POWDER SPRAY GUN WITH ROTARY DISTRIBUTOR

Abstract: A powder spray gun includes a rotary distributor (39) which is capable of operating at slower speeds than liquid spray gun to reduce the problem of powder fusing, increases bearing life, reduces wear on moving parts. The powder spray gun has a powder flow path which extends through a gun body to a powder outlet. A drive mechanism in the form of a pneumatic motor (22) is located within the housing and connected to the distributor to rotate the distributor. The powder thus enters a passageway in the rotating spindle before it passes into the rotating distributor. A non-rotating flow tube (49) through which powder flows into the passageway in the spindle, with a gap (51) being formed between the non-rotating flow tube and the rotatable spindle. The gap communicates with the chamber whereby pressurized air from a pressurized air chamber escapes through the gap to provide a rotary seal between the tube and the spindle.

Description: POWDER SPRAY GUN WITH ROTARY DISTRIBUTOR BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to electrostatic powder spray guns, and more particularly to a gun having a rotating member at the powder outlet for distributing the powder in a uniform spray pattern. 2. Description of the Prior Art In electrostatic powder painting, dry paint particles are fluidized in a powder hopper and pumped through a hose to one or more spray guns which spray the powder onto a product to be coated. The spray guns impart a charge to the powder particles, typically with a high voltage charging electrode. When the powder particles are sprayed from the front of the gun, they are electro- statically attracted to the product to be painted which is generally electrically grounded and which may be suspended from an overhead conveyer or otherwise carried in a spray booth. Once these charged powder particles are deposited onto the product, they adhere there by electrostatic attraction until they are conveyed into an oven where they are melted to flow together to form a continuous coating on the product. Powder coating generally provides a tough and durable finish such as would be found on many appliances, garden furniture, lawn mowers, and other products. It is believed that powder spray guns with rotating distributors at the powder outlet provide improved spray patterns and other benefits. The designs of many powder spray guns of this type have been based upon similar liquid spray guns that have rotating atomizers at the fluid outlet. Examples of liquid spray guns of this type are shown in U.S. Patents Nos. 4,887,770 and 5,346, 139. The rotating distributors in liquid spray guns rotate at very high speeds, with a typical speed of such spray guns being around 20.000-50,000 rpm. These high speeds are necessary because the distributors must atomize the liquid coating material, and the atomization is best achieved at these speeds. The guns are not generally designed to be capable of slower speeds, because slower speeds would not effectively atomize the liquid and because the rotary distributors are driven by air turbine motors which cannot operate effectively at slower speeds. An example of a powder spray gun haying design similar to one of these liquid spray guns is shown in U.S. Patent No. 5,353,995, in which a powder spray gun has a rotating distributor or deflector at the powder outlet and in which the distributor is turned by means of a turbine located in the gun. The adoption of the designs of liquid spray guns having rotary distributors to the design of powder spray guns having rotary distributors results in several problems. One of these problems involves the use of the high-speed air turbine motor as the distributor driver. If the distributor in a powder spray gun rotates at speeds as high as 30,000-50,000 rpm, the power particles will acquire a kinetic energy which will mm to heat as the powder panicles hit the distributor, causing the powder to fuse onto the rotating distributor. The problem of powder fusing has become more acute as new powders have been developed which are finer in size and which are susceptible to fusing more easily. Some recently developed powders are more prone to building up on the rotary distributor due to impact fusion. These newer powders are also more likely to build up elsewhere in the powder flow path. The distributor for a powder spray gun should rotate at a lower speed than that usually required for a liquid spray gun in order to reduce the problem of impact fusion. Another problem involves the inherent tendency of powder to build up along the powder flow path. Unlike liquids, powder tends to accumulate at various locations in the flow path, and such powder accumulations can have various adverse effects. The built-up powder can eventually break loose and become deposited on the part being coated. Powder can also accumulate in areas around the bearings of the rotating components, which can cause excessive wear on the components and impede the free rotation of the components. Further problems arise where rotating members engage