[특허]Flameless thermal spray apparatus with electronic ignition and single air supply

Galbraith, Stephen L.

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특허 상세정보

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Flameless thermal spray apparatus with electronic ignition and single air supply

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	B05B-001/24 B05B-007/20 B05B-007/00 B05B-011/00
출원번호	US-0374201 (2011-12-15)
등록번호	US-9095863 (2015-08-04)
발명자 / 주소	Galbraith, Stephen L. Deily, Michael F. Farrar, Lawrence C. Lane, Kevin M.
출원인 / 주소	Galbraith, Stephen L.
대리인 / 주소	Foley & Lardner LLP
인용정보	피인용 횟수 : 0 인용 특허 : 11

초록

An apparatus and method for forming a fusible coating or structure comprising a combustor that is operative to combust a fuel and contain the resulting flame to produce combustion products; components for cooling the combustion products to produce a hot carrier gas stream; and elements for introducing fusible material into the hot carrier gas stream; made lightweight and easier to operate through the addition of a continuous electronic ignition system and a single air manifold.

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1. A thermal spray gun comprising: a lower air manifold assembly that is operative to receive a propane input stream and a main air input stream, to divide said main air input stream into a combustion air amplifier air input stream and an upper air amplifier air input stream and, to combine said propane input stream with said combustion air amplifier air input stream to produce a combustion gas and air stream;a heater assembly that is operative to receive said combustion gas and air stream, said heater assembly comprising a perforated heater plate and a diverter cone;an igniter that is operative to ignite said combustion gas and air stream to produce a flame on said perforated heater plate, said igniter comprising an electrode tip;an upper air manifold assembly that is operative to receive said upper air amplifier air input stream and to produce a diverter air amplifier high velocity air stream and a cooling air amplifier high velocity air stream, said diverter air amplifier high velocity air stream being operative to draw a diverter air inlet stream into said upper air manifold assembly to produce an inner diverter outlet steam and an outer diverter outlet stream, and said cooling air amplifier high velocity air stream acting to draw a cooling air inlet stream into said upper air manifold assembly to produce a cooling air outlet stream; anda feed tube assembly that is operative to receive a powder feed input stream and to produce a powder feed outlet stream, said feed tube assembly comprising a feed tube tip;wherein said inner diverter outlet stream is operative to cool said feed tube tip and said diverter cone and to surround said powder feed outlet stream; andwherein said outer diverter outlet stream is operative to urge said flame radially outward. 2. The thermal spray gun of claim 1 wherein said lower air manifold assembly is further operative to divide said main air input stream into said combustion air amplifier air input stream, said upper air amplifier air input stream, and a shielding air inlet stream; and wherein said feed tube assembly is further operative to receive said shielding air inlet stream and to produce a shielding air inlet stream that is operative to cause said powder feed outlet stream to contract to produce a powder contraction zone and then to expand to produce a powder expansion zone. 3. The thermal spray gun of claim 1 wherein said igniter further comprises a conductive electrode tube having and electrode inlet hole and an annular void, an electrode insulator and an electrode, said electrode being separated from said electrode tube by said electrode insulator. 4. The thermal spray gun of claim 3 wherein said electrode inlet hole and an annular void receive a portion of said combustion gas and air stream and produce a pilot gas air mixture stream that is ignitable by a spark traveling across a spark gap between said tip electrode and said electrode tube. 5. The thermal spray gun of claim 4 further comprising: an electronic ignition circuit comprising: a step-up transformer, a normally-open relay, an igniter switch, a micro-controller that energizes said normally-open relay when said igniter switch is closed, a capacitor, a spark transformer, and a fire starter integrated circuit;wherein, when a first voltage is applied to said capacitor after said igniter switch is closed, said fire started integrated circuit is operative to conduct a current, said capacitor is operative to discharge said current to ground, and said spark transformer is operative to impose a second voltage across said spark gap. 6. The thermal spray gun of claim 1 wherein said electrode tip is mounted substantially flush with said perforated heater plate, protruding from said perforated heater plate, or recessed from said perforated heater plate. 7. The thermal spray gun of claim 1 further comprising: a normally-closed dead man's switch that is operative to shut off said propane input stream when said dead man's switch is not depressed. 