Abstract:
A device to provide improved anti-smudging, better gripping and longer shelf-life to products and surfaces includes an electric superheated steam generator and an electric low-ion plasma generator to provide superheated steam and low-ion plasma to the surfaces of products including plastics. One embodiment envisions the superheated steam generator and the low-ion plasma generator being contained in a housing while another embodiment anticipates a conveyor means positioned in front of the superheated steam generator and the low-ion plasma generator. A method for the improving of anti-smudging, gripping and shelf-life for properties includes the application of superheated steam and low-ion plasma by means of a superheated steam generator and a low-ion plasma generator to products for specific periods of time and at specific distances to attain desired surface and bulk properties. The superheated steam and low-ion plasma may be applied individually, simultaneously or sequentially.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional patent applications Ser. No. 61/338,866 filed on Feb. 23, 2010 and Ser. No. 61/337,530 filed on Feb. 5, 2010, both, by the present inventors and is co-filed with PCT patent application no. ______ entitled “Clean Green Electric Protectors For Materials.” This application uses the low-ion plasma generator disclosed in U.S. Pat. Nos. 5,963,709 granted Oct. 5, 1999 and 6,816,671 granted Nov. 9, 2004 as well as the superheated steam generator disclosed by U.S. Patent Application Publications 2007/0145038 published Nov. 14, 2007 and 2010/129157 published May 27, 2010 which are incorporated by reference. 
     
