Abstract:
Apparatus for reducing static electricity comprises 
     (a) electrically conductive cable means having tips spaced therealong to dispense ions in response to voltage application to the cable means, 
     (b) the cable means defining cable extents each of which is flexible and includes elongated metallic extent to which voltage is applicable, 
     (c) and needles having shanks extending adjacent the cable metallic extent to make sideward electrical contact therewith so as to receive voltage application, the needles defining the tips openly exposed outwardly of the cable extents to dispense ions into the atmosphere near the cable means, 
     (d) at least certain of the needles having surfaces at said tips consisting of tungsten or tungsten alloy for dispensing positive ions without corroding.

Description:
BACKGROUND 0F THE INVENTION 
     This application is a continuation-in-part of Ser. No. 680,143, filed Dec. 10, 1984, which is a continuation-in-part of Ser. No. 570,926, filed Jan. 16, 1984, which is a continuation-in-part of Ser. No. 420,904, filed Sept. 21, 1982, which is a continuation-in-part of Ser. No. 369,925, filed Apr. 19, 1982, which is a continuation-in-part of Ser. No. 290,423, filed Aug. 6, 1981, which is a continuation-in-part of Ser. No. 259,503, filed May 1, 1981, which is a continuation-in-part of Ser. No. 241,684, filed Mar. 9, 1981, which is a continuation-in-part of Ser. No. 124,242, filed Feb. 25, 1980. 
    
    
     This invention relates generally to the provision of cable means with corrosion resistant ion dispensing needles, located in zones for treatment of work such as plastic articles, animals and edibles, and electronics parts. 
     There is a need for low cost, efficient means to induce collection of air-borne particles, and to suppress static build-up in certain article treating zones (electric parts procution, plastic parts or material production, paper rolling apparatus, surgical operating rooms, clean room assemblies, and circuit board fabrication, etc.). Prior ion dispensing devices were not easily installable to conform to special requirements as to product shape, zone size, etc., and often did not achieve desired static neutralization contrary to expectations, also, ion dispensing needles which are positively charged tend to corrode, undesirably. 
     SUMMARY OF THE INVENTION 
     It is a major object of the invention to provide method and apparatus to achieve controlled neutralization or reduction of static charge on or associated work, or to achieve controlled net positive or negative ion flux in area at or adjacent to work, and without detrimental needle corrosion. 
     The apparatus in accordance with the invention basically comprises: 
     (a) electrically conductive cable means having tips spaced threalong to dispense ion in response to voltage application to the cable means, 
     (b) the cable means defining cable extents each of which is flexible and includes elongated metallic extent to which voltage is applicable, 
     (c) the needles having shanks extending adjacent the cable metallic extents to make sideward electrical contact therewith so as to receive voltage application, the needles defining the tips openly exposed outwardly of the cable extents to dispense ions into the atmosphere near the cable means, 
     (d) at least certain of the needles having surfaces at said tips consisting of tungsten or tungsten alloy for dispensing positive ions without corroding. 
     As will appear, the needles may consist entirely of tungsten or tungsten alloy with a precious metal, or such composition may be formed as a layer (as by plating, cladding, or other application) on a metal needle (stainless steel, copper, etc.); and the so formed needles may be employed in a dual cable system one cable having positive voltage applied thereto and to said needles, or a single cable carrying such needles may be employed. 
     As will appear, the cables are typically flexible so as to bend and fit in different work areas; and spacers may typically have grooves in which the first and second cables are retained in such close alignment that tips on the two flexible cables project in generally the same direction, i.e., toward the work area, up or down; and auxiliary cable means may be provided, with controlled voltage application thereto, to enhance ion travel toward the work area to neutralize static. The cables may include cores consisting of wire strands penetrated by the needles. 
     As will appear, pairs of cables, each with ion dispensing tips, may be located at adjusted distances from the work, the cables of each pair having adjusted separation and being respectively adapted to receive positive and negative voltage application, the levels of which may be controlled, all for the purpose of achieving static charge neutralization or reduction at or adjacent the work. In addition, the spacing of the tips or needles on the cables is adjusted to achieve that objective. 
     Typically, groups of tips on the first cable of a pair are staggered relative to groups of needles on the second cable of that pair; and the tips are located in association with the spacers to achieve desired balance of positive and negative ions in the work zone toward which the tips project, or some excess of positive ions. 
     The needles may incorporate layer of metal on the tungsten, that layer being bondable (as by welding or soldering) to the cable metal; the needles may have cores other than tungsten; those cores may be loosely exposed for bonding to the cable metal; and the needles may have pointed opposite ends, for purposes as will appear. 