8. The thermal spray gun of claim 1 further comprising: a shroud that surrounds at least a portion of said heater assembly; anda heat shield that surrounds at least a part of said shroud. 9. The thermal spray gun of claim 1 further comprising: an umbilical comprising the following components: a propane hose, a single air hose, a powder hose, a plurality of signal wires, a spark ignition power wire, and an electrical ground;wherein said components are bundled within a protective sleeve. 10. The thermal spray gun of claim 1 further comprising: a valve for controlling the rate of flow of said combustion air amplifier air input stream. 11. A thermal spray gun comprising: means for receiving a propane input stream and a main air input stream, dividing said main air input stream into a combustion air amplifier air input stream and an upper air amplifier air input stream, and combining said propane input stream with said combustion air amplifier air input stream to produce a combustion gas and air stream;means for receiving said combustion gas and air stream, said means for receiving comprising a perforated heater plate and a diverter cone;means for igniting said combustion gas and air stream and producing a flame on said perforated heater plate, said means for igniting comprising an electrode tip;means for taking up said upper air amplifier air input stream and producing a diverter air amplifier high velocity air stream and a cooling air amplifier high velocity air stream, said diverter air amplifier high velocity air stream acting to draw a diverter air inlet stream into said means for taking up said upper air amplifier air input stream to produce an inner diverter outlet steam and an outer diverter outlet stream, and said cooling air amplifier high velocity air stream acting to draw a cooling air inlet stream into said means for taking up said upper air amplifier air input stream to produce a cooling air outlet stream; andmeans for accepting a powder feed input stream and producing a powder feed outlet stream, said means for accepting comprising a feed tube tip;wherein said inner diverter outlet stream is operative to cool said feed tube tip and said diverter cone and to surround said powder feed outlet stream; andwherein said outer diverter outlet stream is operative to urge said flame radially outward. 12. The thermal spray gun of claim 11 wherein said means for receiving is further operative to divide said main air input stream into said combustion air amplifier air input stream, said upper air amplifier air input stream, and a shielding air inlet stream; and wherein said means for accepting is further operative to receive said shielding air inlet stream and to produce a shielding air inlet stream that is operative to cause said powder feed outlet stream to contract to produce a powder contraction zone and then to expand to produce a powder expansion zone. 13. A method for thermal spraying comprising: receiving a propane input stream and a main air input stream in a thermal spray gun, dividing said main air input stream into a combustion air amplifier air input stream and an upper air amplifier air input stream, and combining said propane input stream with said combustion air amplifier air input stream to produce a combustion gas and air stream;receiving said combustion gas and air stream in a means for receiving, said means for receiving comprising a perforated heater plate and a diverter cone;igniting said combustion gas and air stream and producing a flame on said perforated heater plate;taking up said upper air amplifier air input stream and producing a diverter air amplifier high velocity air stream and a cooling air amplifier high velocity air stream, said diverter air amplifier high velocity air stream educting a diverter air inlet stream to produce an inner diverter outlet steam and an outer diverter outlet stream, and said cooling air amplifier high velocity air stream educting a cooling air inlet stream to produce a cooling air outlet stream; andaccepting a powder feed input stream and producing a powder feed outlet stream; wherein said inner diverter outlet stream is operative to surround said powder feed outlet stream; and wherein said outer diverter outlet stream is operative to urge said flame radially outward. 14. The method of claim 13 further comprising: dividing said main air input stream into said combustion air amplifier air input stream, said upper air amplifier air input stream, and a shielding air inlet stream; andreceiving said shielding air inlet stream to produce a shielding air inlet stream that is operative to cause said powder feed outlet stream to contract to produce a powder contraction zone and then to expand to produce a powder expansion zone. 15. A thermal spray gun comprising: a manifold assembly that is operative to receive a propane input stream and a main air input stream, to divide said main air input stream into a combustion air input stream and a cooling air input stream, to combine said propane input stream with said combustion air input stream