    
     BACKGROUND  
       [0002]    1. Field 
         [0003]    The present application relates to improved anti-smudging, gripping and shelf-life properties of products and surfaces through the use of low-ion plasma, superheated steam and gas system surface treatments as well as system combinations thereof. 
         [0004]    2. Prior Art 
         [0005]    There is currently a great need for bottles made of many materials, including plastics, for the containment and storage of consumer products. Plastic bottles often have labels on them which need to appear visually sharper and not smudge with use or age. Profitability is increased to a great extent when these conditions are achieved by making products more aesthetically pleasing and attractive as well as increasing the shelf-life of the bottle and its identifying label. Longer-lasting and visually sharper product labels allow older goods to stay on the shelf and remain for sale longer before replacement with fresher items. This would be especially important with non-perishable goods that, if marked with sharp and long-lasting labels, could be left on shelves indefinitely and still remain appealing and marketable to consumers. Older items, with still fresh-appearing labels, could be placed at the front of shelves and sold first. Costs associated with inventory and replacement of goods could thereby be substantially decreased. 
         [0006]    Improvements in the physical properties of bottles are vital as well. Surface treatments are needed that can beneficially affect properties such as hardness, fatigue, creep, stickiness, gripability and the reactivity of a bottle&#39;s material. Often the transparency of a bottle is impaired by the presence of a wax or glue coating that is applied during processing. Methods are needed to remove the wax or glue without damaging labels if present; thereby making a surface that is matte, due to the presence of glue, transparent. Alternatively, a system is needed to create a matte finish, if desired, on bottles directly or in a manner that does not disturb labels, lettering or bar codes. Bottle or container surfaces often need to be cleaned before the application of labels as well. 
         [0007]    Surface heat treatment using an open flame as the heat source is the present solution for the meeting of many of the above goals. Flame treatment is the current industry standard for surface cleaning of bottles prior to application of items such as chemical etch/photo etch/screened nameplates, pressure sensitive labels and decals, UID and mil-spec labeling, serialization and bar-code identification, specialty engravings, large-format digital and screen printing and specialty food and packaging labels. Flame is also required for heat transferred decals which may display abstract design elements resembling, for example, henna tattoo artwork. Flame curing is needed for labels, produced by DI-NA-CAL®-brand heat transfer labels, for example, which are formulated with a protective lacquer and, sometimes, a custom-designed adhesive print coat. Examples of methods and processes using flame to prepare and alter surfaces of bottles for application and/or preservation of labels and direct printing on a surface include U.S. Pat. Nos.: 6,991,261 by Dronzek, Jr., et al., 6,939,602 by McGee, et al., 6,616,786 by Blom, et al., 6,513,435 by Detzner, 6,086,991 by Hubbard, et al., 5,925,208 and 5,711,839 by Dronzek, Jr., et al. and 5,085,034 by Haas. 
         [0008]    As an alternative to open flame as a heat source, U.S. Pat. Nos. 6,013,333 by Carson, et al., and 6,086,991 by Hubbard, et al. suggest the use of plasma. This plasma, however, is not low-ion plasma, which can be defined as plasma with an ion percentage by volume of 2% or less. Upon application, ions in the plasma have been found to have a beneficial impact on surface properties. Plasma with low-ion content may be generated by the devices of U.S. Pat. Nos. 5,963,709 by Staples, et al. and 6,816,671 by Reddy, et al. Small amounts of thermal plasma may be created in very high temperature environments employing high temperature heating elements composed of materials such as molybdenum, tungsten and molybdenum disilicide materials. Plasma can also generated by RF means, as illustrated by U.S. Pat. Nos. 3,648,015 by Fairbairn, which relates to cold plasma, 5,403,453, 5,387,842, 5,414,324, 5,456,972 by Roth, et al., 5,669,583, 5,938,854, 6,146,724 by Roth and 6,245,132 by Feldman et al.. Not all techniques can produce air plasma at normal pressures and not all techniques, except for U.S. Pat. Nos. 5,963,709 and 6,816,671, can be considered to produce substantial heat delivered simultaneously with hot gas. The plasma recombination leads to heat but only generally at a recombining surface. 
         [0009]    Superheated steam, which is often used synonymously with saturated and super-saturated steam, although there may be some differences, may be generated in a number of ways for various purposes. U.S. Pat. No. 6,900,421 by Varma is directed to a sterilizing apparatus using microwave heating for the generation of superheated steam. U.S. Pat. No. 6,880,491 by Reiner, et al. concerns the generation of superheated steam using hydrogen peroxide and a combustible fluid, wherein the combustion process decomposes the hydrogen peroxide to produce superheated steam. U.S. Pat. No. 7,115,845 by Nomura, et al. consists of a superheated steam generator that uses electromagnetic induction to produce the superheated steam. Here, in one embodiment of the present application, the superheated steam generator may be comprised of a heater such as the coil-in-coil type disclosed in U.S. Publication No. 2007/0145038 by Vissa, et al., which overcomes problems associated with the relationship of Psat and Tsat. The heater may also be of the type disclosed in U.S. Publication No. 2010/129157 by Reddy, et al.. In the present patent application, the use of superheated steam, alone or in conjunction with low-ion plasma has been shown to improve surface and bulk properties of products exposed to it. 
         [0010]    When an open flame is applied directly to a bottle to remove glue and wax or to improve surface and bulk properties, a number of disadvantages are presented including: 
         [0011]    a) Flame treatment processes are environmentally harmful. They produce CO 2  and SO 2  soot. Typically, 20,000 BTU natural gas burners produce about 22 moles of greenhouse gasses per hour (10 25  molecules per hour). Combustion products from fuels containing carbon also often produce very toxic gasses such as carbon monoxide (CO). Such a method is not environmentally friendly or a green technology. 
         [0012]    b) Combustion gas input is used which requires plumbing for delivery and application adding to the cost of set-up and operation. 
         [0013]    c) Combustion flame has a narrow area of impact and is therefore its application is non-uniform. To attain the needed uniformity many burners may be needed, adding to the cost and complexity of the process. 
         [0014]    d) There is a high potential for explosion due to the presence of combustible gas. Combustion flame is commonly associated with combustion emissions and fire hazards. Employees must be adequately trained and be provided with protective equipment. 
         [0015]    e) Flames are inherently energy inefficient with, typically, about 10% of the energy being used in directed flame operations. Most of the energy is not applied to the product. 
         [0016]    f) There is a lack of precise control from combustion flames leading to lack of optimization of processes. 
         [0017]    g) Flame combustion produces high noise. It also requires the added cost of hearing protection for workers and possible specialized placement and sound insulation of process equipment. 
         [0018]    h) There is a continuous requirement for consumables such as reactant gasses leading to increased costs and decreases in profitability. Safety and environmental clean-up costs are incurred. 
         [0019]    It is therefore apparent that the current technology is not meeting the above stated goals in an environmentally safe, energy efficient or cost effective manner. With the increase in potentially disastrous effects associated with global warming and the volatile economy, new devices and methods are needed to address these effects, where the present flame treatment technology does not, in regards to improvement of anti-smudging, gripping and shelf-life properties of products and surfaces. 
       SUMMARY 
       [0020]    In accordance with a favored embodiment, a low-ion plasma and superheated steam (LIP™) system for surface treatment and cleaning for the improvement of anti-smudging, gripping and shelf-life of products and surfaces comprises a means to electrically generate low-ion plasma and a means to electrically generate superheated steam. Such low-ion plasma and superheated steam will be applied to the surface of a product in order to cause the enhancement and improvement of the above and other surface and physical properties of bottles and other products made of various materials to, in part, enhance the appearance and life of labels found on the bottles and products. This new method will alleviate problems associated with the current technology including toxic emissions, safety concerns, explosion hazards, pollution, noise, inefficiency, lack of optimization and high costs due to consumables, insurance and specialized training in operation and safety. These and other benefits will become apparent in the following descriptions of the embodiments of the LIP™ system. 
     
