CN1867409A - Apparatus for themal spray coating - Google Patents
Apparatus for themal spray coating Download PDFInfo
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- CN1867409A CN1867409A CN 200480029634 CN200480029634A CN1867409A CN 1867409 A CN1867409 A CN 1867409A CN 200480029634 CN200480029634 CN 200480029634 CN 200480029634 A CN200480029634 A CN 200480029634A CN 1867409 A CN1867409 A CN 1867409A
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Abstract
A system for thermal spray coating of a particulate material onto a substrate includes a spray gun apparatus having dual vortex chambers for the mixing of fuel gas and oxygen. The apparatus provides a jet flame resulting from a compression wave formed by compressed air. Dual venturis control the flow of fluidized coating material particles to provide smooth and controlled delivery of coating material to the spray gun.
Description
The cross reference of related application
The application requires U. S. application No.10/909, and 115 benefit of priority, this application are filed on July 30th, 2004, and its requirement is filed in the U.S. Provisional Application No.60/509 on October 9th, 2003,948 benefit of priority, and it is herein incorporated by reference.
Technical field
The present invention relates to be used for the equipment of thermal spraying, and be specifically related to a kind of portable thermic lance, the coating material that is used for containing polymer is coated in substrate.
Background technology
Term " thermal spraying " refers to a kind of like this technology, and in this technology, when single molten drop or particle were positioned on the substrate surface, heating also promoted the raw material of coating material.By means of using fuel gas or electric arc, the coated device of coating material (for example thermic lance) heating, and be transformed into fusion or plasticity molten drop or particle, under the effect of Compressed Gas, these particles are pushed out outside the spray gun.When coating material particle bumped against substrate, they flattened and form attached to the some flakelets on the substrate surface (" thin plate (splat) ").These thin plates cool off, and have formed the coating material layer of the coating with laminated construction.
Known various types of thermic lance.For example, the U.S. Patent No. 5 of Weidman, 285,967 disclose a kind of high speed oxygen-fuel (" HVOF ") thermic lance, be used for for example melted powder synthetic of thermoplastic compound, thermoplasticity/metal composite or thermoplasticity/ceramic composition is sprayed on substrate, thereby in this substrate, form coating.This spray gun comprises HVOF flame generator, is used for providing HVOF air-flow to the fluid-cooled nozzle.The part of air-flow is transferred and is used for the preheating powder, in the downstream position of nozzle, the powder of preheating is injected in the primary air simultaneously.In determining the outer cover in nozzle boundary line, be provided with forced ventilation source and vacuum source, be used to cool off before being deposited in the substrate, be in aloft melted powder.
Thermic lance generally uses the mixture of oxygen-fuel gas, air-fuel gas or air-liquid fuel, oxygen-liquid fuel, and perhaps electric arc and plasma melt these single molten drops as heating agent and the molten drop that these are single is advanced in the ready substrate.Hot spray apparatus belongs to the device of following general hot-spraying technique classification: (1) wire combustion; (2) dust-firing; (3) two-wire material electric arc; (4) plasma-powder; (5) high speed oxygen-fuel gas-powder; (6) high speed oxygen-fuel gas-wire rod; (7) high-speed air-liquid fuel-powder; (8) high speed oxygen solution-air attitude fuel-powder; (9) explosive powder (detonation gunpowder); (10) water cannon-plasma (water cannon plasma).Usually hot spray apparatus is the device of wire combustion spraying, dust-firing spraying, plasma spraying and electric arc spraying.
In the wire combustion spraying coating process, start combustion heat source, and will be line or bar-shaped raw material is driven in the heating agent, in heating agent, compressed air stream accumulates in thermal source around the raw material of axial feed, thereby raw material is fused into vaporific, and raw material is pushed in the substrate, so that deposited coatings.
Use existing wire combustion spraying technology spraying polymeric material to carry out repeatedly attempting, but, when the air compressional wave that needs is made polymerization wire rod atomizing directed so that when directly impacting thermal-flame on the raw material, attempt success, thereby and consumed the atomizing molten drop that is produced.The high temperature relevant with this device can cause the coating embrittlement.Before burning, existing wire combustion technology uses siphon plug (siphon plug) to come mixture of oxygen and fuel gas.This is a kind of complexity and expensive element for processing.
In the dust-firing spraying coating process, start combustion heat source, and axially or tangentially will be in the flame of pulverous raw material introducing propagation.Transport the material powder material by means of powder feeder or hopper that spray gun is installed.
Used the dust-firing spraying coating process to come the coat polymers material, still, the temperature of flame has consumed the raw material more than 50% or 50%.In addition, higher relatively temperature can burn coating subsequently coating and/or cause the coating embrittlement.Before burning, existing dust-firing technology uses the siphon plug to come mixture of oxygen and fuel gas.This is a kind of complexity and expensive element to processing.Combustion powder equipment can not produce aims at and directed compressional wave, nor can be provided at cooling and mixing air in the nozzle body, can reduce flame temperature thus.
In electric arc spraying process, will have opposite polarity, two kinds of wire raw material wire rods similar or dissimilar material are fed in the spray equipment, in this spray equipment, guide two kinds of wire rods to clash into mutually, thereby knocking-on electric arc cause raw material to melt rapidly.The compressed air stream of assembling makes atomization of molten material, and material is advanced in the substrate.The generation source of electric arc is the MIG welding rectifier, and in this rectifier, positive charge is applied on the raw material, and negative electrical charge or earth potential then are applied on another wire raw material wire rods.
Electric arc need be the material of wire, and this material must conduct electricity, so electric arc spraying and be not suitable for means as painted plastic material.
