Abstract:
A Machine and method for producing the illusion of snow is disclosed and described. It produces said product in a manner such that is easier to manufacture, operate, and produce than is currently available.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This is a continuation-in-part of patent application Ser. No. 10/287,413 filed Nov. 4, 2002 now abandoned, which is a continuation-in-part of patent application Ser. No. 09/996,175 filed Nov. 20, 2001 now U.S. Pat. No. 6,474,091, which is a continuation-in-part of patent application Ser. No. 09/664,271 filed Sep. 18, 2000, now U.S. Pat. No. 6,321,559. 

   FIELD OF THE INVENTION 
   This invention relates to the production of illusionary snow. More particularly, a machine which capable of creating the illusion of snow for theatrical or special effect purposes without the use of refrigeration, and without causing the accumulation of any residual moisture in the area in which it is used and which has reduced operating noise 
   BACKGROUND OF THE INVENTION 
   The world of theater and special effects has prided itself on the ability to create illusions. The masters of this art are continually creating their magic for the entertainment of their patrons. One of the most challenging illusions is that of snow. This presents a distinct difficulty. Limitations based on temperature and accumulation of moisture have always plagued the special effects creators. 
   There are many commercially available machines for producing snow. Many of these liquid based snow machines have been able to produce artificial snowflakes. The flakes formed were tight groupings of bubbles that were moist and had a tendency to clump together. This caused difficulty in dissipation. Additionally, there were concerns regarding moisture buildup in the area in which the machine was used. The problems of slippery floors, surfaces, and staining from the product have not been overcome. In an attempt to overcome these problems, people have attempted the use of fans in order to more widely distribute the artificial snow produced by these earlier machines. However, the flakes tend to form agglomerates which are not substantially effected by the auxiliary fans. These auxiliary fans do not overcome the physical difficulty of moisture buildup or the danger, which it presents. 
   The current invention overcomes these deficiencies. It provides for the creation of illusionary snow by an apparatus that utilizes a solution, which is commercially available as FG-100 Evaporative Snow (manufactured by Snow Masters, Plantation Fla.) drawn into a turbulent carrier wave of air at the same point at which the flakes are produced. The preciseness of placement of the carrier wave prevents tight clumps from forming, and causes greater separation between the flakes. Once the individualized flakes are carried from the machine, the evaporative process occurs and prevents moisture buildup. It has now been shown that evaporative snow may be produced with machine emitting reduced operating noise. 
   SUMMARY OF THE INVENTION 
   A machine for producing an evaporative snow as small individualized particles which are easily dispersed, are free from agglomerates and leave no moisture and residue in the area of use, said machine comprised of a pump to deliver evaporative snow solution to a flake generator comprising of an impeller or impellers which causes the flakes to form on the surface of a sock, said flakes are dispersed by a sock by a airflow of 500-3000 cubic feet per minute, created by said impeller (s) and produces external noise levels up to around 90 decibels measured three feet from the machine. 
   In one embodiment the machine produces external noise levels are between about 50-80 decibels measured three feet from the machine. 
   In yet another embodiment the machine produces external noise levels are between about 50-70 decibels measured three feet from the machine. 
   In yet another embodiment the machine produces external noise levels are between about 50-60 decibels measured three feet from the machine. 
   The machine reduces external noise through:
         (a) directing air flow to a plastic duct;   (b) sealing the duct with foam;   (c) containing the fan in the duct in a non rigid mounting;   (d) and by using special sized and shaped foam baffles to reflect and absorb noise energy, that are rotated to counteract a particular fan frequency.       

   The foam may be any acoustical foam as is commonly known. 
   The machine may use multiple fans for generating the air flow. 
   The machine may use various discharge nozzle or air portal shapes to reduce noise for evaporative snow production. 
   The machine may use modified outer case material, size, shape or insulation properties to reduce noise for evaporative snow generation. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a complete illusionary snow machine that incorporates all of the aspects of the invention. 
       FIG. 2  illustrates the pump with connecting hose and the flake generator. 
       FIG. 3  illustrates a front view of the apparatus 
       FIG. 4  illustrates the apparatus in a cut away from the front 
       FIG. 5  illustrates the apparatus in a cut away from the rear 
       FIG. 6  is a foam streamer attachment 
       FIG. 7  illustrates the foam streamer in a cut away 
       FIG. 8  shows the side view of outer case of the low noise illusionary snow machine. 
       FIG. 9  illustrates the cutaway view of the apparatus demonstrating the internal sound dampening features of the invention. 