    
     
       DRAWINGS  
       Figures 
         [0021]      FIG. 1  is a perspective view of the LIP™ system. 
           [0022]      FIG. 2(   a ) is an interior view of the LIP™ system revealing the low-ion plasma generator and superheated steam generation devices contained therein. 
           [0023]      FIG. 2(   b ) is a perspective view of the low-ion plasma generator contained in the LIP™ system. 
           [0024]      FIG. 2(   c ) is a perspective view of an example of a superheated steam generation device contained in the LIP™ system. 
           [0025]      FIG. 3  is a perspective view of the LIP™ system and a product conveyor means. 
           [0026]      FIG. 4  is a front view of two LIP™ units arranged side by side with a conveyor means. 
           [0027]      FIG. 5  is a view of the single-hole nozzle design for the low-ion plasma generator. 
           [0028]      FIG. 6  is a view of the slit nozzle design for the low-ion plasma generator. 
           [0029]      FIG. 7  is a view of the multi-hole # 1  nozzle design for the low-ion plasma generator. 
           [0030]      FIG. 8  is a view of the multi-hole # 2  nozzle design for the low-ion plasma generator. 
           [0000]    
         
           
                 
               
                 
                 
                 
                 
               
             
                 
                     
                 
                 
                   DRAWINGS - Reference Numerals 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                   10 
                   LIP ™ system 
                    20 
                   housing 
                 
                 
                   22 
                   vertical section 
                    24 
                   horizontal section 
                 
                 
                   26 
                   cowling 
                    28 
                   access panel 
                 
                 
                   30 
                   access opening 
                    34 
                   closed end 
                 
                 
                   36 
                   open end 
                    38 
                   plasma nozzle aperture 
                 
                 
                   40 
                   steam nozzle aperture 
                    60 
                   superheated steam generator 
                 
                 
                   62 
                   steam nozzle 
                    80 
                   low-ion plasma generator 
                 
                 
                   82 
                   plasma nozzle 
                    82(a) 
                   single hole plasma nozzle 
                 
                 
                   82(b) 
                   slit plasma nozzle 
                    82(c) 
                   multi-hole #1 plasma 
                 
                 
                     
                     
                     
                   nozzle 
                 
                 
                   82(d) 
                   multi-hole #2 plasma 
                   100 
                   conveyor means 
                 
                 
                     
                   nozzle 
                 
                 
                     
                 
               
            
           
         
       
       
    