In the plasma powder paint finishing, by means of inert gas is passed through by between electrode and the formed gap of nozzle, produce thermal source, wherein electrode and nozzle are on the current potential.The arc discharge of high voltage, high-frequency, small amperage, the gap between bridged electrodes and the nozzle.The electric arc of this small amperage makes the inert gas partial ionization, and has produced the conductive path that is used for low voltage, high-amperage voltage, thereby finishes circuit.Thereby inert gas is separated fully, expands, and leaves nozzle bore at a high speed.During gas separated combination again, produce heat, melt the feedstock material powder of tangentially being injected plasma torch with this heat.The speed of flame is advanced to feedstock material powder in the substrate.
Plasma gun has been used to spray the high-temperature polyester that has aluminium component, will burn some polymeric materials but be intended that.The operating cost of this device has also limited it as the device that is used for economic in-place coating powdery paints.
In the detonation flame spraying gun system, by a string controlled blast, heat source in propagated.By with internal combustion engine in valve similarly install, oxygen-fuel gas mixture is spurted in the chamber.Yet this chamber at one end opens wide, and does not have piston.By means of with the spark plug of valve mechanism co-ordination, light oxygen-fuel gas mixture.The circulation that repeats repeatedly refuelling each second and light, the blast wave that is produced has melted raw material, and raw material is advanced in the substrate.Raw material is transported from the powder feed arrangement with powder type.
Detonation-gun is bigger, and needs special-purpose room.It can not use at the scene.Detonation-gun is used to apply hard and fine and close coating, and is not suitable for spraying polymeric material.
High speed also is not suitable for the coat polymers material, and this is because fuel and the needed pressure of oxidation mediators gas have guaranteed bigger flame and higher temperature.And very high speed is harmful to plastic droplets.Flame temperature can reduce the quality of coated coating and make its embrittlement.And, the high operating cost of device even stoped it to become the possibility of viable means of the low-cost polymeric material of coating.
The powder feeder is multiple structure, and still, basic function is to transport to be pulverous material.These structures are: have fluid bed that Venturi tube transports, have mechanical screws that Venturi tube transports, have gravity feed that Venturi tube transports, have the meter wheel that Venturi tube transports.Needing the powder feeder will be pulverous material is transported to the various device from the material source that comes with described equipment branch.This equipment can be hot spray apparatus, electrostatic powder paint gun, extrusion screw and injection-molded equipment.In all situations, necessary is to transport accurate measurement and feeder that do not have the material of pulsation.This is especially necessary for hot spray powder burner and electrostatic gun.
Current fluid bed venturi powder feeder technical deficiency is to use in hot spray apparatus and electrostatic powder paint gun.In electrostatic gun and thermal spraying apparatus, the nozzle place produces vacuum and measures the needed pressure of raw material (spray rate), speed and mobile in order to raw material be transported to needed pressure in the substrate, speed and flow to be different from.At present used equipment all uses identical pressure, speed and the source of flowing for metering and delivery functions.This can produce harm to two independent functions.Mechanical screws/Venturi tube and meter wheel Venturi tube separate these two kinds of functions, but they can suffer restraints, wear and tear and come from the influence of the pulsation of staggered feed in wheel or the screw rod.
Powder spray coating device is transported to polymer/powder material spray in the substrate through electrostatic gun.This spray gun is applied to electric charge on the raw material, and raw material is in the electric charge different with the substrate of want coating.Coated parts are placed in the stove, thus the polymeric material that fusing and curing electricity adhere to.In second embodiment of this technology, substrate that will coating is placed in the stove, and is heated on the fusing point of the polymeric material that will apply.Then, the parts that heat are immersed in the fluid bed of raw polymer powder,, and be deposited in the substrate thus with the contacted material fusing of heater block.
For using, these two embodiment are restricted.They require high-energy to become original operation stove.Because they are permanent plants of factory, thereby they can not on-the-spotly use.Can coated parts be subjected to the restriction of the size of available stove.In the example of electrostatic apparatus, because can influence electric charge, some combination of metal and/or conducting polymer may be left out.
As mentioned above, attempted using existing plasma spray technology to apply and be pulverous thermal spraying polymeric material, and obtained very limited achievement.In addition, produced the equipment that is exclusively used in application of polymer powder materials.The thermal source of these equipment is oxygen-fuel gas or propane air Mixture.Their effect is similar to common hot spray powder burning rifle.Yet they are better than higher temperature thermal spray combustion powder apparatus for metal and ceramic material design a little to the temperature requirement of polymeric material.
There is restriction in the effect of these equipment.The requirement that they are not handled the particle speed of reply in the heating agent and flow and the standalone feature of consistent with the thermal output of spray gun desired pressure of the spray rate of surveying and flow is provided.Or they are for used material and thermal output provide spray rate accurately, speed perhaps is provided accurately and flows to realize the suitable time of staying, perhaps both are traded off.And all previous embodiment of these equipment use siphon plug gas mixer.In the example of propane air Mixture thermal source, the stoichiometric function of flame is not separated with the accurate speed and the flow air of the material that is used to supply raw materials.When extra air be imported in the flame, when advancing particle, the temperature of flame raises along with the suitable mixing of propane and oxygen.In the embodiment of these all previously knowns of equipment, because before flame contact polymer feedstock material, they can not tackle the requirement of cooling flame, so the temperature of flame is too high.When polymer feedstock material contacted with flame, this high temperature caused this polymer feedstock material burning or has become additional fuels sources.This bright orange flame that is produced when being imported in the heating agent when polymeric material demonstrates.This burning of raw material causes deposition to reduce below 50%.In addition, it has stoped use static grade (5 to 160 microns scopes) material, and these materials can provide more even smooth coating.This has limited the equipment of fluid bed material usually, and this material and transports more coarse coating in 80 to 200 microns scope.Because the temperature of existing equipment is too high, they can not deal with the needs for compressional wave, thereby have influence on the effective transmission of the thermal source of reduction temperature to the polymeric material raw material.Previous embodiment depended on before the coat polymers raw material substrate is preheating to 400 , to obtain available deposited coatings.Up to now, all technology all can not be handled the importance that cooling air or compression jets are aimed at the orifice gas jet.At last, the equipment of previously known is restricted aspect the scope of spray parameters and control.