to produce a combustion gas and air stream, to divide said cooling air input stream into a diverter air amplifier high velocity air stream and a cooling air amplifier high velocity air stream, said diverter air amplifier high velocity air stream being operative to draw a diverter air inlet stream into said manifold assembly to produce an inner diverter outlet steam and an outer diverter outlet stream, and said cooling air amplifier high velocity air stream acting to draw a cooling air inlet stream into said manifold assembly to produce a cooling air outlet stream;a heater assembly that is operative to receive said combustion gas and air stream, said heater assembly comprising a heater plate;an igniter that is operative to ignite said combustion gas and air stream to produce a flame on said heater plate; anda feed tube assembly that is operative to receive a powder feed input stream and to produce a powder feed outlet stream. 16. The thermal spray gun of claim 15 wherein said manifold assembly is further operative to divide said main air input stream into said combustion air amplifier air input stream, said upper air amplifier air input stream, and a shielding air inlet stream; and wherein said feed tube assembly is further operative to receive said shielding air inlet stream and to produce a shielding air inlet stream that is operative to cause said powder feed outlet stream to contract to produce a powder contraction zone and then to expand to produce a powder expansion zone. 17. The thermal spray gun of claim 15 wherein said igniter further comprises a conductive electrode tube having an electrode inlet hole and an annular void, an electrode insulator and an electrode, said electrode being separated from said electrode tube by said electrode insulator. 18. The thermal spray gun of claim 17 wherein said electrode inlet hole and an annular void receive a portion of said combustion gas and air stream and produce a pilot gas air mixture stream that is ignitable by a spark traveling across a spark gap between said tip electrode and said electrode tube. 19. The thermal spray gun of claim 18 further comprising: an electronic ignition circuit comprising: a step-up transformer, a normally-open relay, an igniter switch, a micro-controller that energizes said normally-open relay when said igniter switch is closed, a capacitor, a spark transformer, and a fire starter integrated circuit;wherein, when a first voltage is applied to said capacitor after said igniter switch is closed, said fire started integrated circuit is operative to conduct a current, said capacitor is operative to discharge said current to ground, and said spark transformer is operative to impose a second voltage across said spark gap. 20. The thermal spray gun of claim 15 wherein said electrode tip is mounted substantially flush with said perforated heater plate, protruding from said perforated heater plate, or recessed from said perforated heater plate. 21. The thermal spray gun of claim 15 further comprising: a normally-closed dead man's switch that is operative to shut off said propane input stream when said dead man's switch is not depressed. 22. The thermal spray gun of claim 15 further comprising: a shroud that surrounds at least a portion of said heater assembly; anda heat shield that surrounds at least a part of said shroud. 23. The thermal spray gun of claim 15 further comprising: an umbilical comprising the following components: a propane hose, an air hose, a powder hose, a plurality of signal wires, a spark ignition power wire, and an electrical ground. 24. A thermal spray gun comprising: an umbilical comprising a gaseous fuel hose, a powder hose, and an air hose that is operative to convey a main air input stream;a manifold assembly that is operative to divide said main air input stream into a plurality of air streams, one of which is a combustion gas and air stream and another of which is a hot air stream;a heater assembly that is operative to receive and combust said combustion gas and air stream;a thermal spray gun on-off switch that is operable to tum the thermal spray gun off when released by an operator;a spark ignition electrode assembly that is operative to ignite said combustion gas and air stream within said heater assembly when activated by said operator;a shielded powder tube assembly comprising a powder feed tube that is shielded from said hot air stream by a shielding air tube powder feed tube and that extends into said hot air stream. 25. The thermal spray gun of claim 24 wherein said umbilical comprises a gaseous fuel hose, a powder hose, and a single air hose that is operative to convey a main air input stream. 26. The thermal spray gun of claim 24 wherein said powder feed tube extends about three inches into said hot air stream.

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Flameless thermal spray apparatus with electronic ignition and single air supply

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Flameless thermal spray apparatus with electronic ignition and single air supply

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