    
     DESCRIPTION  
     FIGS.  1 ,  2 ( a ),  2 ( b ),  2 ( c ),  3  and  4   
     Best Mode 
       [0031]    The embodiment of the best mode of the LIP™ system for the improvement of anti-smudging, gripping and shelf-life properties of products and surfaces is illustrated in  FIG. 1  (perspective view),  FIG. 2(   a ) (cut-away view),  FIG. 2(   b ) (perspective view of low-ion plasma generator) and  FIG. 2(   c ) (perspective view of superheated steam generator). The LIP™ system  10  is comprised of a housing  20  configured with a vertical section  22  and a horizontal section  24  contiguous with and located above the vertical section  22 . An access panel  28  is located at the top of the housing  20  in the horizontal section  24  covering an access opening  30 . A cowling  26  is attached to the horizontal section  24  and has an open end  36  on one side and a closed end  34  on the other with the open end  36  being attached to the horizontal section  24 . The cowling  26  has a plasma nozzle aperture  38  and a steam nozzle aperture  40  cut through its closed end  34  allowing for placement of the plasma nozzle  82  of the low-ion plasma generator  80  and the steam nozzle  62  of the superheated steam generator  60 . In this embodiment the plasma nozzle aperture  38  and the steam nozzle aperture  40  are positioned to allow the plasma nozzle  82  and the steam nozzle  62  to be placed side by side. In this embodiment the low-ion plasma generator  80  is of the type disclosed in U.S. Pat. No. 5,963,709 by Staples and U.S. Pat. No. 6,816,671 by Reddy. The superheated steam generator  60  of the present embodiment is of the types disclosed in U.S. Publication No. 2007/0145038 by Vissa or U.S. Publication No. 2010/129157 by Reddy, et al.. 
         [0032]    A conveyor means  100  is positioned in a manner to move products in front of the steam nozzle  62  and the plasma nozzle  82  projecting through the closed end  34  of the cowling  26 . The speed of the conveyor means is variable can be changed to match requirements in regards to product material type and the property or feature that is in need of alteration by the low-ion plasma and/or superheated steam. The order of the operations (i.e., low-ion plasma, superheated steam) may be changed or one operation may not follow each other right away or one or the other operation may be omitted entirely to achieve desired results. The distance between the conveyor means  100  and the steam nozzle  62  and the plasma nozzle  82  may be adjusted as well. 
         [0033]    Operation 
         [0034]    In the present embodiment, a bottle or other product is propelled by the conveyor means  100  in front of the steam nozzle  62  and plasma nozzle  82  of the LIP™ system  10 . The steam nozzle  62  projects superheated steam, which contains ions, produced by the superheated steam generator  60  and the plasma nozzle  82  projects low-ion plasma produced by the low-ion plasma generator  80  on a product or surface. In this manner the bottle or product is passed through both a superheated steam and low-ion plasma stream for a predetermined optimal time for the attainment of the desired improved surface properties. The product may also be passed in front of the plasma nozzle  82  first and then passed in front of the steam nozzle  62 . A cooling cycle may also be employed between applications of steam and plasma. It is also contemplated that the product to be treated may be passed only through the plasma stream projected by the low-ion plasma generator  80  or alternatively only through the superheated steam stream of the superheated steam generator  60 . The temperature and flow rates of the plasma and steam are variable and controllable as well. The experiments and testing described below present various temperatures, environments and exposure times anticipated and evaluated for different embodiments. 
       Alternate Embodiments 
       [0035]      FIGS. 5-8  show alternate embodiments of the plasma nozzle  82  of the low-ion plasma generator  80  of the LIP™ system  10 .  FIG. 5  displays a single-hole plasma nozzle  82 ( a ) while  FIG. 6  shows a slit plasma nozzle  82 (b). Multiple holes are depicted in  FIG. 7  for the multi-hole # 1  plasma nozzle  82 ( c ) and in  FIG. 8  for the multi-hole # 2  plasma nozzle  82 ( d ). These and other anticipated embodiments of the plasma nozzle  82  give great versatility in the direction and intensity of the projection of the plasma stream produced by the low-ion plasma generator  80 . The plasma nozzle  82  can be designed to meet any requirement of plasma direction control in regards to the size, shape or material of a product and in accordance with the desired surface and bulk properties. The special design and materials of the nozzles  62  and  82  in some way affect the delivery of a low-ion gas or system. The shapes of the nozzles  62  and  82  can be convex, concave or a combination of the two to achieve diffuse or direct flow for specific uses. Plasma nozzles  82  with single openings found in  FIGS. 5 and 6  allow for a more direct and intense plasma stream for smaller products or smaller areas on a larger product. On the other hand, plasma nozzles  82  with multiple holes, such as those in  FIGS. 7 and 8 , allow for a broader area of plasma application on larger products and surface areas. The plasma nozzles  82  can particularly be adapted to take the shape of an object to be treated, especially if the object has very varying dimensions like a bottle and its mouth. Also anticipated are: plasma nozzles  82  with slits in circular shape around main large hole; steam nozzle  62  to direct steam flow into plasma stream; the use of insulating materials between product and LIP™ system  10  to reduce heat transfer to undesired areas and; the use of shrouds or opposite wall backing to retain heat in the LIP™ system  10 . The low-ion and gas can be used to treat metal, inorganic, organic, polymer, composite, solid, semi-solid or liquid surfaces. 
         [0036]    By using an ion generation/formation system, even a slight amount of ions, as low at 0.0001%, 0.001%, 0.01%, 0.1% or 1%, as well as large amounts that may be as great as 10% to 100% by volume of a cold or hot gas, can often greatly impact the anti-smudging and/or shininess of surfaces leading to better commercially applicability. Gas, including steam, and all fluid mixtures are contemplated with a small to large concentration of ions. Plasma may be generated from any ion or chemical gas species of H 2 O, CO 2 , CO or from complex organic gasses which condense, for instance as glue. The gasses employed could be, for example, air, oxygen and ideal gasses such as helium or argon. Also, the gasses could be combustion products or other plasma gasses. Ions in a gas can result from reactions, flame, heating, plasma generation, electric potential, especially at high frequencies in the ranges of kHz, Ghz and MHz, or electrolytic methods for a gas or fluid. Ions can also be introduced through work based systems (e.g., rubbing of surfaces). Ions can be created by discharges in a gas, vacuum or low pressure gas. Ions are also produced during boiling, evaporating or phase change processes. Ions may be produced from intermediary species that have an ionic nature (for example in catalytic reactions and surface reactions). A combination technique can also be used to produce ions. The main idea is to have a fluid with some ions. All fluids including liquids, droplets, gasses and their mixtures are fully contemplated by the inventors as are fluids containing solid particles and solid ions like colloids, zeolites and other soft and hard fibers including nano-materials in relation to the production of ions. 