Although known various device still has the significant need to improving equipment.These improvement comprise: control the thermal source media better; Be used for improved material delivery that the material velocity of thermal source and mobile function and material metering (spray rate) function are separated; Remove siphon plug mixing arrangement; Can before the contact polymer feedstock material, cool off flame temperature; Produce compressional wave, be delivered on the polymer feedstock material so that effectively will reduce the thermal source of temperature; To the needs that the mixing air of cooling is aimed at the nozzle flame jet; To the needs that the compressional wave jet is aimed at the nozzle flame jet; Can spray the static grade material (5 to 160 microns) of less micron, so that improve coating uniformity and smoothness; Can be under the situation that needs or do not need the preheating substrate hardly the coat polymers coating; Can the coat polymers material, its source of acting as a fuel is not consumed simultaneously; Can obtain deposition near 100% polymer coating; When being coated with application layer,, can not destroy the quality of coated polymer coating or reduction coating by means of hot spray apparatus; And can have spray parameters in a big way and can control these parameters.
Summary of the invention
The present invention relates to a kind of novel device that is used for hot applied plastic and powder sprayed coating, and be specifically related to a kind of being used for the polymer coating material is coated to suprabasil portable thermic lance.Material is powder or wire, and thermoplasticity and the thermosetting polymeric powder coating that all are known, i.e. epoxy resin, urethane, nylon, polyester, polyethylene, polypropylene, polyethers, acrylic resin, vinyl, PVC, fluorocarbon polymer, silicones and included mixtures of material and multiple composition have roughly been comprised.Generally speaking, all polymeric materials Powdered, between 5 microns to 500 microns in the scope all can use in said apparatus.And, be drawn as linear or can be drawn as all linear polymeric materials and all can in said apparatus, use.The material that is powder or wire can comprise other organic polymer material or inorganic mineral or metal material, is pulverous metal such as pottery, silica, graphite, carbon and all.Metal material can be following form: copper, brass, bronze, tungsten and chromium carbide, stainless steel, aluminium, zinc, zinc/aluminium, iron and all one pack system metals and can be used for the synthetic of common thermal spraying industry.Bactericide, anti-fouling agent and lubriation material also can be included in the plastics polymer matrix.
Description of drawings
Each embodiment is described with reference to the accompanying drawings, in the accompanying drawings:
Fig. 1 and 2 is the skeleton diagram of system of the present invention;
Fig. 3 is the skeleton diagram that adopts the powder feed system of double venturi;
Fig. 4 is the sectional view that lance driving device of the present invention is shown;
Fig. 5 is the sectional view that gun body is shown;
Fig. 6 is the side view that gun body is shown;
Fig. 7 is the plan cross-sectional view that the fuel and the oxygen channel of gun body are shown;
Fig. 8 is the plan cross-sectional view that the air duct of gun body is shown;
Fig. 9 A, 9B and 9C are respectively end-view, side view and the side sectional views of nozzle;
Figure 10 is the side sectional view of diffuser ring;
Figure 11 is the summary end-view of lance driving device;
Figure 12 A and 12B are respectively end-view and the side views that air distributor cap is shown; With
Figure 13 is the side sectional view that air cap body is shown.
The specific embodiment
The present invention has adopted eddy current fuel-oxygen mixer and other innovation, in order to a kind of portable flame thermal spray gun that has up to 100% coating material deposition efficiency to be provided.Its is simple and conveniently use at the scene, and has given the user bigger flexibility aspect solid smooth face coat or porous or the rough surface coating for example applying, and is used for any specific polymer coating material of any desired thickness.
The polymer and the powdery paints paint finishing of heat coating comprise spray gun, and unique embodiment comprises novel and unique powder feeder and is subjected to adjusting and controlled supply air, oxygen and propane.The polymeric material that applies is placed in the powder feeder, thereby the feed rate of material is controlled by the feed rate Venturi tube, and this polymeric material is directed to the material delivery Venturi tube in feeder, thereby the raw material that will apply is directed to spray gun, in spray gun, this polymeric material is melted, and is advanced in the substrate, so that coating.The control of powder feeder is depended on the pressure of being regulated of fluidisation chamber, material feed rate Venturi tube and material delivery Venturi tube and is flowed.Spray gun is subjected to supply from the powder feeder control of next material rate, and is subjected to the independently travelling speed of material rate and the control of flowing.In addition, spray gun has pressure and controlled oxygen and the propane source of supply that flow, as combustion heat source.The pressure and the controlled air supplies that flows are directed in unique jet of spray tip, and described unique jet has played the effect that the effect of heavy curtain (curtain) is provided and has played cooling combustion flame between the raw material polymer of cold melt and combustion flame.Identical air is directed in the compression jets, and this compression jets is aimed at the nozzle air jet, makes the combustion flame that will cool off impact on the raw material.These jets have formed compressional wave.The compressional wave that is produced in this technology allows heating agent promptly is delivered on the thermo-plastic polymer material that will melt.This compressional wave and pressure cooker are similar.But it is a system open rather than sealing.This compressional wave is concentrated in around the axle that is formed by polymer wire rod or powder, and has the momentum forward away from chamber.This system allows rapid melt raw material material, and can not burn trickle material or reduce the quality of these materials.
