , . ... .... .. . . .
2~&~2~
, inlet op~ning 30 is adapted to mate with canopy exhaust opening 28, as discussed below. A top plate 34 of the collector (see FIG. 1) has an exhaust opening 36 which fits under a fan plenum assembly 38 and is sealed against a bottom wall portion 40 of fan plenum 38, as illustrated in FIG. 9, disposed about an inlet opening 42, as discussed in more detail below.
A principle feat~re of this invention is the construction of a base 44 which enables the canopy 14 to 10 be automatically properly aligned with respect to the ~an plenum assembly 38i so that a powder collector 24 can be moved into and out of position and quickly aligned and effectively sealed to both the exhaust opening ~S of powder spray canopy 14 and inlet opening 42 of the fan plenum 38. The ~ase 44, as illustrated in FIG. 3, includes a rectan~ular table 46 having a central section 48 and opposite end sections 50 and 52 cantilevered outward from opposite ends of the central section 48.
The table is supported on t~o substantially parallel beams 54 and 56 which extend transversely to the length of the table and have leg elements 58 at each end. Beams 54 and 56, which are positioned un~er the intersections of the central section 48 and the opposite end sections 50 and 52, are secured to the table by means such as ~elding. The triangular braces 60, secured to the bottom of the table and to the beams, provide additional support. The parallel beams 54 and 56 project outward from one side 62 of table 46 and form a base to which a fan support 64 (See FIG. 4) is secured.
Leveling means 72 are provided on base 44 to simultaneously level the fan plenum assembly 38 and ::
-.~ , . . .
2 1 ~ 3 canopy 14, as discussed in more detail below. Theleveling means includes vertically adjustable feet 72 at the bottom of legs 580 The fan support 64, as illustrated in FIG. 4, has a front wall 80 with an openiny 82 adapted to mate with the exhaust ope~ing 28 (see FIG. l) of canopy 14. A
rectangular frame 84 around opening 82 provides a smooth surface against which the ~IDi~ shaped seal 32 of the powder colleotor is sealed, as discussed below. A plate 86, secured along the bottom edge of opening 82, is level with the table 46 which forms the inner floor of spray booth 12. Plate 86 extends into the inlet opening 30 of collector 24 so that any powder which bui3.ds up on the inner booth floor 46 can be easily swept into the collector. The fan support 64 includes two parallel side walls 88 and 90 secured to and extending substantially normal to front wall 80. The lower surfaces of ~he side walls are secured, by means such as welding or bolts, to the upper surface of the portions of the parallei beams 54 and 56 which project outward from side 52 of table 46.
The upper sur*aces of side walls 80 and 90 are perpendicular to the frame 84 and provide a support surface on which the bottom of the fan plenum assembly 38 can be attached by means such as nuts and bolts, as illustrated in FIG. 6.
An important feature of this invention relates to the ability of the fan support 64 to maintain a : perpendicular relationship between the opening 82 through : the front wall 80 of fan support 64 and the inlet opening ; 30 42 of the fan plenum assembly 38. This relationship is critical to enablè both the inlet opening 30 and the .
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exhaust opening 36 of powder collector 24, which are perpendicular to one another, to be quicXly and ~asily aligned with and properly sealed to both the opening 82 through the front wall 80 of fan ~upport 64 and the inlet opening 42 of the fan plenum asse~lbly 38. Once the canopy 1~ is securely mounted on table 46, the side wall of the canopy can be secured to the front wall 80 of the fan support so that the exhaust opening 28 is immovably aligned with the opening 82. Since the inlet opening of fan plenum assembly 38 is securely mounted to the top surface of sidewalls 88 and 90, which in turn are perpendicular to the fronk wall 80, the inl t opening of fan plenum assembly 38 is automatically aliyned to be perpendicular with the opening 82 in the side wall o-f fan 15 support 64.
By establishing a perpendicular relationship between the inlet opening 42 of the fan plenum and the opening 82 of the front wall of the fan support, the powder collector 24 can be rolled into position, as illustrated in FIG. 2, and simultaneously aligned with respect to the canopy and the fan plenum assembly so that an e~:Eective air tight seal can be achieved. That is, both inlet and exhaust openings 30 and 36, respectively, of powder collector 24 are located against fan support opening 82 and fan plenum inlet opening 42, respectively, so that an air tight seal can be ~uickly and easily achieved, as discussed in more detail below. An air tight seal is very important to the proper functioning of the powder coating system 10 because it enables more air entrained po~der to be removed from powder coating booth 12, and prevents escape of the powder from the booth into the plant en~ironment and from the collector into the fan ~: 14 .