         [0037]    The inventors have tested surfaces (laser surface reflection and projection) treated by the techniques below for producing ions. It has been found that ions in the fluid provide a great benefit to surfaces by rendering them smudge resistant, better gripping and visually more sharp and attractive. Also found was that the good properties are retained over time, i.e., retained over days, months and possibly years thus improving shelf-life. The shine is retained over many months proving that the technique of having a small amount of ions applied as an anti-corrosive (or anti oxidant) to materials including metals, common plastics, ceramics, nano-materials, paper, PTFE, PTE, styrene, polystyrene, textiles, polyester, ester, polycarbonates, composites and others, as well as products including bottles, storage containers, labels and plastic adhesives is effective in improving product shelf-life. It is anticipated that the surfaces of organic items including fruits, vegetables, meat or even the skin of humans may benefit from the superheated steam, low-ion surface treatment described by the present application. Applicable surface types include transparent, partially transparent, non-transparent and “speckled” surfaces. Tests further indicate that it is more difficult for droplets to fall off ion treated surfaces. This is often an indication that the surface energy is higher for ion treated surfaces. The gripping ability of ion treated surfaces was better, indicating that the coefficient of friction may have been better after such surface treatment. Again, 1% to as little as 0.0001% or less by volume of ions in the fluid seems good enough to achieve these results. Testing indicates that the LIP™ system represents a new technology which allows the use of hot air and gasses to efficiently transfer energy from just above room temperature to 1000° C. containing very low amounts of plasma. 
       Experiments and Testing 
       [0038]    A typical scenario for surface processing for the elimination of flame and the attainment of a better surface that was applied to multiple embodiments is given below: 
         [0039]    1. Particular Objective: 
         [0040]    1.1. To replace a flame based process. The flame process suffers from: (1) environment consideration arising from emissions of the combustion products, i.e., CO 2 , SO 2  and soot; (2) has a narrow area impact; (3) possibly suffers from commonly recognized combustion and related fire hazards; (4) has the potential of causing explosions; (5) is energy inefficient; (6) cannot be precisely controlled; (7) makes combustion noise; and (8) is costly because of the requirement for constantly used consumables such as reactant gasses. 
         [0041]    2. Specific Goal for the Test: 
         [0042]    The specific goal is the replacement of the multiple flame processing nozzle design on a bottle conveyor line with a safer and more technologically current product. 
         [0043]    3. Test Procedure: 
         [0044]    3.1 The printed or labeled faces of bottles are held together by glue which is currently burnt off by the flame. 
         [0045]    3.2 The surfaces of two bottles were treated with a low-ion plasma only and with a low-ion plasma and steam process at speeds exceeding 200 ft/min 
         [0046]    3.3 The bottles were attached to a linear stage (conveyor means  100 ). Velocity and interaction time defined a Uα/2α were measured. This is a standard Fourier number or dimensionless interaction time parameter and can be used to scale a process. α is treatment area or beam size. U is the velocity of movement and α is the thermal diffusivity 
         [0047]    4 Equipment: 
         [0048]    4.1 6.5 kW Low-ion plasma generator  80  (For product description see www.mhi-inc.com.) 
         [0049]    4.2 1 kW HGA-S-01 superheated steam generator  60 . 
         [0050]    4.3 Bearing Slide (conveyor means  100 ) 
         [0051]    4.4 Bottle samples provide from outside MHI 
         [0052]    4.5 LIP™ system  10  of combination energy delivery sources and gasses and different nozzle orientations. 
         [0053]    5 Results: 
         [0054]    5.1 The flame may be easily and safely replaced. Both the overall goals and specific goals can me met. 
       GENERAL TEST 
       [0055]    1.1. The present application describes a new plasma use and use of steam plasma in various forms in order to obtain a better surface. A better surface is for metal ceramic or polymer (plastic) with improved surface and/or bulk properties including better transparency, hardness, fatigue, wear etc. The low-ion plasma generator  80  was run at 1260° C. at the exit. 
         [0056]    1.2. The platform was about 2″ from the front of the low-ion plasma generator  80 . 
         [0057]    1.3. The low-ion plasma generator  80  fan speed was set at 1.5 meters per second. 
         [0058]    1.4. The HGA-S-01 superheated steam generator  60  was setup to inject steam diagonally into the plasma stream (steam/plasma test only). The diagonal is better than normal but both are possible. 
         [0059]    2. Small volumes and large volumes can be treated with the new process. 
         [0060]    Typical Small Volume Procedure: 
         [0061]    2.1. Low-ion plasma generator Test
       2.1.1. The low-ion plasma generator  80  will start and heated to the maximum recommended temperature.   2.1.2. The top half of each bottle will be covered with high temperature tape so that the before and after effects of the test can be shown.   2.1.3. The marked bottles will be installed on the bearing slide (conveyor means  100 ).   2.1.4. For the plasma test bottle # 1  will be used. p 1  2.1.5. High temperature tape will be used to cover the non-tested area of the bottle so that further runs may be completed on the same bottle.   2.1.6. Using the bearing slide (conveyor means  100 ) the samples will be moved in front of the plasma stream at a known (estimated) rate of speed. The length of travel will be known and the movement of the bottle will be timed for each run.   2.1.7. Data for the run time, sample, temperature, and any notes will be recorded.       
 