This equipment comprises two eddy current, this pair eddy current by on same point, but injection of oxygen and propane are propagated in opposite direction, thereby in the first order chamber that forms by diffusion ring body and gun body, oxygen and propane are pre-mixed, and the eddy current that is rich in oxygen moves in the counterclockwise direction, and the eddy current that is rich in propane moves along clockwise direction.Rightabout along 180 degree moves this pair eddy current from spray site, and enters in the relative mouth.After entering these mouthfuls, the eddy current that is rich in oxygen is directed to so that intersect with the eddy current that is rich in propane, and finishes mixing of combustion gases in the second level chamber that is formed by diffusion ring body and jet stem.Then, the annular gap of the burning gases that mix by forming by jet stem and diffuser ring, thus entered in the chamber that surface, jet stem and gun body by the back of nozzle body, diffuser ring form.Then, gas leaves nozzle through the orifice gas outlet, thus propagating burning flame.This gas mixed method is new, novel and uniqueness.Go for processing is simple, easy, and removed the siphon plug assembly of the complexity seen in all other combustion heat spraying equipments.Owing to have dual cavity and two eddy current, thereby it has alleviated tempering, and this is because for keeping burning, in eddy current and especially when speed increases, gas, makes in the situation of delivery rate greater than burn rate to second chamber from the first chamber through port, is difficult to occur tempering.Therefore this method is safe in essence.
This equipment comprises alignment pin, and this alignment pin allows compression jets to aim at flame jet and flame cooling jet air-spray.In one embodiment, the compression jets in the air cap body is aimed at the flame cooling blast in the nozzle along the radius of lid air cap body, and the radius in the nozzle.These burning gases that allow to be cooled impact and the compression raw material.In another embodiment of this equipment, compression jets is aimed at along the radius that is formed by flame jet in the nozzle and the compression jets in the air distributor cap.This embodiment allows the hot gas of higher temperature to impact on raw material, but at all in other the mode, for the content of just having described in the above, similar on operation and the function.Compression jets in the air distributor cap is by means of embedding alignment pin in the gun body with respect to nozzle flame jet or cooling jet air-spray orientation, and pass the diffusion part, enter nozzle body, thus nozzle fix in position, simultaneously directed and fixedly cooling blast and flame jet with respect to gun body.Second alignment pin is arranged in gun body, and it aims at air distributor cap.This air distributor cap preferably has the hole of two alignings, these two holes allow the compression jets orientation that will aim at cooling air-spray in the nozzle or the flame jet in the nozzle.There is not known hot spray apparatus to comprise this alignment characteristics.This feature is unique and novel.It is highly important that and guarantee that the parameter of setting does not change along with any aligning of spray gun assembly.And, there is not known powder combustion thermal spray apparatus to use the compressional wave jet to realize heat is delivered on the powder feedstock material rapidly.Equipment of the present invention is heat of compression flame gas not only, but also the cooling air-spray is provided, and this cooling air-spray has played the effect of the heavy curtain between thermal-flame and the low-melting polymer coating material.
This equipment comprises new, unique and novel flame cooling jet air-spray.These jets are in the centre position between the continuous subsequently flame jet in nozzle, and with one heart than the more close outlet that is used for material feedstock of flame jet.This being arranged between flame jet and the coating material provides air curtain, makes coating material directly not contact with the high-temperature combustion gas of flame jet.Present embodiment make from the hot gas of flame jet be cooled before material feedstock contacts.There is not known thermal spraying apparatus to comprise this feature.
The air draught that independent control is used for the oxygen flow of oxidized fuel gas and is used for the nozzle cooling has avoided having the shortcoming of oxidation and material cooled all being used single air flow source.That is to say that if fuel gas oxidation is all used identical air-flow with coating material, the air mass flow that then abundant increase is used to cool off has been extinguished fuel gas flame so that cooling may cause the stoichiometry of air too much.And on the other hand, air mass flow is remained on to cause in the flammable restriction of air/fuel ratio and fully do not cool off coating material.This can cause low melting point polymer overheated and burn again, thereby stops them to use as coating material.Equipment of the present invention and system have avoided this problem.
By means of the material outlet of nozzle, this equipment provides at the anterior independent control of spray gun raw material and has entered the speed in the thermal source and flow.For all powder thermospraying equipment, in particular for the thermal spraying apparatus of low-melting flammable polymer feedstock material, this independent delivery is necessary.It is flammable that polymer feedstock material is Powdered.When they contacted with flame, they can be used as extra fuels sources.At least for this reason, for desired feed rate, Gong Ying speed must be greater than the burn rate of raw material at least.Yet the time of staying of coating material in the heating tape must be enough so that be delivered to heating agent on the raw material, so that all particles are suitably melted.There is not known existing thermal spraying apparatus to have this independently necessary function.All existing powder combustion thermal spray devices are used identical speed and are flowed and set up spray rate, and its front portion that is delivered to spray gun is entered in the heating agent.Needed spray rate and needed speed and the time of staying are two inconsistent functions, and they must be separated.By means of new, unique and novel powder feeder, our embodiment has had this feature.