       FIG. 10  illustrates the front discharge area sound reduction features 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The ilusionary snow solution  2  under pressure is drawn into connecting hose  3  by means of an in-line liquid pump  1  at a rate of 4 ounces per minute. The liquid then continues to a flake generator  7  where it saturates a sock  4 . An impeller  5  contained within flake generator  7  causes flakes to form and to be projected into the air while an integrated carrier fan  6  facilitates the distribution of individual flakes. The flake generator  7  will produce a constant 3000 cubic feet per minute of airflow. This volume of air is forced through sock  4  and holes  8 , which are on the outer surface of flake generator  7 . Pressure of the air coming through sock  4  causes flakes to be formed on the outer surface of said sock  4 . The volume of air produced by impeller  5  that exits flake generator  7  through the holes  8  lift the flakes from the surface of sock  4 . Once the flakes are lifted from sock  4 , they are projected away from the apparatus by means of airflow produced by carrier fan  6 . When the force of air contacts the flakes produced carrier fan  6  there are two physical phenomena that occur. First the flakes are broken into smaller particles. This is a novel part of the current invention. The other commercially available machines have a great tendency to produce larger agglomerates, which in turn lead to excessive moisture buildup in the surrounding area. Second, once the flakes are separated into smaller particles, they are more easily dispersed in the area away from the machine. Once they are in the air in this matter the overall ratio of surface area exposed to air greatly increases. With this increased surface are comes a greater ability to speed the evaporative process. These two factors combine to speed the evaporative process and make it more complete. Another novelty of the current invention lies in the design of carrier fan  6  being lined up with flake generator  7  to lift the flakes and eject them from the apparatus in a manner that is greatly increased then a machine that would not contain both of these features placed together and at a proper distance from one another. This allows the flakes to remain in the air for a longer period of time and thus increases the transit time before they reach the ground. This increased time provides more exposure to air and allows for the completeness of evaporation to occur. The final result is an evaporative artificial snowfall that is truly free from residue of any type. Additionally, the snow produced does not resemble typical artificial snow that is ejected from a carrier hose or other apparatus. The current invention lifts the illusionary snow in a manner that produces a gentle cloud of snow in a wider horizontal area. The individualized flakes provide a cloud of gently falling flakes that is truly more realistic than anything currently available. 
   In one embodiment it has been found that one need not place the carrier fan in a centered position behind the flake generator. It has further been discovered that when placing a drum fan outlet below the flake generator and sock, one can produce a greater amount of illusionary snow, without increasing the velocity of the air from the carrier fan. In using a drum fan with the current invention, it has been discovered that a very large volume of illusionary snow can be produced. The volume is such that this embodiment allows the subject invention to be used in large arenas and stadiums. The same velocity of 3000 cubic feet per minute will generate a noticibly increased amount of illusionary snow. This is an important feature because without the need or increased air velocity, there is no increase in any noise created by the apparatus. If the apparatus were to be used indoors eg. in the theater, the amount of noise created would be minimal. Additionally, with the increased efficiency comes the ability of the user to regulate the flow rate of the solution into the apparatus. The solution can have a flow rate between 1-4 ounces per minute and still produce illusionary snow. 
     FIG. 3  illustrates an embodiment with apparatus housed within a case  140  which has a handle  170  on either side to facilitate carrying. A container  150  for holding the solution is placed inside when opening door  145 . The sock  155  as previously described is mounted on the front upper portion of the apparatus. An outlet air exhaust  165  provides air from the carrier fan. 
     FIG. 4  shows the interior of the case  140  in which a drum fan  205  as is comonly known in the art, is used to produce the necessary velocity to project the illusionary snow from the apparatus. There is a plate  185  for holding inlets  175  and  185  through which a remote control means can be connected to operate the apparatus. The circuit board  220  receives electrical power from either electrical inlet  195  or  200  which are secured to case  140  by means of a connecting plate  190  and can be controlled through a suitable controlling means as connected to either connector  175  or  180 . 
     FIG. 5  illustrates the aforementioned elements, and additionally shows placement of the flake generator  160  and the pump  225 . 
   The method for producing an illusionary snowfall which employs an evaporative snow solution, is a method comprising the steps of: Supplying electricity to the unit and drawing said evaporative snow solution into an apparatus through a hose, which is connected to a pump, directing said solution from said pump to a flake generator, which forms flakes on the outer surface of a sock, said flake generator comprises an impeller which disperses evaporative snowfall away from the apparatus, and a carrier fan which provides added velocity in projecting the illusionary snow from the apparatus. 
   In a further embodiment of the subject invention it has been discovered that if one prevents the air from the holes on the outer surface of the flake generator, from reaching the sock, the illusionary snow will be produced in larger form as opposed to individual flakes.  FIG. 6  illustrates an attachment which is connected to the outside of the flake generator and prevents the air from the holes on the outside of the flake generator from removing individualized flake. The air flow from the flake generator that reaches the sock, creates a solid form. In this embodiment, a cylindrical sheild  235  prevents air from the holes on the outer surface of the flake generator  245  from reaching the sock.  FIG. 7  shows the position of a sock  240  within the cylindrical shield. In this embodiment, the cylindrical sheild produces long cylindical columns of illusionary snow. These long cylindrical columns are carried from the sock by air that reaches the sock from the flake generator. Once the cylindrical column exits the cylindrical shield, the carrier fan propels it away from the apparatus. One can make the shield in various shapes in order to change the shape of the column. 