         [0068]    2.2. Steam/Plasma Test 1
       2.2.1. The HGA-S-01 superheated steam generator  60  will be heated to 400° C. while running at a flow rate of 20 mL/min   2.2.2. The sample bottle will be passed in front of the steam flow.   2.2.3. The sample will then be run in front of the low-ion plasma generator  80 .       
 
         [0072]    2.3. Steam/Plasma Test 2
       2.3.1. The HGA-S-01 superheated steam generator  60  will be heated to 400° C. while running at a flow rate of 20 mL/min   2.3.2. The sample bottle will be passed in front of the combined steam/plasma steam flow.       
 
         [0075]    3. Data:
       3.1. Plasma Testing Data       
 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
               
               
                 Run # 
                 Sample ID 
                 Temp 
                 Time 
                 Notes 
               
               
                   
               
             
             
               
                 1 
                 Water 
                 1190 
                 n/a 
                 Water bottle 
               
               
                 2 
                 1F 
                 1260 
                 0.840 
                 Wax was cleared 
               
               
                 3 
                 1B 
                 1260 
                 1.10  
                 Center strip was cleared as rest 
               
               
                   
                   
                   
                   
                 was blanked off with tape 
               
               
                 4 
                 1B 
                 1260 
                 n/a 
                 Wax cleared 
               
               
                   
               
             
          
         
       
       
         
           