.
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plenum.
Another aspect of the invention relates to the fan plenum assembly being supported by the base 44 instead of the canopy, as was often the case in the prior art. This enables the c~nopy to be constructed of a lightweight, non-metallic material, such as for example a plastic like polypropylene. One advantage of a plastic canopy is that the powder coating material does not have an electrical attraction to the plastic and will not tend to stick to the sides of the canopy as with a metal canopy. This is particularly important when the color is changed and the system has to be cleaned before a new color of powder is sprayed. Further t the canopy can be made of a translucent material which provides improved lighting inside the spray booth to better enable a system operator to monitor the system. Further, the plasti~ is light weight which is more manageable to assemble and lower in cost.
Referring to FIG. 10, there is illl~strated the front of po~der collector 24 which has inlet opening 30. A
seal means 32, typically comprising an elastomeric seal " with a "D" shaped cross section, is disposed around inlet openlng 30. When the powder collector is in place, as illustrated in FIG. 2, conventional latches, not shown, attached to fan support 64 pull collector 24 against the front wall 80 of fan support 64 and tightly compresses seal 32 against the frame 84 to form an air tight seal between the rear wall of the canopy and th~ inlet opening 30 of powder collector 24.
Another important feature of the present invention ' 2 ~ 2 3 relates to a seal means 99 including a seal assembly 100 disposed about the inlet opening 42 in bottom 40 of the fan plenum assembly 38, as illustrated in FIGS. 7, 8 and The seal assembly 100 includes a retractable, pneumatic seal member 102 secured in a bracket or extrusion 104. Extrusion 104 has an upper ~all 105 which is secured to bottom wall 40 by any means suoh as spot welding. Oppositely disposed, bracket side walls 106 and 108, extending dow~ward from upper wall 105, converge inward toward each other and then turn outward to form oppositely disposed cur~ed recesses 110 and 112 whi.ch grip the top edges of seal member 102. The seal member 102 is preferably constructed of an elastomeric material and has a normal deflated, retracted shape, the cross section of which is illustrated in FIG. 8, including an upper surface 114, two side walls 116 and 118 which project downward`from the upper surface 114 and initially converye inward to form shoulders 120 and 122 and then diverge outward to form inwardly curved troughs and lower, outwardly rounded corners 124 and 126 which intersect at rib 128 haviny a jagged, outwardly facing surface 130. The seal member 102 also has a hollow inner chamber 132.
As illustrated in FIG. 9, after the powder collector 24 is in place under fan plenum 38, seal member 102 is inflated with air into its expanded condition so that the hollow inner chamber forms a substantially circular cross section forcing rib 128 outward away from bottom surface 114. In this position, the surface 130 of rib 128 compresses against the top plate 34 of collector 2~ and forms an air tight seal around powder collector exhaust opening 36 and fan plenum inlet opening 42.
.
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When the seal assembly loo is in the retracted - position of FIG. 8, powder collector 24 can be moved in or out from under fan plenAm 38 to replace the collector when a new color is be~ng sprayed or the cartridge filters need replacing. That is, when the powder collector is rolled under the fan plenum assembl.y, the seal 102 is in the retracted position and does no~
interfere with the collector being moved into position.
After the collector is positioned so that both its inlet and exhaust openings 30 and 36, respectively, are aligned with fan support opening 82 and fan plenum assembly inlet opening 42, respectively, collector 24 is secured in place with a latch mechanism, as previously discussed, to pxovide an air tight seal ~etween the rear wall of canopy 14 ~nd the inlet opening 30 into powder collector 2~.
The seal assembly 100 is then inflated into the expanded position of FIG. 9 to compress seal 102 against the collector's upper plate 34 and form an air tight seal between exhaust opening 36 and air plenum inlet openin~
42. The pneumatic seal exerts a downward force on collector 24 and thus additionally functions to secure the collector 24 in position. Thus, even if collector 2.
is inadvertently unlatched, it is still secured with ; ' respect to the fan plenum because of the downward force from seal assembly lO0. When collector 24 is to be moved : out from under fan plenum 38, the seal is simply deflated and it contracts to its normal deflated condition, as illustrated in FIG. 8, so as not to interfere with the movement of the collector.