As mentioned above, this equipment comprises new, unique and novel powder feeder.This fluidized bed powder feeder allows material feed rate and the function that enters the material velocity in the heating agent and flow are separated.This realizes by means of the unique combination with two Venturi tube generators (opposite with).First is a material feed rate Venturi tube, the speed when it is adjusted to control raw material is transported to second Venturi tube in open wide connecting.Should open wide connect and make second Venturi tube vacuumize and provide to be independent of the desired speed of first Venturi tube and flowing of flowing.When not requiring that material flows, second Venturi tube continues to work.This continuous speed and flow with for the raw material that will spray in the anterior place of spray gun need transport with the time of staying and be complementary.This continuous speed has guaranteed that with flowing material feeding flexible pipe can be at the bending place of this flexible pipe aggregate material material powder, and gathering can cause back pressure and fluctuation.When the needs material, first Venturi tube is powder sucking-off from powder feeder hopper, and injects desired amount in the vacuum port of second Venturi tube.Flowing and speed low than second Venturi tube always of first Venturi tube.In material feeding flexible pipe, have no chance to produce back pressure.Not fluctuation, and point-device pulse free material stream is transported in the heating agent.All other existing fluid bed venturi powder feeder equipment depend on raw material that a Venturi tube will measure speed and are transported to hot spray apparatus, electrostatic powder paint gun, injection molding machine, extruder or bulk materials and handle and transport.Thereby, transport the speed of air or gaseous mediums and the speed of the material depend on expectation of flowing when being transported in the concrete equipment.The notion of single Venturi tube has the inconsistent problem of pulsation, fluctuation, obstruction and speed of transporting of desired material.Such reason is: with the material sucking-off and when injecting in the material feedstock delivery flexible pipe, occur material in the flexible pipe and assemble, cause back pressure, stoped air to flow in the Venturi tube and reduced vacuum.Material in the flexible pipe must flow out from the flow that reduces before rebuliding vacuum and transporting new material.This repetition that circulates, and much more very flow of material always from change to considerably less or do not have.
Although they self are new, uniqueness and novel for above-mentioned features, but they provide really the equipment of coat polymers and powder coating raw material effectively a cooperative relationship that works, deposition near 100%, and can not reduce raw material, coated coating or the quality of substrate.
Referring now to Fig. 1, shown a kind of coating application system 10, it uses thermic lance of the present invention to apply coating material.This coating application system 10 comprises portable thermic lance 100, and this spray gun 100 is connected with source of supply A, fuel gas F (as methane, ethane, propane, butane, acetylene etc.), the source of supply O of oxygen and the source of supply CM of coating material of compressed air stream.Spray gun 100 preferably includes handle 110, so that convenient manually use.As used herein, term " oxygen " comprises pure oxygen and has at least oxygen-containing gas mixture with the as many oxygen composition of air.It is Powdered that coating material is, these particles of powder sizes preferably from about 5 microns in about 500 microns scope.When system is in when operation, the coating material powder is by the air fluidisation, and air and coating material particle all be supplied in the thermic lance 100, so that coating 12 is coated on the surface of substrate 14.
Coating material can be can melt and quality can significantly reduced any thermoplastic, polymeric materials.This class thermopolymer including, but not limited to: polyethylene (low-density and highdensity), polypropylene (low-density and highdensity), polyurethane (low-density and highdensity), nylon are (for example, nylon 6, nylon 11), the composition of nylon copolymer, EVA, EEA, ABS, PVC, PEEK, PVDF, PTFE (for example, Teflon ) and other fluorocarbon polymer, polycarbonate, acrylic acid, polyethers, polyester, epoxy resin, silicones and their chemistry and/or physics.Other component in the coating material as the metal of independent powder or coating powder (for example can comprise; zinc, aluminium, allumen, ferrous metal alloys, copper and copper alloy etc.), pottery, carbon, graphite or functional component; such as coloring agent, conductive material (for example, being used for electromagnetic shielding), fluorescer or phosphor material, anti-fouling agent, reflecting material, material obsorbing radar waves, UV protector, bactericide etc.
The substrate 14 that coating material will apply can be porous or be not porous materials (for example, steel, aluminium), timber, cork, glass, pottery, solid-state or foamed polymer material, contain paper material, asphalt material, gypsum, cement, concrete, stone or can admit any other material of coating.The various application that are used for hot-spraying coating comprise the spraying or the coating of following things: the various structures of the mark of bridge, ship, aircraft, ground moving vehicle, building, expressway or other type, road sign, marine environment, such as dock or harbour; With other suitable any operation of the paint application that contains the polymer coating material.
All supply inputs that A, F, O and CM use all have the device of independent control flow rate and/or pressure, so that allow the thermic lance operator to regulate.Coating material between the substrate surface of the thermic lance outlet and the coating of wanting the individual flow rate variations and/or the variation of flying distance can produce smooth face coat, perhaps coarse face coat, perhaps as expected, various physics coating feature.
Referring now to Fig. 2 and 3, the coating application system comprises dual venturi system, is used to control the feeding of coating material from coating material source of supply CM to thermic lance 100.More particularly, the air from compressed air source CA has been divided into independent controlled air current A, B, C and D.As mentioned above, air current A is directly connected to thermic lance 100.Air-flow B is in check fluidized bed air source of supply.Air-flow C is in check material feed rate air supplies.Air-flow D is in check material delivery air supplies.
Coating material source of supply CM comprises hopper 20, and in this hopper 20, the bed 23 of coating material particle is received and is supported on the fluid bed gripper shoe 22 of porous.The compressed air that comes from fluidized bed air supply air flow B is conducted through fluidized bed air feed line 24 and enters the plenum chamber under the gripper shoe 22.Compressed air rises by gripper shoe 22 and makes grain bed 23 fluidisations.
Be conducted through conduit 25 from the compressed air of air-flow C and enter first Venturi tube 26, and pass the axial passage 27 of this Venturi tube.The coating material particle of fluidisation 29 is inhaled in this passage 27 through entering the mouth, and is directed in second Venturi tube 30.Mouthfuls 21 in order to the pressure between balance hopper 20 inside and outside.Inlet 28 uses as material siphon port and/or air siphon port.