             3.2. Steam/Plasma Test 1 Data. Separately treated. 
           
         
       
     
         [0000]    
       
         
               
               
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Run # 
                 Sample ID 
                 Temp 
                 Time 
                 Notes 
               
               
                   
                   
               
             
             
               
                   
                 1 
                 2B 
                 400/1260 
                 n/a 
                 Wax cleared 
               
               
                   
                   
               
             
          
         
       
       
         
           
             3.3. Steam/Plasma Test 2 Data. Concomitantly treated. 
           
         
       
     
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
               
               
                 Run # 
                 Sample ID 
                 Temp 
                 Time 
                 Notes 
               
               
                   
               
             
             
               
                 1 
                 2F 
                 475/1260 
                 n/a 
                 Wax cleared, no deformation 
               
               
                 2 
                 3F 
                 382/1260 
                 n/a 
                 Wax cleared, no deformation 
               
               
                   
               
             
          
         
       
       
         
           
             3.4. Large Volume procedures involve combinations of power and surface speed. Use of low and large area sources. Alternating steam, plasma and other heat sources like IR, Laser (all wavelengths are considered but some may be more preferable such as excimer lasers or carbon dioxide lasers), electron beam, ion beam and even flame in all combinations and order of treatment and re-treatment etc.. 
           
         
       
     
         [0080]    LIP™ TESTING SCHEDULE 
         [0081]    Procedure # 1 
       LIP 6.5P with 4″ Slit Nozzle  82   b          
 
         [0083]    Procedure # 2 
       LIP 6.5P with 1″ Round Nozzle  82   a          
 
         [0085]    Procedure # 3 
       LIP 6.5P with Multihole Nozzle # 1   82   c          
 
         [0087]    Procedure # 4 
       LIP 6.5P with Multihole Nozzle # 1   82   c          
 
         [0089]    Procedure # 5 
       LIP 6.5P with Multihole Nozzle # 1   82   c      LIP 10D with Multihole Nozzle # 1   82   c      2 LIP units side-by-side spaced˜8″ apart       
 
         [0093]    Procedure # 6 
       LIP 6.5P with Multihole Nozzle # 2   82   d      LIP 10D with Multihole Nozzle # 2   82   d      2 LIP units side-by-side spaced˜ ¼″ apart          
 
         [0097]    Procedure # 7 
       LIP 6.5P with Multihole Nozzle # 2 +(x2) 1 kW LTA units w/4″ knife   LIP 10D with Multihole Nozzle # 2 +(x2) 1 kW LTA units w/4″ knife   2 LIP units side-by-side spaced˜ ¼″ apart          
 
         [0101]    Procedure # 8 
       LIP 6.5P with Multihole Nozzle # 2 +1 kW LTA units w/4″ knife+1 kW TTA steam unit w/4″ knife   LIP 10D with Multihole Nozzle # 2 +(x2) 1 kW LTA units w/4″ knife   2 LIP units side-by-side spaced˜ ¼″ apart          
 