A further advantage of inflatable seal 100 is that it can account to some deyree for cases where the top : of the collector 24 is not completely level with respect :
to the bottom of fan plenum 38. That is, even where these two components are not completely level with respect to one another, an effeckive seal will be made between collector 24 and fan plenum 38 by means of pneumatic seal 100, because pneumatic seal 100, being resilient, can correct to some degree for misalignment between collector 24 and fan plenum 38. This ls yet another way in which the presenk invention facilitates the quick and easy leveli.ng and sealing of collector 2 with respect to fan plenum 38 and booth canopy 14.
Anoth~r important feature of the present i.nvention relates to the mounting of hollow, cartridge filters 120 to the top plate 34 of the powder co]lector 24, as generally illustrated in FIG. 1. The filters 120 are suspended from a support assembly 12 , as explained in detail below. The cartridge filters 120, as illustrated in ~IGS. 11 and 12, include an elongated hollow member 124. formed of a filter media, such as a cylindrically shaped, filtering wall with a pleated outer surface and a hollow interior disposed about a longitudinal centerline 125. The cartridge filter 120 has a closed bottom end cap 126 with an internally threaded boss 128 secured to the ~ottom end thereof and an open top end cap 130 secured to the top end thereof.
As illustrated in FIG. 12, a tie rod 132 is threaded at both ends 134 and 136 and extends through the hollow interior of cartridge filter 120. Tie rod 132 is threadably engaged at end 134 to threaded boss 128 and at the opposite end 136 to support assembly 122. Between : 30 ends 134 and 136 is a handle 138 extending transverse to ~ a centerline 140 through the tie rod. In the preferred :: :
.
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embodiment, the handle is secured in a bore 1~2 through rod 132. The handle enables an assembler to easily rotate the tie rod and thread or unthread it from the ; ~oss 128. A roll pin 144, located near the threaded portion of end 136, extends transversely to centerline 140 through the tie rod and is preferably secured in and extends outward from both sid~s of a bore 146 through rod 132 (See FIGS. 12A & 12B). The roll pin 144 engages a slot 148 in a bushing 150 to prevent the rotation of tie lo rod 13~ when the cartridge i~ being disassembled from the support 1~2, as discussed below. Note that roll pin 144 is located adjacent the shoulder 152 formed at the intersection of the threaded and unthreaded sections of tie rod 132. While a single roll pin is illustrated, an additional roll pin can be installed in bore 153 if desired.
A tie rod centering bracket 154, as seen in ~IGS. 11 and 12, is formed of a circular plate 156 having a hole 158 through its center to freely xeceive the tie rod 132.
A plurality of radial extending arms 159, preferably four, are each attached at one end to the plate 156 and have an upstanding leg 160 at the other end. The radial '~ arms 159 are spaced at substantially 90 degrees with respect to each other. The ups-tanding leys 160 abut against the inner surface o~ the cartridge and prevent radial movement of the bracket. The free ends of -the legs are bent to form a stop 162 which rests against the top end 130 of the cartridge to hold bracXet 154 in place. Bracket 154 functions to center the tie rod within ~iIter 120. That is, bracket 15~ insures that the centerline 140 of the tie rod essentially coincides with . ~
the centerline 125 of cartridge 120. This alignment .
?~ 7, 9 prevents the tie rod 132 from moving out of alignment with the centexline 125 of caxtridge 120 during installation or removal of cartridge 120 which would tend to break the boss 128 or deform end cap 126.
Support assembly 122 is adapted to support the fi.lter cartridges 120 below openings 36 in the ~op plate 34 of powder collector 24 whereby the cartridge is secured with a tight seal against the bottom side 172 of top plate 34. Support assembly 122 includes a spider assembly 174 comprised of center bushing 150 and a plurality of trl~ss arms 176, 178 and 180 affixed thereto and projecting radially outwar~ at an angle of about 120 degrees with respect to each other. The outer ends of the truss arms are notched out so that an inner upstanding surface rests in a notch 181 e~tending radially outward from the periphery of opening 36, as seen in FIG. 11, to prevent rotational or radial movement of spider 174. The radial extending surface of the notch in khe truss arms rests on the top surface of plate 34 and supports the cartridge within powder collec~or 24.
To assemble a cartridge 120 into the powder collector 24, tie rod 140 is threaded into the internal threaded boss 128, centering bracket 154 is inser.ed onto the rod 140 in cartridge 120, and cartridge 120 is placed in the powder collector through the inlet opening 30.