     The invention enables static charge control in work zones, elimination of dangerous arcing in such zones, and control of net ion flux in animal or poultry zones and in edibles smoke houses, and clean rooms to provide unusual advantages, as will appear, and extended needle life. 
     These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings in which: 
    
    
     DRAWING DESCRIPTION 
     FIG. 1 is a plan view of apparatus embodying the invention; 
     FIG. 2 is a section on lines 2--2 of FIG. 1; 
     FIG. 3 shows cable support; and FIG. 4 shows cables in an article treatment zone; 
     FIG. 4 shows cables in an article treatment zone; 
     FIG. 5 is a perspective view showing a multiple cable and wire system; 
     FIG. 6 is an elevation showing the FIG. 5 system installed in a clean room; 
     FIG. 7 is a fragmentary elevation showing the FIG. 5 system installed above a perforated, false ceiling; 
     FIG. 8 is like FIG. 7; 
     FIG. 9 is a plan view of cables retained by improved spacer; 
     FIG. 10 is an enlarged plan view of a spacer as shown in FIG. 9; 
     FIG. 11 is a section on lines 11--11 of FIG. 10; 
     FIG. 12 is a perspective view like FIG. 5, showing the FIGS. 9-11 spacers, and voltage adjustment of the cables as well as of an auxiliary wire; 
     FIG. 13 is a sectional view of a modified cable and needle, and FIG. 14 shows a modified needle; 
     FIG. 15 is an elevation showing coated needles bonded to a cable or wire; 
     FIG. 16 is a modified view, similar to FIG. 11; 
     FIG. 17 is an enlarged elevation showing a modified needle; 
     FIG. 18 is a section taken on lines 18--18 of FIG. 17; 
     FIG. 19 is a view like FIG. 18, showing a wire attached to the needle; 
     FIG. 20 is a view like FIG. 18, showing a modified section; 
     FIG. 21 is an enlarged view showing a double pointed needle composite; and 
     FIG. 22 is a section of a needle showing a modified composite. 
    
    
     DETAILED DESCRIPTION 
     Referring to FIGS. 1 and 2, first and second cable means appear at 204 and 206. Each cable includes an elongated conductive metal core 207, and a protective sleeve 208 of insulative, such as polypopulene or polyethylene, material ion dispensing tips, as formed for example by needles, are shown at 209 and 210. The tips project generally in the same direction, as toward work areas 211 seen in FIG. 4, there being work elements 212 in such area, to be made static free. 
     The cable are typically flexible so they can be strung in straight or curved lines or configuration. Note straight cable lengths 204a and 204c, and curved lengths or bends 204b in FIG. 4. Also the cable pair 204 and 206 has adjusted lateral separation characterized in that static electrically at or proximate the work is effectively reduced to non-objectionable level or levels when positive and negative voltages are applied to the respective cables. Note positive voltage source 212 connected at 213 to cable 204, and negative voltage source 214 connected at 215 to cable 206. 
     Spacers are provided as at 217 and located at selected positions along the cables to hold them at adjusted separation K. The latter is typically between 1/2 and 11/2 inches. 
     Such spacers are shown in the form of insulative plastic bars, having two notches 219 at K separation to removably receive the cables, sidewardly, i.e. with snap-in reception. The notches are sized to receive and firmly retain the cables, as shown in FIG. 19. The cables are frictionally held against rotation and the needles or tips 209 and 210 are held projecting in the same direction, despite the bending of the parallel cables to conform to room geometery, as at 204b. 
     Holders are provided to support the cable pairs at selected spacing from enclosure structure. In the example, insulative plastic rods 220 are suitable attached at 221 to the ceiling or wall of enclosure 222, and support the cables. FIG. 3 shows the rod 220 having a side notch at 223, to receive a cable 204 or 206 of a connected pair. 
     The dual cables 204 and 206 as described, may be employed for purposes as described above. 
     Adjustment of the positive and negative ion dispensation by the tip groups 209 and 210 is also enabled to aid in achievement of substantial neutralization of static in work area. In this regard, note in FIG. 1 that the tips 209 in cable 206 are sidewardly offset from a portion 204d of the cable 204 which contains no tips; and that tips 210 in cable 204 are sidewardly offset from a portion 206d of the cable 206 which contains no tips. Also, spacers 217 divide such staggered groups 209 and 210, as shown. Further, the tips or needles in each group can be selectively removed to reduce ion dispensation, to aid in achieving static neutralization. Thus, if there is an excess of + charge at a particular location in the work area, one or more needles 210 or tips carrying + charge and located closest to that area may be removed from cable 104, thereby to aid in achievement of charge balance in the work area. Alternatively needles 209 may be added to cable 206. The needles may be pulled from the cable, and re-inserted at will. Note in FIG. 2 that the needles extend adjacent the sides of th cores 207, and held in that position by the plastic sleeve. 