         [0105]    Further embodiments concerning the order of application of the superheated steam and low-ion plasma streams anticipate increased versatility. The superheated stream may be applied to a product before, after or simultaneously to the application of the low-ion plasma. In some cases the low-ion plasma or superheated steam may be applied by themselves to achieve desired results. If desired, the product may be allowed to cool after the application of the plasma or steam and before the application of the other. Typically, the low-ion can be generated with non-combustible air, but if needed, could be generated with a variety of other gasses. The type of product to be treated and the surface or bulk property to be augmented can determine which of these and other embodiments is to be employed. Units of the LIP™ system  10  may be used singly, side-by-side or facing each other and with or without a conveyor means  100  depending on the needs of the customer. In general, the LIP™ system  10  is designed for continuous short-time exposure of forced convective heat, utilizing ions in a flowing gas. The major heat transfer mechanisms are ion recombination and forced convection while a minor heat transfer mechanism is radiative as apposed to the co-filed PCT patent application no. ______ entitled “Clean Green Electric Protectors For Materials” which relies predominately on radiative heat and little on convection for heat transfer. The forced convection is of a hot gas with temperatures above 100° C., 200° C., 500° C., 750° C., 1000° C. or 1250° C. Ions are supplied by low-ion plasma and all sources and mechanisms of heat are directed with velocity. Also, the forced convection acts to enhance the affects of the low-ion plasma. 
       Advantages 
       [0106]    While fully realizing there are many other advantages provided by the LIP™, from the description above, a number of advantages of the embodiments of the LIP™ system over the use of open flame become evident including: 
         [0107]    a) No toxic emissions or greenhouse gasses are produced. Device uses only air input requiring no other gasses and, as a result, no venting is needed as only air is released into the environment. The replacement of a combustion flame with an “air flame” is more energy efficient, improves productivity and is safer, thereby improving the insurance profile of the user. 
         [0108]    b) The LIP™ system has a very wide area flexibility which increases line speed dramatically. 
         [0109]    c) There is no possibility of explosion from the inlet source with the LIP™ system since no combustion gasses are involved. LIP™ systems can be integrated with over-temperature controls leading to less monitoring and labor savings. 
         [0110]    d) The LIP™ system is over 90% efficient. Energy savings depend on the user&#39;s objectives and the total power replaced, but as an example, a 30 kW flame is generally replaced by 6 kW of clean electric for select operations. 
         [0111]    e) Precise control is available to fully optimize all processes and provides for safety controls such as over-temperature cut-off. Directional application of stream of gas and low-ion plasma is possible. 
         [0112]    f) Quiet operation requiring no hearing protection. 
         [0113]    g) LIP™ systems offer great savings in many ways. The system uses only air and electricity rather than costly consumables including combustible gas. Insurance premiums may be influenced in a positive many due to increases in safety provided by the LIP™ system including no flame, no combustible gas and low noise output. Allows a user to differentiate itself from the competition by allowing the user to stress its use of green technology. Depending on the application, the LIP™ system is often less expensive in general that conventional flame technology. 
         [0114]    h) The use of low-ion plasma overcomes the problems of excessive heat generated by the recombination of high percentages of ions in plasma. Fewer ions to be recombined lead to less heat allowing for uses where too much heat created by too many ions, for example, would cause melting and be destructive. 
         [0115]    i) The heat generated by low-ion plasma is controllable and, in effect the low percentage of ions beneficially catalyzes reactions on a surface or in a gas-ion mixture. 
         [0116]    The LIP™ system provides even further advantages over open flame and other methods due to the great flexibility it provides. Though the preferred embodiment calls for the use of low-ion plasma, the LIP™ system can perform its function of improving anti-smudging, better grip-ability and improved shelf life with plasma with percentages of ions from 0.0001% to 100% by volume. Further flexibility is provided by the fact that meeting the stated goals of product improvement do not depend on the order in which the superheated steam and low-ion plasma are applied. Studies at MHI Inc. have revealed that the LIP™ system is effective regardless of the order in which the steam or plasma is applied and is even effective if a product is subjected to only one. The system can be employed for direct flow or at any angle required. It may be used for material heat treating in complex situations where the surface to be heated is out of sight allowing for treatment without expensive and time consuming disassembly. 
         [0117]    It is anticipated that the improvements that the low-ion plasma and superheated steam LIP™ system provides may be employed on a wide and diverse array of applications encompassing: engine parts, printing on plastic food containers, energy-efficient window coatings, safe drinking water, voice and data communications components, waste processing, coatings and films, electronic computer chips and integrated circuits, advanced materials (e.g., ceramics), high-efficiency lighting, plasma enhanced chemistry, surface finishing and cleaning, processing of plastics, gas treatment, spraying of materials/nano crystals, glass heating and cutting, aluminum, nano-structures, chemical analysis, semiconductor production for computers, changing surface polarity or influencing transparency, modification of chemical compounds, hydrogen, melting and vaporization, boilers, energy systems (including nuclear, combustion and equipment), televisions and electronics, standard metallurgical processing at improved efficiencies and ease of use, and microbial reduction Improved surface and/or bulk properties, e.g., hardness, fatigue and wear, will be imparted to metal, ceramic and polymer (plastic) materials by the LIP™ system. 
         [0118]    The above descriptions provide examples of specifics of possible embodiments of the application and should not be used to limit the scope of all possible embodiments. Thus the scope of the embodiments should not be limited by the examples and descriptions given, but should be determined from the claims and their legal equivalents.