The perforated baffles shown in FIG. 10 are removed during this step so that the interior of collector 2~ is completely open. Support assembly 122 is then secured across opening 36. The assembler then reaches into the opening 36 through the top plate 34 and ho-ding handle 138 pulls up cartridge 120 so that the upper threaded end :::
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~ .
. ' ", " , ", i . . . ; . `' t ' ' i' ' ' ' , , i,, ' ' ' ' of rod 132 passes through bushing 150, with roll pin 144 inserted into slot 148 of bushing 150. The assembler pulls up on h~ndle 138 until seal 182 of cartridge 120 rests against the bottom surface 1'72 of plate 34. Next, a nut 183 is threaded onto the upper ~hreaded end of tie rod 132 and tightened to compress gasket 182 and seal cartridge 1~0 around inlet hole 360 When the cartridge is to be removed from the powder collector, the nut 183 is unthreaded. As the nu~ is turned in the counterclockwise direction to unthread i-t, roll pin 144 engages slot 148 in bushing 150 to prevent tie rod 132 from turning and being unthreaded from the threaded boss 128.
The patents listed herein are intended to be incorporated by reference in their entireties, It is apparent that there has been provided in accordance with this invention apparatus and methods for sealing a powder collector assembly against a spray booth and a fan plenum assembly and a cartridge mount assembly that satisfy the objects, means and advantages set forth hereinbefore. According to the invention, a powder spray canopy is aligned with a fan plenum assembly by a fan support bracket which is itself supported by the base which supports the canopy so that a powder collector can be quickly aligned and effectively sealed to both the powder spray canopy and the fan assembly. A pneumatic seal is provided between the fan plenum and collector to facilitate this operation. A support assembly is provide : ~ for the filter cartridges which enables an assembler to ; '0 easily and quickly install and remove the filter , , :
211 ~6~
cartridge as needed from the powder collector.
While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing teachings. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
,~
~ '~
~ : 22
Claims (24)
1. A powder coating system, comprising:
a base;
a fan support secured to said base, said fan support being adapted to support a fan plenum assembly having an inlet opening in a bottom wall thereof;
a canopy of a powder spray booth having an exhaust opening in a side wall, said canopy secured to said base;
and a powder collector having an inlet opening in a front wall and an exhaust opening in a top plate, said powder collector being adapted to be sealed against said canopy and said fan plenum assembly whereby said exhaust opening in said side wall of said canopy is sealed with respect to said inlet opening of said powder collector and said inlet opening of said fan plenum assembly seals against said exhaust opening of said powder collector.
a base;
a fan support secured to said base, said fan support being adapted to support a fan plenum assembly having an inlet opening in a bottom wall thereof;
a canopy of a powder spray booth having an exhaust opening in a side wall, said canopy secured to said base;
and a powder collector having an inlet opening in a front wall and an exhaust opening in a top plate, said powder collector being adapted to be sealed against said canopy and said fan plenum assembly whereby said exhaust opening in said side wall of said canopy is sealed with respect to said inlet opening of said powder collector and said inlet opening of said fan plenum assembly seals against said exhaust opening of said powder collector.
2. The apparatus of claim 1 further including leveling means on said base.
3. The apparatus of claim 2 wherein said leveling means simultaneously levels said fan plenum assembly and said canopy.
4. The apparatus of claim 3 further including leveling means on said powder collector for leveling said powder collector with respect to said fan plenum assembly and said canopy whereby said inlet opening of said powder collector is aligned for sealing with respect to said exhaust opening of said canopy and said exhaust opening of said powder collector is aligned for sealing against said inlet opening of said fan plenum assembly.
5. The apparatus of claim 1 wherein said base includes two substantially parallel beams having legs at each end and a substantially rectangular table secured to said beams, said table having a central section secured to said parallel beams and opposite first and second end sections extending from opposite ends of said central section cantilevered outward from said parallel beams.
6. The apparatus of claim 5 wherein said canopy is secured on said table and a portion of said beams project outward from one side of said table and have said fan support secured thereto.
7. The apparatus of claim 1 further including seal means between said fan plenum assembly and said powder collector for sealing said exhaust opening of said powder collector against said inlet opening of said fan plenum assembly.
8. The apparatus of claim 7 wherein said seal means includes a bracket and a pneumatic seal member securely gripped therein.