Compressed air from material delivery air stream D is directed in the air injection nozzle 31 of second Venturi tube 30.Be conducted through the axial passage 32 of second Venturi tube from the coating material particle of first Venturi tube discharge or by the air that siphon port 28 is extracted, and for example be sent to thermic lance 100 by flexible tube-shaped catheter, pipeline or other suitable device.
Use first and second controlled Venturi tubes separately that the control performance of good coating process is provided.And dual venturi system has overcome the problem relevant with single venturi system, and promptly speed is slow, material blocks and the pulsation operation do not expected, and is opposite with the smooth flow of material.Should be understood that the above-mentioned dual venturi system that is used for material delivery (Fig. 2 and 3) needing to can be used for the fluidized powder material controlled supply to any distributing equipment or be used for the material supply of any common purpose.And, although system described here is with the fluid of compressed air as motion, but in above-mentioned dual venturi system, what is suitable for any desired purpose according to, can use any Compressed Gas (for example, nitrogen, inert gas, oxygen, carbon dioxide etc.) such as helium or argon gas.
Referring now to Fig. 4 to 8, gun body 120 is an elongated member, is preferably made by aluminium alloy or any other suitable metal.Axial passage 122 is suitable for receiving the fluid stream of compressed air and coating granule and distally their discharge ends towards air gun 100 is guided.Oxygen Flow vertically and is distally carried by oxygen supply passage 121, and then passes oxygen delivery channel 125, and it is angled towards outlet 136 that this transports passage 125, with the axis X angulation α of gun body.Fuel gas F is longitudinally transported by fuel gas service duct 124 (Fig. 7), pass fuel gas delivery channel 127 then, this transport passage 127 export towards shared oxygen-fuel gas 136 angled, preferably also with the axis X angulation α of gun body.The scope of angle [alpha] more preferably from about 40 ° to 50 °, but when seeing fit, can adopt these extraneous angles preferably from about 30 ° to about 80 °.Because the angled orientation of oxygen delivery channel 125 and fuel gas delivery channel 127, thereby in following swirl gas mixing chamber 115 (Fig. 4), two eddy current have been formed.Oxygen flows along a circular direction, and fuel gas flows along opposite direction, thereby provides the rotation of oxygen and fuel gas to mix.Compressed air longitudinally and is distally carried by air feed passage 123, then by air delivery channel 126, this transports among the passage 126a and 126b (Fig. 8) that passage 126 branches into inclination subsequently, and these two passages end at the distal surface 137 of gun body.
The far-end of gun body 120 comprises nozzle carrier 128, and it is a groove, and the structure of this groove and size are configured to admit the proximal part of nozzle 150.Diffuser seat 133 is a groove, and its structure and size are configured to admit diffuser ring 140.The structure in hole 131 and size are configured to admit alignment pin 111, and when diffuser ring 140 and nozzle 150 were installed in their corresponding seats 133 and 128, this alignment pin 111 had kept the resting position of these assemblies.Threaded portion 135 is suitable for the connection that screws of air cap body 190.The distal portions of gun body 120 also comprises the installation surface 134 that the far-end of general cylindrical shape extends, and is used to install air distributor cap 170.
Referring now to Fig. 9 A, 9B and 9C, nozzle 150 comprises the general cylindrical shape body, and it has 151a of proximal stem portion and the 151b of distal end flange portion.The 151a of bar portion is suitable for being received within the nozzle carrier 128 of gun body.O shape is encircled 159a, 159b seat in corresponding circumferential recess 151e, and circumferentially extends at the periphery 151c of nozzle 150, thereby air seal and holder are provided.O shape ring 159c is positioned in around the proximal part of bar 151a.
Flange part 151b comprises a plurality of passages 155, and these passages 155 are along length direction (direction that promptly the is parallel to axle) orientation of nozzle, so that fuel gas and oxygen are from wherein passing through.Passage 155 comprises proximal part 155a, and it has the cross section of relative broad; With distal portions 155b, it has the cross section of relative narrower.
The passage 154 of flange part 151b is angled so that has radial component 154a and extension 154b along its length.The opening part of passage 154 on the periphery 151c of flange part 151b allows air to enter and at the distal surface 151d place of nozzle air is discharged.
The unique construction of nozzle 150 makes it possible to fully control flame, air and coating material and flows, and allows air curtain to come the protective finish material granule to make it to avoid quality decline under too much heat.More suitably, provide enough heats to melt particle, particle is ejected on the substrate surface then.
With reference to Fig. 9 A and 9B, can see, passage 155 and 154 remote outlet generally with alternately or interlace mode be arranged on around the distal surface 151d of nozzle, become corresponding circular concentric to arrange.Yet the outlet of air duct 154 is with one heart more near 152 1 distance D of coating material passage, thereby the high-temperature combustion gas that places oxygen-fuel gas flame and the air curtain between the coating material stream are provided.Therefore, coating material is heated fully, causes fusing, but do not burnt, perhaps reduce quality by the fuel flame jet.Distance D can be any distance that is suitable for any purpose described here, and generally can still when appropriate, can adopt this extraneous distance in about 0.1 millimeter to 5.0 millimeters scope.
Referring now to Figure 10, diffusion part 140 comprises annular solid 141, the axially open 142 that its 151a of bar portion with confession nozzle passes through.Circumferentially wall 141a and the right annular wall 141b of proximal end face define the swirl gas mixing chamber 115 that is used for mixed fuel gas and oxygen together at least in part.Mating holes 144 is suitable for admitting alignment pin 111, and this alignment pin 111 vertically is provided with by mating holes 144, then enters in the groove 153 as above-mentioned nozzle.Lateral opening 143 allows to enter the second eddy current mixing chamber 116 (Fig. 4) from the fuel oxygen mixture of swirl gas mixing chamber 115, and this second eddy current mixing chamber 116 is limited by the distal face of the diffuser ring near-end opposed face 156 (Fig. 9 B, 9C) to annular surface 146 (Figure 10) and the 151b of nozzle flange portion at least in part.As mentioned above, two eddy current mixing that equipment of the present invention provided have prevented tempering, and the steady operation of spray gun and other benefit are provided.
Referring now to Figure 11, the end-view of summary shows flowing from oxygen supply passage 121 and fuel gas service duct 124, leave shared outlet 136 and the first swirl gas mixing chamber 115 that flows through, then by the lateral opening 143 in the diffusion part 140, and enter in the second swirl gas mixing chamber 116, enter and flow through the fuel oxygen channel 155 of nozzle 150 from this second swirl gas mixing chamber 116.
Referring now to Figure 12 A and 12B, air distributor cap 170 comprises annular solid 171 and axial passage 172.Alignment pin 112 (Fig. 4) is received in the groove 173 of air distributor cap 170 (Figure 12 B), aiming at air distributor cap and gun body 120, and air distributor cap is fixed on the gun body 120.Air distributor cap comprises a plurality of radial port 174, in order to the guiding air from the first annular air flow chamber 117 (Fig. 4,11) to the second annular air flow chamber 118 (Fig. 4), air is directed into and hole 154 by nozzle from this second annular air flow chamber 118.Air enters first air flow chamber 117 by air delivery channel 126a and 126b (Figure 11).Fumarole 175 is inwardly angled, and compressed air from wherein by and when being launched into flame, compressional wave is provided.
With reference to Figure 13, air cap body 190 comprises the parts 191 of general toroidal, and it has axial passage 192.The inner surface 193 of this air cap body 190 comprises threaded portion 195, is used for screwing with the threaded portion 135 (Fig. 6,7) of gun body.The first annular air flow chamber 117 is limited by the inner surface 193 of this air cap body and the outer surface 176 of air distributor cap 170 (Figure 12 B) at least in part.
In operation, coating material passes the flame of oxygen-fuel gas at the outlet side of spray gun, and in flame, coating material is fused into molten drop.Flame is jet flames, and it is by means of being formed by the compressional wave that compressed air provided that guides at angle in the equipment axis alignment.The air stream of discharging by nozzle provides a heat " buffering ", is crossing heat effect decline low quality to prevent coating material particle.Control fuel supply source F, oxygen supply source O, compressed air A respectively and be used for first and second Venturi tube 26 and 30 of coating material source of supply CM, make the user can control spraying coating process primely.Can use multiple coating material, and efficient and coating quality excellence.
Although foregoing description has comprised a lot of details, these details should not be considered to qualification of the present invention, but only as the example of the preferred embodiment of the present invention.In the scope of the present invention and main idea that limit as claims, those skilled in the art will understand much other
Embodiment.
Claims (26)
1. thermal spray system comprises:
(a) spray gun applicator, it provides and has been used for the coating material injection is penetrated in substrate by the temperature band of the reduction in flame district, and this spray gun applicator comprises:
Gun body, it has for the axial pipe of coating material from wherein passing through, and this gun body comprises fuel gas feed line, oxygen supply conduit and air-pressure duct; With
Be installed in the assembly on this gun body distal portions, this assembly comprises nozzle, and this nozzle has a plurality of first passages, is used for oxygen-fuel gas mixture stream is ejected into the flame district at far-end, so that high-temperature combustion gas to be provided; And have a plurality of second channels, be used for compressed air stream distally is sprayed onto the flame district, so that the temperature band of reduction to be provided, this assembly also comprises air distributor cap, this air distributor cap has a plurality of mouthfuls, be used for Compressed Gas distally being discharged, so that compressional wave to be provided, so that coating material is melted rapidly towards the inside angled direction of the axis of this gun body and towards the flame district; With
(b) be used for coating material is fed to the device of described spray gun applicator.
2. thermal spray system as claimed in claim 1, wherein, described assembly also comprises first annular compartment, is used for spiral vortex type mixed fuel gas and oxygen; With second annular compartment, be used for the spiral vortex type mixing and flow through next fuel gas and oxygen from this first annular compartment.
3. thermal spray system as claimed in claim 1, wherein, described nozzle has for axial passage, proximal stem portion and the distal end flange portion of coating material from wherein passing through, this flange part comprises described a plurality of first and second passages of arranging in an alternating manner, described first passage longitudinal extension is by described flange part, and described second channel has some radial directed parts and portrait orientation part respectively, and wherein this radial directed is partly with the some inlet openings on the periphery that is arranged on this flange part.
4. thermic lance paint finishing as claimed in claim 3, wherein, described first passage has the respective distal end outlet of arranging the distal surface place that is arranged on described nozzle with circular, and the portrait orientation of described second channel partly ends at the respective distal end outlet of arranging the distal surface place be arranged on described nozzle with circular, and the circular arrangement of the outlet of this second channel is concentric and less than the circular arrangement of the outlet of this first passage with the circular arrangement of the outlet of described first passage.
5. thermal spray system as claimed in claim 1, wherein, the device that is used to supply coating material comprises:
The fluid bed of coating material particle;
First venturi apparatus is used for coating material particle stream is transported to compressed air from this fluid bed;
Second venturi apparatus is used to receive the coating material particle stream from this first venturi apparatus, and this coating material particle stream is transported in the described spray gun applicator,
Wherein, each in described first and second venturi apparatuses is all independently controlled by compressed air independent air-flow separately.
6. thermal spray system as claimed in claim 5, wherein, described coating material comprises thermoplasticity or thermoset copolymer material.
7. thermal spray system as claimed in claim 6, wherein, described polymeric material is selected from the group that is made of following material: epoxy resin, polyurethane, nylon, polyester, polycarbonate, polyethylene, polypropylene, acrylic polymer, polyvinyl chloride resin, fluorocarbon polymer, EVA, PEEK, PVDF, silicones and composition their chemistry or physics.
8. thermal spray system as claimed in claim 5, wherein, described coating material comprises zinc, aluminium, allumen, ferrous metal alloys, copper, copper alloy or pottery.
9. thermal spray system as claimed in claim 5, wherein, described coating material comprises colouring agent, conductive material, fluorescent material, phosphor material, anti-fouling agent, reflecting material, radar absorbing material or UV protector.
10. thermal spray system as claimed in claim 5, wherein, the granular size of described coating material from about 5 microns in about 500 microns scope.
11. thermal spray system as claimed in claim 1, wherein, described coating material is the form of wire rod.
12. thermal spray system as claimed in claim 1, wherein, described spray gun applicator is portable, and comprises handle.
12. a thermic lance applicator comprises:
Gun body, it has for the axial pipe of coating material from wherein passing through, and this gun body comprises fuel gas feed line, oxygen supply conduit and air-pressure duct; With
Be installed in the assembly on this gun body distal portions, this assembly comprises nozzle, and this nozzle has a plurality of first passages, is used for oxygen-fuel gas mixed flow distally is ejected into the flame district, so that the gas of high-temp combustion to be provided; And have a plurality of second channels, and be used for compressed air stream distally is sprayed onto the flame district, so that the temperature band of reduction to be provided, wherein, this assembly also comprises first annular compartment, is used for spiral vortex type mixed fuel gas and oxygen; With second annular compartment, be used for the spiral vortex type mixing and flow through next fuel gas and oxygen from this first annular compartment.
13. thermic lance applicator as claimed in claim 12, wherein, described assembly also comprises air distributor cap, and this air distributor cap has a plurality of mouthfuls, be used for Compressed Gas distally being discharged, in order to compressional wave to be provided towards the inside angled direction of the axis of this gun body and towards the flame district.
14. a method that is used for the coating material coated substrates, this method comprises:
(a) provide the flame district of hot combustion gas;
(b) compressed air is sprayed onto in this flame district, so that the temperature band of reduction to be provided;
(c) compressed air is introduced this flame district with an angle, so that compressional wave to be provided;
(d), and be injected in the described substrate with the temperature band of coating material injection by described reduction.
15. method as claimed in claim 14, wherein, described substrate is metal, timber, cork, glass, pottery, polymer, contains paper material or asphalt material.
16. method as claimed in claim 14, wherein, described coating material contains polymer resin.
17. method as claimed in claim 16, wherein, described coating material is a granular materials, the size of this granular materials from about 5 microns in about 500 microns scope.
18. method as claimed in claim 15 wherein, provides the described step in flame district to comprise that burning is imported into the oxygen-fuel gas mixture in flame district as air ring.
19. method as claimed in claim 18, wherein, the step that compressed air is sprayed onto in the flame district with temperature band that reduction is provided comprises: ejection compressed air stream ring, this compressed air stream ring is concentric with described oxygen-fuel gas stream ring, still places between hot combustion gas and the coating material.
20. a device that is used for the supplying powder material, it comprises:
Be contained in the fluid bed of the dusty material particle in the housing;
First Venturi tube is used for the dusty material grain flow is transported to compressed air from this fluid bed;
Second Venturi tube is used to receive the dusty material grain flow from this first venturi apparatus, and sprays this dusty material grain flow,
Wherein, each in described first and second Venturi tubes is all independently controlled by compressed air independent air-flow separately.
21. device as claimed in claim 20, wherein, described dusty material comprises thermoplasticity or thermoset copolymer material.
22. device as claimed in claim 21, wherein, described polymeric material is selected from the group that is made of following material: epoxy resin, polyurethane, nylon, polyester, polycarbonate, polyethylene, polypropylene, acrylic polymer, polyvinyl chloride resin, fluorocarbon polymer, EVA, EAA, ABS, PEEK, PVDF, silicones and composition their chemistry or physics.
23. device as claimed in claim 20, described coating material comprises zinc, aluminium, allumen, ferrous metal alloys, copper, copper alloy, pottery, carbon or graphite.
24. device as claimed in claim 20, wherein, described dusty material comprises colouring agent, conductive material, fluorescent material, phosphor material, anti-fouling agent, reflecting material, radar absorbing material, bactericide or UV protector.
25. device as claimed in claim 20, wherein, the size of described dusty material particle from about 5 microns in about 500 microns scope.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US50994803P | 2003-10-09 | 2003-10-09 | |
| US60/509,948 | 2003-10-09 | ||
| US10/909,115 | 2004-07-30 |
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| CN1867409A true CN1867409A (en) | 2006-11-22 |
| CN100434190C CN100434190C (en) | 2008-11-19 |
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| Application Number | Title | Priority Date | Filing Date |
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| CNB2004800296344A Expired - Fee Related CN100434190C (en) | 2003-10-09 | 2004-09-27 | Apparatus for themal spray coating |
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| CN102869814A (en) * | 2010-05-11 | 2013-01-09 | 苏舍美特科（美国）公司 | Metal matrix ceramic wire manufacturing technology and usage |
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