     Also in FIG. 1, perpendiculars 226 from cable 204 intersect tips 209, such perpendiculars spaced from tips 210, and perpendiculars 227 from cable 206 intersect tips 210, such perpendiculars spaced from tips 209. 
     Tip protection means may also be provided (as shown in FIGS. 4a-4d, referred to above) on the cables 204 and 206. 
     From the above FIGS. 1-4 it will be seen that the method of substantially neutralizing static electricity at work in an extended work zone (the work occupying only a local relatively small portion of that zone) involves the steps: 
     (a) dispersing into the bulk of the extended work zone including said portion thereof both positive and negative ions, 
     (b) such dispersing carried out to substantially balance the positive and negative ion content in that portion of the zone. 
     Also, both positive and negative ions are dispersed from a large number of intermixed multiple points spaced about the extended zone. 
     Referring now to FIGS. 5 and 6, elements which remain the same as in FIGS. 1-4 are given the same numbers. 
     The system includes not only the first and second cable means or cable 204 and 206, as before, but also auxiliary means spaced from the cable means in the general direction of ion flow or travel toward the work, such auxiliary means being at or near ground potential, and having exposed electrically conductive surface extent. In the example, the auxiliary means comprises a bare wire 230, aluminum or copper for example, which extends generally parallel to and below the cables 204 and 206. It may be supported, for example, by the insulative plastic rods 220, as in a side notch 231 in each rod. The wire 230, grounded as at 232, is centered generally below the high voltage, positive and negative cables 204 and 206, at a distance of between 3 and 12 inches therefrom, the optimum distance being between 4 and 6 inches. It is found that the grounded wire enhances static neutralization effect all the way to the floor 233, including the area of the work 212 at distances of 7-9 feet below the cables 204 and 206. Also, the second cable 230 tends to balance the positive and negative field ionization, thereby improving the static neutralization--even to zero in many cases. In this regard, pairs of cables 204 and 206, and wires 230, are typically separated by distance &#34;d&#34;, which is 3-5 feet. 
     In FIG. 7, a false, electrically insulative, ceiling panel 240 extends parallel to and below the structural ceiling 241, leaving a ceiling spaced 242 therebetween. Panel 240 is perforated at a large number of row and column locations, as at 252, to pass air as from space 242 into a work zone 211. The perforations may taper downwardly, and have upper entrance diameters of about 3/4 inch and lower exit diameters of about 5/16 inch. Cables 204 and 206 are suspended in space 242, as by plastic rods 220a, or other supports, to emit positive and negative ions via tips as referred to above. The ions then pass downwardly into zone 211 via perforations 252. Ground wire 230 is suspended by panel 242 and plastic support rods 220b below cables 204 and 206. The ground wire helps draw or attract the ions through the perforations 252. FIG. 8 shows a panel 240a, like panel 240, below cables 204 and 206 and also below ground wire 230. Floor 233 may be as at 247 to pass air and dust from space 211 to a filter 248 and return to space 242. 
     In FIGS. 9-12, the cables 304 and 306 correspond to cables 204 and 206, respectively in FIG. 5, and the auxiliary wire 330 corresponds to wire 230 in FIG. 5. Rods 320 support the cables and wire as in FIG. 5. Wire 330 is supplied with voltage as from source 350, which is adjustable, and cables 304 and 306 are supplied with voltage from sources 312 and 314, which are adjustable. Typically, voltage from source 312 is more positive than voltage from source 314, and is therefore shown as +, whereas source 314 is shown as -. See adjustment knobs 312a, 314aand 350a. Voltage from source 350 may be neutral, (i.e. grounded), positive or negative. The function of wire 330 is to enhance static neutralization effect in the work area therebelow, as described in FIG. 5. 
     The improved spacers 370 have elongated parallel grooves 340 and 341 in which the cable 304 and 306 are retained at locations and separation from one another characterized in that static electricity at or proximate the work to be treated is effectively reduced to non-objectionable levels when the differential voltages are applied to the cables 304 and 306. See in this regard the tips defined by needles 309 and cables 304 and needles 310 on cable 306. The needles are associated with the spacers, wherein the cables are gripped, so that the tips point in directionally controlled relation. The spacers are located along the cables at spacing L which varies beteen 3-4 inches and 2 feet. Needles 309 are associated with spacers which alternate with spacers associated with needles 310; and typically there are more needles 310 per unit length of cable than there are needles 309. An example is shown in FIG. 9, wherein spacers 307a carry one positive needle each, on cable 304, whereas alternate spacers 307b carry two needles, each, on cable 306. Needles 310 normally are negatively charged. 