stationary members along the powder flow path, since a rotary seal is required at this point of engagement to prevent powder from entering between the rotating and stationary members. Conventional seals, such as lip seals or O-rings, are unsatisfactory because of the friction created between the rotating members and the stationary members. Powder in this area combined with the friction accelerates wear, and the powder can fuse because of the kinetic energy of the friction. SUMMARY OF THE INVENTION The problems of the prior art are obviated by the present invention which provides a unique powder spray gun having a rotary distributor. The spray gun of this invention is capable of operating at slower speeds than prior art spray guns, and thus the problems associated with powder fusing are reduced or eliminated. In addition, by operating at slower speeds, the spray gun of the present invention increases bearing life and otherwise reduces wear on moving parts within the gun. The spray gun of the present invention provides a rotating distributor which rotates at speeds which are much slower than the speeds of the prior art spray guns. Turbines, such as those used in prior art spray guns, can operate effectively only as slow as about 2,500 rpm. At slower speeds they will not operate at a consistent or even speed, or may not operate at all. The present invention avoids the use of a turbine to turn the distributor, so that it can achieve much slower speeds effectively. Preferably, the distributor in the gun of the present invention can rotate evenly and consistently at speeds of from 0 to 2.500 rpm. To achieve these slower speeds, the gun of the present invention preferably uses a pneumatic or air motor or an electric motor. Other suitable motors can also be effectively used. As compared with the air turbines used in the prior art, an air motor or an electric motor is relatively inexpensive. In addition, an air motor or electric motor or other comparable motor can be easily replaced if it fails or becomes worn. Unlike the prior art designs which required the turbine to be mounted coaxially with the rotatable distributor, the motor used in the spray gun of the _ present invention is radially offset from the central axis of the gun, so that the central axis can be devoted to the powder flow path. By locating the drive means along an axis which is spaced from the central longimdinal axis of the spray gun, an unincumbered flow path is provided for the powder and a simplified gun design is achieved. The resulting clear, unimpeded path for the powder has no changes in powder flow direction, and no significant obstructions or impediments in the powder flow path on which powder could accumulate. The problem of powder accumulations in the gun is avoided by providing a pressurized chamber around a rotating spindle which has a central passageway forming part of the powder flow path. The chamber around the spindle is connected to a supply of pressurized air. and the chamber is pressurized slightly above the pressure of the fluidized powder flow through the gun. Air in the pressurized chamber can escape from the chamber around the spindle and around its associated bearings, and when the air escapes, it effectively sweeps powder from the periphery of the spindle, keeping the areas around the spindle and the bearings clean of powder. In addition, the air escapes through an annular gap formed between the stationary powder supply mbe and the rotating spindle, providing an effective rotary seal without the necessity of additional components. The rotary seal provided by this invention avoids the use of conventional seals, such as lip seals or O-rings, and avoids the problems of friction created between the rotating spindle and the stationary mbe which would otherwise accelerate wear and tend to cause increased powder fusing. The overall design of the spray gun of the present invention is thus simpler, relatively inexpensive to manufacture and maintain, and easier to operate. The parts are arranged in a modular design, making it easy to replace parts. These and other advantages are provided by the present invention of a powder spray gun which comprises a housing including a body. A powder flow path extends through the body to a powder outlet. The powder flow path is generally located along the central longitudinal axis of the bod}'. A rotatable powder distributor is located at the powder outlet. A drive mechanism is located within the housing along an axis radially spaced from the longitudinal axis of the body and is connected to the distributor the rotate the distributor. In accordance with another aspect of the present invention, a spindle is mounted for rotation within the body. The spindle has a passageway therethrough which forms a part of the powder flow path. The distributor communicates with the passageway and is attached for rotation with the spindle. The powder thus enters the passageway in the rotating spindle before it passes into the rotating distributor. In accordance with yet another aspect of the present invention, a chamber is formed within the body, the chamber is connected to an air supply to pressurize the chamber. A nonrotating flow mbe through which powder flows into the passageway in the spindle, with a gap being formed the nonrotating flow mbe and i the rotatable spindle. The gap communicates with the chamber whereby 2 pressurized air from the chamber escapes through the gap to provide a rotary seal 3 between the mbe and the spindle. 