     FIGS. 8-10  show schematics of an embodiment by which operating noise is reduced to 90 decibels (dB) or less. The embodiment will operate and produce output noise up to about 90 dB. It has further been discovered that in making the adaptations to reduce noise, the machine may be operated with a fan speed between 500-3000 cubic feet per minute (CFM) 
     FIG. 8  shows a schematic of one preferred embodiment. In this embodiment the illusionary snow solution  305  is drawn into a connecting hose  309  by an in-line pump. The external switch  306  is attached to housing  302  and allows for an operator to remotely start and stop the machine using remote control  307 . Air enters through inlet  308  into a duct  303 . In this embodiment, the machine has a support bracket  304  which allows, if desired, the operator to hang the machine from a support bracket  304 . As previously described, the solution is pumped to a nozzle  301  which is attached to a nozzle discharge support  319 . The aforementioned flake generator lifts the evaporative snow off the nozzle  319  and projects the evaporative snow away from the machine. 
     FIG. 10  shows a close up schematic of the nozzle which is placed on the flake generator on the discharge chamber  312  that is placed in the center of the nozzle support  319 . Nozzle support  319  is the outer portion of the flake generator described above. The nozzle support  319  also is formed with air portals  318  which facilitate the lifting of the evaporative snow flakes off nozzle  301  and project them away from the machine. 
     FIG. 9  shows a more detailed schematic of the parts in one preferred embodiment. Evaporative snow solution  305  is drawn into hose  309  and is pumped by pump  310  into an in-line hose  311  to a discharge nozzle  312 , which saturates an attached fabric sock  301 . High velocity air pushes the solution through the fabric sock  301  which generates flakes that are pushed off the fabric with high velocity air streaming through four slotted air portals  318 . This air lifts the flakes into the air and sends them 10 to 60 feet away. In one embodiment the apparatus may be hung above a stage on the support bracket  304 . An internal electrical fan/blower  315  provides the high velocity air that is directed towards the nozzle support  319 . The air source is from the inlet area  308 . The air velocity and pump rate are controlled by an internal circuit board  316  whose settings are controlled through external dip switches  306  or a remote controller  307 . This allows an operator to control the sizes of the flakes and the distances they travel. Previously, this process of generating evaporative snow has created loud continuous noise levels that are unacceptable in the theatrical and film industries. The two significant noise sources have come from the fan/blower  315  or the rushing of air through narrow orifices  312 , and  318 . The preferred embodiment of the apparatus significantly reduces the noise levels from both sources. The machine now operates and produces external operating noise up to about 90 dB. Since the fan/blower  315  is such a strong source of noise, multiple methods of sound attenuation were employed for this evaporative snow machine. The main cutaway of the main housing  302  in  FIG. 10  shows the noise attenuation features. The fan/blower  315  is contained with exterior foam  320  in a plastic duct  303 . Since the fan/blower  135  is not rigidly mounted to plastic duct  303  or main housing  302 , most of the noise energy travels through the interior of sealed plastic duct  303 . Using noise attenuation calculations unique to the frequency of the fan/blower  315  used for the application, double walled foamed baffles  314  and single walled foamed baffles  313  are specifically located, spaced, and sized for a particular fan/blower  315 , so as to absorb some sound energy, reflect some noise energy back into itself so that it counteracts new sound waves, and lowers the frequency of the sound waves emitted. Acoustical foam  317  is specifically designed for the baffles  313  and  314  and to line the interior of the plastic duct  303  to absorb and reflect some of the noise energy. The single wall foamed baffle  313  and double walled foam baffle  314  are located towards the inlet area side  308  side and towards the nozzle discharge area  319  side. The cutout opening on the single wall foamed baffle  313  and the double walled foamed baffle  314  are rotated 90 degrees from each other to create an overlap, so the sound waves do not have a direct path out of the interior of plastic duct  303 . The baffles  313  and  314  overlap. Shape and spacing can be changed for the noise levels and frequencies of different models of fans/blowers  315 . The preferred embodiment of this apparatus uses polyethylene for the plastic duct  303  and main housing  302  to minimize noise energy transfer through the main housing  302 . 
   The second major source of noise in an evaporative snow machine is through the discharge area  319 . When high velocity air compresses to travel through narrow orifices, whistles and jet noise are the result. In order to attenuate the noise in the discharge area  319 , the in-line hose  311  is located and sized to remove most of it from the air flow, the air portals  318  were slotted and smoothed out to even out the air flow around the nozzle  301 , and a particular nozzle fabric may be chosen to muffle the noise from the discharge nozzle  312 . All other potential air discharge locations are sealed and rough edges smoothed to minimize the jet and whistle noises. This improved the efficiency of the evaporative snow machine and reduced the direct air velocity out the orifices, thus reducing the noise levels significantly. 
   While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.