9. The apparatus of claim 8 wherein said pneumatic seal member is constructed of an elastomeric material with a cross section including an upper surface, two side walls, and a lower surface with an upstanding rib and a hollow inner chamber, wherein the seal member is collapsed in a deflated state where the upstanding rib is in a first position closer to said upper surface and is expanded in an inflated state where the upstanding rib is in a second position further away from said upper surface than in said first position.
10. The apparatus of claim 9 wherein said seal means assists in securing said powder collector in position.
11. The apparatus of claim 10 further including a second seal means between said fan support and said powder collector to seal a fan support opening through a wall in said fan support to said inlet opening in said powder collector, and wherein said fan support opening is sealed to said exhaust opening of said canopy.
12. The apparatus of claim 10 further including said canopy being constructed of a light weight, nonmetallic material.
13. A method of sealing a powder collector against both a canopy of a spray booth and against a fan plenum assembly, comprising the steps of:
providing a base which supports both said canopy and said fan plenum assembly, said canopy having an exhaust opening and said fan plenum assembly having an inlet opening;
leveling said base whereby said exhaust opening of said canopy and said inlet opening of said fan plenum assembly are simultaneously leveled;
leveling said powder collector having an inlet opening and an exhaust opening with respect to said base whereby said inlet opening of said powder collector is aligned for sealing to said exhaust opening of said canopy, said exhaust opening of said powder collector is simultaneously aligned with said inlet opening in said fan plenum assembly; and pneumatically sealing said inlet opening of said fan plenum assembly to said exhaust opening of said powder collector.
providing a base which supports both said canopy and said fan plenum assembly, said canopy having an exhaust opening and said fan plenum assembly having an inlet opening;
leveling said base whereby said exhaust opening of said canopy and said inlet opening of said fan plenum assembly are simultaneously leveled;
leveling said powder collector having an inlet opening and an exhaust opening with respect to said base whereby said inlet opening of said powder collector is aligned for sealing to said exhaust opening of said canopy, said exhaust opening of said powder collector is simultaneously aligned with said inlet opening in said fan plenum assembly; and pneumatically sealing said inlet opening of said fan plenum assembly to said exhaust opening of said powder collector.
14. The method of claim 13 further including the step of sealing said exhaust opening of said canopy to said inlet opening of said powder collector prior to pneumatically sealing said inlet opening of said fan plenum assembly to said exhaust opening of said powder collector.
15. The method of claim 14 including the step of initially aligning said canopy with respect to a conveyor extending through said spray booth.
16. A filter cartridge mount assembly, comprising:
a hollow filter cartridge;
a bottom plate secured to a bottom end of said cartridge, said bottom plate having an internally threaded boss;
a tie rod extending through said cartridge and threadably engaged at one end to said threaded boss and at an opposite end to a support assembly; and said support assembly being adapted to be supported in an opening within a powder collector whereby said cartridge is secured against a top plate of said powder collector.
a hollow filter cartridge;
a bottom plate secured to a bottom end of said cartridge, said bottom plate having an internally threaded boss;
a tie rod extending through said cartridge and threadably engaged at one end to said threaded boss and at an opposite end to a support assembly; and said support assembly being adapted to be supported in an opening within a powder collector whereby said cartridge is secured against a top plate of said powder collector.
17. The apparatus of claim 16 further including a handle extending through said tie rod.
18. The apparatus of claim 16 wherein said support assembly includes a spider assembly having a center bushing and a plurality of truss arms affixed thereto and projecting radially outward therefrom, the outer ends of said truss arms being notched out to rest against the periphery of said opening in said top plate of said powder collector to support said cartridge therefrom.
19. The apparatus of claim 18 further including notches in said top plate extending radially outward from the periphery of said opening and engaging said truss arms to prevent rotational or radial movement of said spider assembly.
20. The apparatus of claim 16 further including a centering bracket on said tie rod to engage the interior wall of said cartridge and maintain a centerline of said tie rod essentially coincident with a centerline through said cartridge.
21. The apparatus of claim 18 further including a roll pin extending through said tie rod to engage a part of said support assembly to prevent said tie rod from being unthreaded from said boss when said cartridge is removed from said powder collector.
22. A filter cartridge mount assembly, comprising:
a hollow filter cartridge having a closed bottom and an open top;
a handle provided within the interior of said cartridge which can be grasped by an operator to pull up on said cartridge from the interior thereof when installing said cartridge in a collector.
a hollow filter cartridge having a closed bottom and an open top;
a handle provided within the interior of said cartridge which can be grasped by an operator to pull up on said cartridge from the interior thereof when installing said cartridge in a collector.