4 BRIEF DESCRIPTION OF THE DRAWINGS 5 FIG. 1 is a side sectional view of the spray gun of the present invention. 6 FIG. 2 is a detailed view of a portion of FIG. 1. 7 FIG. 3 is an end sectional view of the spray gun taken along line 3—3 of 8 FIG. 1. 9 FIG. 4 is an end elevational view of the spray gun taken along line 4—4 ιo of FIG. 1. i i FIG. 5 is a side sectional view of the spray gun similar to FIG. 2 showing 12 a different cross section taken along line 5—5 of FIG. 4. 13 FIG.6 is a side sectional view similar to a poπion of FIG. 1 but taken alone 14 a different sectional line showing other components in the rear end panel. 5 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 6 Referring more particularly to the drawings and initially to FIG. 1, there 7 is shown a powder spray gun 10 according to the present invention comprising a 8 housing including a body 11. The body 11 is formed of a nonconductive plastic 9 material and has a central chamber 12. The forward end of the chamber 12 is 0 enclosed by a front end cap 13 which is also formed of a nonconductive plastic 1 material and which is threadedly attached to the front of the body 11. A mbular 2 housing sleeve 14 having a hollow interior 15 is attached to the body 11 and extends rearwardly from the body. A rear body member 16 is mounted on the rear of the sleeve 14, and a rear end panel member 17 is removably mounted on the rear of the body member 16 by a pair of clamping assemblies 18. Instead of the clamping assemblies 18, the rear end panel member 17 can be mounted on the rear of the body member 16 by a threaded connection or by other means. A drive mechanism comprising a motor 22 is mounted in the body 11 and extends rearwardly from the body in the sleeve interior 15. The motor 22 is preferably a pneumatic or air motor, but may also be a small electric motor. Although any suitable air motor may be used, the preferred air motor is a model MMR0700N available from Micro Motors, Inc. The air motor 22 is connected to an air supply line 23 which extends through the sleeve interior 15 and is connected to a connection 24 at the rear end panel 17 (FIG. 4) A suitable regulated air supply is connected to the connection 24 to operate the air motor 22. The air motor 22 is also connected to an air exhaust line 25 which extends through the sleeve interior 15 and is connected to a connection 26 at the rear end panel 17. The air motor 22 has an output shaft 27, and the motor turns the shaft at a various speeds depending upon the pressure of the regulated air supply. A typical shaft rotational speed would be between 0 and 7,000 rpm. A gear 28, which is mounted on the shaft 27 engages another gear 29 which attached by means of screws 30 to a spindle 31 rotatably mounted in the chamber. The gears 28 and 29 produce a suitable gear reduction, e.g., 3 to 1 , which decreases the rotational speed of the spindle 31 and increases the torque produced by the air motor 22. The spindle 31 rotates within the chamber 12 in the body 11, and is supported on front and rear sleeve bearings 36 and 37. A bearing retainer 38, which is threadedly mounted on the front of the body 11 and which covers the chamber 12, is located between the front sleeve bearing 36 and the front end cap 13 and holds the front sleeve bearing 36 in place. A two-piece rotatable powder distributor or nozzle assembly 39 is mounted on the front end of the spindle 31. The nozzle assembly 39 comprises a inner nozzle member 40 and an outer nozzle member 41. The inner nozzle member 40 is threadedly connected to the front end of the spindle 31 to rotate with the spindle. The outer nozzle member 41 is spaced from the inner nozzle member 40 with a gap 42, 51 therebetween for the passage of powder, and the outer nozzle member is attached to the inner nozzle member 40 by means of a plurality of screws 43 (FIG. 5) which extend across the gap 42, 51, so that the outer nozzle member rotates with the inner nozzle member. If desired, vanes may be located within the gap on one of the nozzle members to achieve the desired spray pattern for the powder as the nozzle members rotate or to enhance the ability of the nozzle assembly 39 to deliver powder. The spindle 31 has a central interior passageway 48 through which powder flows. The interior passageway 48 communicates with the gap 42, 51 between the nozzle members 40 and 41, so that powder flowing through the passageway in the spindle 31 flows directly into the gap between the nozzle members. Powder enters the passageway 48 in the rotating spindle 31 from a nonrotating mbe 49 which extends into the rear of the spindle. The mbe 49 extends rearwardly from the spindle 31 through the center of the sleeve interior 15 and to the rear end panel 17 where it is connected to a powder supply hose 50. The supply hose 50 can be connected to a conventional powder supply system comprising a fluidized powder hopper, a pump and a control module. The forward end of the mbe 49 extends partially into the spindle passageway 48, and an annular gap 42, 51 is thus formed between the stationary mbe 49 and the rotating spindle 31. As the spindle 31 rotates within sleeve bearings 36 and 37, the powder which flows through the spindle could enter the bearings and impede the rotation of the spindle. To prevent powder from entering the bearings, positive air pressure is maintained within the chamber 12. The positive air pressure is achieved by connecting the chamber 12 to an air line 52 (FIG. 3) which extends through the sleeve interior 15 to a connection 53 (FIG. 4) on the rear end panel 17. Preferably, the air pressure in the chamber 12 is maintained at around 15-25 psi. Air can escape from the chamber 12 between the front sleeve bearing 36 and the spindle 31 and between the rear sleeve bearing 37 and the spindle. As the air escapes from the rear bearing 37, it is channeled through the annular opening ?, and eventually it enters the passageway 48 in the spindle and becomes part of the powder flow. The escape of air from the pressurized chamber 12 thus sweeps powder accumulations from the path through which the air flows, and the surfaces around the sleeve bearings 36 and 37 and the spindle 31 are thus maintained relatively free of powder. The flow of air through the annular opening ? also prevents powder from flowing from the powder flow path of the passageway 48 into areas around the spindle 31 and the bearings 36 and 37. This escape of air effectively creates an air seal at the annular gap 42, 51 which is formed where the stationary mbe 49 engages the rotating spindle 31. When a rotating member engages a stationary member, it is necessary to provide a rotary seal of some kind to prevent powder from leaking from the flow path, and the positive pressure in the chamber 12 and the escape of air from the chamber through the annular opening ? provides such a rotary seal between the stationary mbe 49 and the rotating spindle 31. In order to provide the capability of holding the spindle 31 in a fixed nonrotating position when attaching or removing the nozzle assembly 39, a spindle locking assembly 58 is provided in the body 11. The spindle locking assembly 58 comprises a locking member 59 (FIG. 2) capable of moving radially within a bore in the body 11. One end 60 of the locking member 59 extends from the exterior of the body 11 and the other end 61 is capable of projecting into one of several shallow holes 62 formed around the exterior of the spindle 31. The locking member 59 is urged radially outwardly by a spring 63 and is held inwardly by a conventional retaining clip 64. As the end 60 is locking member is depressed, the other end 61 of the locking member engages one of the holes 62 to hold the spindle 31 in place and prevent the spindle from rotating. As the end 60 is released from the retaining clip 64, the spring 63 pushes the locking member 59 radially outwardly to release the spindle 31. By using the spindle locking assembly 58 to hold the spindle 31 stationary and to prevent rotation of the spindle when attaching or removing the nozzle assembly 39, the present invention avoids the use of special tools which were necessary with prior art spray guns. Electrical power to charge the powder enters the gun through an electrical connection 69 located in the rear end panel 17. The connection' 69 is connected to a high-voltage multiplier 70 mounted in the sleeve interior 15 between the body 11 and the rear end panel 17. The multiplier 70 can be the same as or similar to those used in other electrostatic powder spray guns. The multiplier 70 is connected to a limiting resistor 71 located within the body 11, and the resistor 71 is connected to a conductive O-ring 72 located in a groove between the body 11 and the front end cap 13. A plurality of electrodes 73 are mounted in the front of the end cap 13 and extend from the front of the gun around the outer radial periphery of the nozzle assembly 39. Although any number of electrodes can be used, preferably two or three electrodes are used, with the electrodes equally spaced around the nozzle assembly. In the illustrated embodiment, two electrodes 73 are used, each 180° with respect to each other. The tip of each electrode 73 extends from the front surface of the end cap 13 and charges the powder as it exits from the gap 42, 51 formed in the nozzle assembly 39. By locating the electrodes 73 outside of the powder spray path, distinct mechanical advantages are achieved. The rotational speed of the spindle 31 is varied by changing the pressure of the air supply to the air motor 22. However, the same air pressure to the air motor 22 will not always produce the same spindle speed due to changes in powder flow rates and specific gravity of the powder, due to frictional drag of the powder which varies according to the powder flow rate. Therefore, it is usually necessary to measure directly the rotational speed of the spindle 31. Spindle speed is detected by a speed detector comprising a sensor 78 (FIG. 3) located within the sleeve interior 15. A pair of fiber optic lines 79 extend from the sensor 78 through a bore 80 in the body 11. The ends of the fiber optic lines 79 are aimed at the rotating gear 29. The gear 29 includes the pair of screws 30 which are of contrasting appearance with the gear. For example, if the gear 29 is made of a material which is dark in color or light absorbent, the screws 30 would be made of a light or bright or shiny material. One of the fiber optic lines 79 carries light to illuminate the screws 30 on the gear 29. The other of the lines 79 carries light reflected from the screws 30 back to the sensor 78. As the gear 29 rotates, light reflected by the screws 30 and carried to the sensor 78 by the fiber optic lines 79 is used to detect the presence of the screws 30 and thereby detect each rotation of the gear 29. The speed of rotation of the gear 29 matches the speed of rotation of the spindle 31, so the spindle speed is determined thereby by the sensor 78. The sensor 78 can be connected to a suitable output device or control device through an electrical connection 81 located on the rear end panel 17. The speed detector can be connected to the air supply to the air motor 22 in accordance with known techniques so that the speed of the spindle can be controlled. The rear end panel 17 may also be provided with two or more additional air connections 86 and 87. These connections 86 and 87 may be used for additional capabilities, such as, for air supplied to the portals on the front of the end cap 13 to shape the flow of powder existing from the nozzle assembly, or for air supplied to the electrodes 73 to cool or shape the air around the electrodes, or for air used to sweep accumulated powder. If it is desired to supply air to the electrodes 73, for example, another air hose 88 (FIG. 5) would be provided in the sleeve interior 15 and would be connected to an air passageway 89 extending through the body 11. A suitable vent or port (not shown) would then be provided in the front end cap 13 so that air could exit around the electrode 73. Various modifications can be made to the preferred form of the invention just described. For example, instead of a pneumatic motor or air driven motor, other suitable motors can be used which drive the spindle at variable speeds and which would reliably drive the spindle at speeds less than 2,500 rpm. An electric motor may be suitably used for this purpose. Other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art, all within the intended spirit and scope of the invention. While the invention has been shown and described with respect to particular embodiments thereof, these are for the purpose of illustration rather than limitation. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the an has been advanced by the invention.

Claims: CLAIMS What is claimed is: 1. A powder spray gun, which comprises: a housing including a bod)'; a powder flow path extending through the body to a powder outlet, the powder flow path generally located along the central longitudinal axis of the body; a rotatable powder distributor located at the powder outlet; and a drive mechanism located within the housing along an axis radially spaced from the longitudinal axis of the body and connected to the distributor the rotate the distributor. 2. A powder spray gun as in claim 1, wherein the drive mechanism is a motor is capable of evenly rotating the distributor at speeds less than 2,500 rpm. 3. A powder spray gun as in claim 1, comprising in addition a spindle connected for rotation with the distributor, the spindle having a central passageway forming a portion of the powder flow path, the powder flowing through the rotatable passageway before encountering the rotatable distributor. 4. A powder spray gun as in claim 3, comprising in addition a latching mechanism mounted in the body and capable of engaging the spindle to selectively prevent the spindle from rotating. 5. A powder spray gun as in claim 1, comprising in addition a plurality of discrete electrodes mounted to extend from the exterior of the housinε, the " electrodes located radially beyond the outer diameter of the distributor. 6. A powder spray gun as in claim 1, wherein the powder flow path is substantially straight through the body and without obstacles or spacer elements extending through the flow path. 7. A powder spray gun as in claim 1, wherein the body includes a chamber which is connected to a supply of pressurized air, and wherein air can escape from the pressurized chamber into the powder flow path. 8. A powder spray gun as in claim 7, comprising in addition a spindle mounted in the chamber and connected for rotation with the distributor, the spindle having a central passageway forming a portion of the powder flow path, wherein powder is swept from the periphery of the spindle by escape of pressurized air from the chamber into the flow path. 9. A powder spray gun as in claim 7, comprising in addition a spindle mounted in the chamber and connected for rotation with the distributor, the spindle having a central passageway forming a portion of the powder flow path, and a nonrotating flow mbe through which powder flows into the passageway, a gap being formed between the nonrotating flow mbe and the rotatable spindle, the gap communicating with the chamber whereby pressurized air from the chamber escapes through the gap to provide a rotary seal between the mbe and the spindle. 10. A powder spray gun as in claim 1, wherein the drive mechanism is a pneumatic motor. 11. A spray gun for spraying coating material, which comprises: a housing including a body; a spindle mounted for rotation within the body, the spindle having a passageway therethrough for the flow of coating material; a distributor communicating with the passageway and attached for rotation with the spindle, coating material flowing from the passageway into the distributor to be sprayed from the gun; and a drive mechanism located within the body and connected to rotate the spindle and the distributor. -16- 1 12. A spray gun as in claim 11, wherein spindle and the distributor 2 rotate about the central longimdinal axis of the body, and wherein the drive 3 mechanism is located along an axis radially spaced from the longimdinal axis of 4 the body. 1 13. A spray gun as in claim 11, comprising in addition a plurality of 2 discrete electrodes mounted to extend from the exterior of the housing, the 3 electrodes located radially beyond the outer diameter of the distributor. i 14. A spray gun as in claim 11, wherein the body includes a chamber 2 which is connected to a supply of pressurized air, and wherein air can escape from 3 the pressurized chamber into the passageway. 1 15. A spray gun as in claim 14, wherein coating material is swept from 2 the periphery of the spindle by escape of pressurized air from the chamber into 3 the passageway. i 16. A spray gun as in claim 14, including a nonrotating flow mbe through which coating material flows into the passageway, a gap being formed between the nonrotating flow mbe and the rotatable spindle, the gap communicat- ing with the chamber whereby pressurized air from the chamber escapes through the gap to provide a rotary seal between the mbe and the spindle. i 17. A spray gun as in claim 11, wherein the drive mechanism is a 2 pneumatic motor capable of evenly rotating the distributor at speeds less than 3 2,500 rpm. 1 18. A spray gun for coating material, which comprises: 2 a housing having a body; 3 a chamber within the body, the chamber connected to an air supply to 4 pressurize the chamber; 5 a spindle mounted for rotation within the chamber, the spindle having a 6 central passageway forming a portion of a powder flow path; 7 a nonrotating flow mbe through which powder flows into the passageway, 8 a gap being formed between the nonrotating flow mbe and the 9 rotatable spindle, the gap communicating with the chamber whereby 10 pressurized air from the chamber escapes through the gap to provide l i a rotary seal between the mbe and the spindle; 12 a distributor attached for rotation with the spindle and receiving powder 13 from the passageway to be sprayed from the gun; and 14 a drive mechanism located within the housing and connected to rotate the 15 spmdle and the distributor. 1 19. A spray gun as in claim 18, wherein spindle and the distributor 2 rotate about the central longimdinal axis of the body, and wherein the drive 3 mechanism is located along an axis radially spaced from the longimdinal axis of 4 the body. i 20. A spray gun as in claim 18, comprising in addition a plurality of discrete electrodes mounted to extend from the exterior of the housing, the electrodes located radially beyond the outer diameter of the distributor. 21. A spray gun as in claim 18, wherein the drive mechanism is a pneumatic motor capable of evenly rotating the distributor at speeds less than 2,500 rpm. 22. A spray gun for coating material, which comprises: a housing including a body; a flow path for the coating material extending through the body to an outlet; a rotatable distributor located at the outlet; a drive mechanism located within the housing and connected to the distributor the rotate the distributor; and a plurality of discrete electrodes mounted to extend from the exterior of the housing, the electrodes located radially beyond the outer diameter of the distributor. i 23. A spray gun as in claim 22, comprising in addition, an internal 2 electrical power supply located within the housing and connected to the electrodes. i 24. A spray gun as in claim 22, comprising in addition a conductive ring located within the housing around the flow path, the ring connecting the electrodes to a power supply.

Inventors: HOLLSTEIN THOMAS E, SHUTIC JEFFREY R, HOLLSTEIN, THOMAS, E., SHUTIC, JEFFREY, R.
Applicants: NORDSON CORP, NORDSON CORPORATION
Application year: 1996
Main classification: B05B5
IPC codes: B05B3, B05B5, B05B7