     FIGS. 9-12 also show the provision of the spacers or cable spreaders in the form of molded plastic blocks 370 defining the parallel grooves 340 and 341. Pressure is exerted on the sides of the cables in the blocks, to hold the cables in place. The grooves have sideward entrance channels 340aand 341a, and enlarged interiors 340b and 341b communicating with the channels, for reception of the cables, with pressurization. The depths of the grooves are sufficient that the tips of the needles 310 are within channels 340a and 341a, to protect against snagging or injury to other apparatus or person, especially when the cables are wound as during storage or shipment. 
     In FIG. 13 the cable 404 comprises multiple electrical wire strands 405 enclosed within insulative sheath 406. An electrically conductive needle 407 has been pressed into and through the bundle of strands 405 (the core) to spread apart at least some strands and to protrude at tip 407a. This construction enables rapid assembly of needles to the cable, and very good electrical contact of the needles to the core. Also the needle point is preserved, and not blunted by solid core metal. 
     In FIG. 14, the modified needle 500 consists of a conductive metal core 501 (copper for example) on which a tungsten or tungsten alloy layer 502 has been applied, as by coating, cladding, plating, etc. The layer defines the sharp tip or point 502a from which positive ions are emitted. A positive voltage source 504 is connected with the needle or its tip occurs, whereas, with non tungsten needles corrosion can and does occur. The layer 502 may alternatively consist of a metallic tungsten alloy, as for example gold and tungsten, or platinum and tungsten, the weight % of tungsten being in excess of about 50%. The cable core and sheath elements 405 and 406 are the same as in FIG. 13, the needle having been forced through the core to have good sideward electrical contact with the core. All the needles described above in FIGS. 1-13, and to which positive voltage is applied, typically have the tungsten or tungsten alloy construction of FIG. 14, or else a solid tungsten or tungsten alloy composition, throughout the needle. Typical positive voltages are between 5000 and 15,000 volts, DC. Single conductors employing such needles are also contemplated (i.e. omitting the companion negative needle cable). 
     In FIG. 15, a cable means metallic extent 600, which may be flexible (as for example copper wire) is attached to multiple needles 601. Such needles include a layer 601a of conductive metal on a tungsten core 601b, the metal layer being bondable (as by soldering or welding at 602) to the wire 600. The tungsten is employed to resist corrosion, as before. Thorium coated, tungsten tips, appear at 603, for dispensing ions. 
     FIG. 16 shows the provision of needles 611, the opposite ends of which are pointed. The needles project through cables 404, as described above, and including multiple electrical wire strands 405 enclosed within insulative sheaths 406. Needle points 611a project within groove channels 340a and 341a, to dispense ions. Plastic spacer 370 defines the grooves and channels, as before. The needle points 611b are pushed into the cables, and may or may not penetrate the material of the spacer. They enable easy replacement of the needles, if desired, since they easily penetrate the wire strand bundle, when pushed in, and the needles may be easily withdrawn. Such needles may otherwise have the construction of any of the needles described in this specification. 
     FIGS. 17-19 show a modified needle 631 having a non-tungsten core 631a and a thin tungsten layer 631b or coating thereon. Core 631a may for example, consists of steel, aluminum, copper, or alloys thereof, or aluminum alloy or other conductive and solderable (bondable) metal. The core has a locally outwardly exposed portion 631a&#39; directly electrically bonded to the cable means or wire 600, as seen in FIGS. 17 and 19, a soldered area indicated at 624. Portion or flat surface 631a&#39; may be formed as by grinding the needle end, as shown. The wire 600 is shown as looped about the needle upper portion. In FIG. 20 two ground flats are formed as at 631c and 631d, and at different angles, to intersect and form an edge 631e that sharply engages and may slightly penetrate the wire 600 wound tightly thereon, for good electrical contact. 
     In FIG. 21 a modified needle 641 has a core 641a (which may consist of steel), a first tungsten coating 641b and a second thorium coating 641c, and to which a wire 600 may be easily soldered. The double pointed needle has one pointed end portion 642 not coated with thorium, i.e. the tungsten point 647 is exposed to disperse ions, and not corrode. The other pointed end portion 643 is thorium coated. In FIG. 22, the modified needle 651 has an all tungsten core 651a, and thorium coating 651b thereon. 
     Positive or negative voltage may be applied to the FIGS. 15-22 needles.