23. A method of installing a filter cartridge in a powder collector, comprising the steps of:
threading a tie rod into an internally threaded boss carried on the inside of a closed bottom plate of a filter cartridge;
putting a centering bracket on said tie rod to maintain the centerline of said tie rod along the centerline of said filter cartridge;
reaching through an opening in a top plate of said collector to grab said handle and pull an upper threaded end of said rod through a bushing of a support assembly which rests on said top plate across said opening; and threading a nut on said upper threaded end against said support assembly to seal said filter cartridge with respect to said opening.
threading a tie rod into an internally threaded boss carried on the inside of a closed bottom plate of a filter cartridge;
putting a centering bracket on said tie rod to maintain the centerline of said tie rod along the centerline of said filter cartridge;
reaching through an opening in a top plate of said collector to grab said handle and pull an upper threaded end of said rod through a bushing of a support assembly which rests on said top plate across said opening; and threading a nut on said upper threaded end against said support assembly to seal said filter cartridge with respect to said opening.
24. A method of installing a filter cartridge in a powder collector, comprising the steps of:
reaching through the opening in a top plate of said collector and into the interior of said filter cartridge to grasp a handle provided within said filter cartridge;
pulling said filter cartridge by means of said handle up against said top plate; and securing said filter cartridge against said top plate.
reaching through the opening in a top plate of said collector and into the interior of said filter cartridge to grasp a handle provided within said filter cartridge;
pulling said filter cartridge by means of said handle up against said top plate; and securing said filter cartridge against said top plate.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US95557492A | 1992-10-02 | 1992-10-02 | |
| US955,574 | 1992-10-02 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2106029A1 true CA2106029A1 (en) | 1994-04-03 |
Family
ID=25497023
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002106029A Abandoned CA2106029A1 (en) | 1992-10-02 | 1993-09-13 | Powder collection system |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP0645193B1 (en) |
| JP (1) | JPH06218317A (en) |
| CN (1) | CN1051256C (en) |
| CA (1) | CA2106029A1 (en) |
| CZ (1) | CZ205793A3 (en) |
| DE (1) | DE69318019T2 (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102007040896B4 (en) * | 2007-08-24 | 2023-02-16 | Dürr Systems Ag | Device for separating wet paint overspray, installation for painting objects, method for producing a device for separating wet paint overspray and method for converting an existing device for separating wet paint overspray |
| ES2561046T3 (en) | 2008-12-19 | 2016-02-24 | Dürr Systems GmbH | Paint installation and procedure for the operation of a paint installation |
| US8915984B2 (en) * | 2010-06-18 | 2014-12-23 | Airex Co., Ltd | Isolator device |
| CN103657929A (en) * | 2012-09-21 | 2014-03-26 | 招远泽洋工具制造有限公司 | Four-side rotary type powder returning device |
| CN114798288B (en) * | 2022-05-23 | 2022-12-30 | 浙江明泉工业装备科技有限公司 | Based on functional intelligent coating line spraying firing equipment of robot |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4498913A (en) * | 1983-10-06 | 1985-02-12 | Nordson Corporation | Apparatus for filtering air for a powder spray booth |
| US4662309A (en) * | 1986-04-22 | 1987-05-05 | Nordson Corporation | Portable powder spray booth |
| DE9207787U1 (en) * | 1992-06-10 | 1992-09-17 | Hestermann, Gerhard, 7990 Friedrichshafen | Powder coating spray booth |
-
1993
- 1993-09-13 CA CA002106029A patent/CA2106029A1/en not_active Abandoned
- 1993-09-23 DE DE69318019T patent/DE69318019T2/en not_active Expired - Fee Related
- 1993-09-23 EP EP93307548A patent/EP0645193B1/en not_active Expired - Lifetime
- 1993-09-29 CN CN93118313A patent/CN1051256C/en not_active Expired - Fee Related
- 1993-10-01 CZ CZ932057A patent/CZ205793A3/en unknown
- 1993-10-01 JP JP5246677A patent/JPH06218317A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| CZ205793A3 (en) | 1995-02-15 |
| EP0645193B1 (en) | 1998-04-15 |
| DE69318019D1 (en) | 1998-05-20 |
| CN1085130A (en) | 1994-04-13 |
| EP0645193A1 (en) | 1995-03-29 |
| CN1051256C (en) | 2000-04-12 |
| JPH06218317A (en) | 1994-08-09 |
| DE69318019T2 (en) | 1998-08-06 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |