System and method for ionization bar for air nozzle manifold

Abstract

A system and method are provided comprising an air blower 12 and air manifolds 14A, 14B having a body 56 with inlets 40A, 40B coupled to the air blower 12 and a plurality of outlet openings. Each of the outlet openings is coupled to a nozzle 42. The ionizer bar 100 comprises a housing 102, a power cable 106 housed in the housing 102, and a plurality of emitter pins 110 electrically coupled to the power cable 106. A low-voltage power supply 98 provides low-voltage power to energize the ionizer bar 100. The cartridge 80 comprises two side plates 84, 85 forming a channel 86 into which the ionizer bar 100 is mounted. The cartridge 80 is removablely coupled inside the body 56 of the air manifolds 14A, 14B.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional patent application claiming priority to U.S. Provisional Patent Application No. 63 / 496,662, filed on April 17, 2023, entitled "Systems And Methods For An Ionizing Bar For Air Nozzle Manifolds", which is hereby incorporated by reference in its entirety and made a part of this application (this specification).

[0002] Examples of the present disclosure generally relate to air purification and static neutralization systems, and more particularly, to an ionization bar mounted within an air nozzle manifold.

Background Art

[0003] In conventional bottle or can filling applications, compressed air is often used to clean bottles or cans on the assembly line before filling. Similarly, it is often desirable to neutralize static electricity that accumulates on the bottles or cans during the filling operation or is introduced in other ways. Therefore, separate nozzles have been used to blow ionized compressed air into the bottles or cans to achieve both tasks at once. However, these solutions are expensive due to the use of compressed air and the cost of powering the electrical components of the separate nozzles. Also, it is difficult to perform maintenance on individual nozzles.

[0004] Air manifolds having alternatives to compressed air nozzles, such as a series of nozzles, air knives, etc., can be used to direct air received at the inlet from a blower. By providing a cleaning and static neutralization system that uses blowing air rather than compressed air, it is desirable to enable the use of an effective static neutralization device that is easy to manage and maintain as part of the blowing air system without sacrificing the desirable effects of the blowing air.

[0005] By comparing such a system with the disclosure described in the remainder of this application with reference to the drawings, the limitations and disadvantages of prior and traditional methods will become apparent to those skilled in the art. [Overview of the project]

[0006] Systems and methods for processing objects are disclosed herein. One example of the disclosure includes a processing system comprising a blower and an air manifold having a body with an inlet coupled to the blower and a plurality of outlet openings. Each of the outlet openings is coupled to a nozzle. An ionizer bar comprises a housing, a power cable housed in the housing, and a plurality of emitter pins electrically coupled to the power cable. A cartridge comprises two side plates forming a channel into which the ionizer bar is mounted. The cartridge is removablely coupled inside the body of the air manifold. In some examples, the ionizer bar is powered by a low-voltage input.

[0007] Certain aspects of the embodiments disclosed herein as examples are summarized below. These aspects are presented to the reader only to provide a concise summary of certain forms that the invention disclosed and / or claimed herein may take, and should be understood as not intended to limit the scope of the invention disclosed and / or claimed herein. In fact, any invention disclosed and / or claimed herein may encompass a variety of aspects not described below.

[0008] These features, aspects, and advantages of the present disclosure, as well as other features, aspects, and advantages, will be better understood by reading the following detailed description with reference to the accompanying drawings, where similar reference numerals throughout the drawings represent similar parts. [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic diagram of a processing system according to an example of this disclosure.

[0010] [Figure 2] This is a perspective view of an air manifold according to the above example of this disclosure.

[0011] [Figure 3A] Figure 2 is a detailed perspective view of the air manifold with the ionizer bar installed. [Figure 3B] Figure 2 is a detailed perspective view of the air manifold with the ionizer bar installed.

[0012] [Figure 4A] Figure 3 is a perspective view of the bracket for securing the ionizer bar to the air manifold. [Figure 4B] Figure 3 is a side view of the bracket for fixing the ionizer bar to the air manifold.

[0013] [Figure 5A] Figure 3 is a top view of the cartridge used to fix the ionizer bar to the air manifold.

[0014] [Figure 5B] Figure 5A is a bottom perspective view of the cartridge.

[0015] [Figure 6] Figure 3 is a right side view of the ionizer bar.

[0016] [Figure 7] Figure 3 is a front view of the ionizer bar.

[0017] [Figure 8] This is a front perspective view of an air knife according to another example of this disclosure.

[0018] [Figure 9] This is a front perspective view of an air manifold according to yet another example of the present disclosure.

[0019] [Figure 10] FIG. 9 is a front cross-sectional view of the air manifold with the ionizer bar installed.

[0020] [Figure 11] FIG. 9 is a side view of the nozzle used within the air manifold and the elongated cylindrical shaft coupled to the nozzle. DETAILED DESCRIPTION OF THE INVENTION

[0021] The figures are not necessarily to scale. Where appropriate, the same or similar reference numbers are used in the figures to refer to the same or similar elements.

[0022] One or more specific embodiments of the present invention will be described below. These described embodiments are presented by way of example only and are not intended to limit the scope of the present disclosure. Additionally, in order to provide a concise description of these exemplary embodiments, not all features of an actual implementation may be described herein. As with any engineering or design project, in the development of any such actual implementation, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints that may vary from one implementation to another. It should be understood that such development efforts can be complex and time-consuming, but nevertheless, for those skilled in the art having the benefit of the present disclosure, it should be understood that they are routine work in design, fabrication, and manufacturing.

[0023] Due to the advantages of the disclosed system, it is possible to attach an ionization bar within the housing and / or manifold (e.g., for a system using an air knife). The disclosed system is configured to be powered by a low-voltage power source. The disclosed ionization bar and / or low-voltage power source can be attached inside the air knife system (e.g., within the manifold, adjacent to the manifold, etc.).

[0024] In the disclosed example, the processing system for an air nozzle manifold comprises an air manifold having a body with an inlet coupled to an air blower and a plurality of outlet openings, and an ionizer bar disposed within the body, the ionizer bar being connected to a low-voltage power supply to supply low-voltage power to the ionizer bar.

[0025] In some examples, the ionizer bar is connected to a low-voltage power supply via one or more power cables, and the one or more power cables are connected to an air manifold or the ionizer bar via one or more fixtures. In the example, the system further comprises an insulating housing that supports the ionizer bar within its body. In the example, one or more emitter pins are electrically coupled to the power cables and to the ionizer bar through the insulating housing.

[0026] In the example, the system further comprises one or more brackets for mounting an ionizer bar within an air manifold, the ionizer bar being secured to one or more brackets via one or more removable fasteners. In the example, one or more brackets are secured inside the body of the air manifold.

[0027] In some examples, each of the outlet openings is coupled to a nozzle that blows ionized compressed air toward an object or the environment.

[0028] In this example, the system further comprises a second ionizer bar coupled to a low-voltage power supply. In this example, the second ionizer bar is located within an air manifold housing.

[0029] In this example, the system further comprises one or more cartridges, each having two side plates that form a channel into which an ionizer bar is mounted, and the one or more cartridges are removably coupled inside the body of the air manifold.

[0030] In some disclosed examples, the processing system comprises a low-voltage power supply, an air blower, an air manifold having a body with an inlet coupled to the air blower and a plurality of outlet openings, each of which is coupled to a nozzle, an ionizer bar supported by a housing, a power cable connected to the low-voltage power supply to supply low-voltage power to the ionizer bar, and one or more brackets for mounting the ionizer bar within the air manifold, the ionizer bar being secured to one or more brackets via one or more removable fasteners.

[0031] In some cases, the low-voltage power supply is located within the air manifold.

[0032] In some cases, the low-voltage power supply is located adjacent to the air manifold.

[0033] In some examples, the power cable is housed within a portion of the housing, and multiple emitter pins electrically couple the ionizer bar to the power cable.

[0034] In some cases, the housing is an insulating housing that encloses a portion of the ionizer bar.

[0035] In some cases, a low-voltage power supply provides 24 volts of direct current (DC) power.

[0036] In some cases, the low-voltage power supply is connected to a remote power supply.

[0037] In this example, the system further comprises a remote control panel / station that provides user control of the processing system, including controlling the ionization level of the ionizer bar or monitoring feedback of one or more outputs or states related to the ionization process.

[0038] In this example, the system further comprises a second air manifold housing a second ionizer bar. In this example, a remote control panel / station is configured to provide operational control of the ionizer bar and the second ionizer bar.

[0039] Referring to the drawings (where the same reference numerals are used to specify the same components across several drawings), Figure 1 shows a processing system 10 comprising an air supply source 12 configured to deliver a fluid (e.g., air) along a flow path 16 to air manifolds 14A and 14B. In the illustrated example, the flow path 16 comprises fluid conduits 20, 22, 36, and 38, a filter 24, and a split section 32.

[0040] The air supply source 12 may include a high-flow centrifugal blower ("air blower"), which in some examples may include a configuration combining a supercharger and a motor. In one example, the operating characteristics of the blower 12 are such that it has a pressure of about 6.9 to 69 kilopascals (about 1 to 10 pounds per square inch (psi)) and can provide an airflow having a flow rate of about 1.4 to 57 cubic meters per minute (about 50 to 2000 cubic feet (CFM)), or more specifically, about 4.2 to 42 cubic meters per minute (about 150 to 1500 CFM). In some examples, the blower 12 may be housed in a housing. The air blower 12 can be separated from the air manifolds 14A and 14B by a distance of approximately 3.0, 6.1, 9.1, 12, 15, 30, or 61 meters (10, 20, 30, 40, 50, 100, or 200 feet) or more. Therefore, the flow path 16 is configured to provide a path through which the air supplied by the blower 12 can be guided and ultimately delivered to the air manifolds 14A and 14B.

[0041] The blower 12 may be equipped with an outlet 18 connected to a fluid conduit 20 that defines a first portion of the flow path 16. The fluid conduit 20 may be a hose, pipe, such as a flexible hose, stainless steel pipe, polyvinyl chloride (PVC) pipe, or piping. An adapter (not shown) can be used in the flow path 16 to provide a contact point for connecting different conduit materials such as hoses and pipes. A filter 24 may be located downstream of the blower 12. As shown in Figure 1, the filter 24 is sandwiched between conduits 20 and 22. The operation of the filter 24 will be described in more detail below.

[0042] The flow path 16 extends to the distal end of the conduit 22, which can be connected to the inlet 30 of a flow divider 32 that receives the airflow. The flow divider 32 can be configured to distribute or divide the airflow to a plurality of outlets 33 and 34. Additional fluid conduits 36 and 38 can connect the outlets 33 and 34 to air manifolds 14A and 14B, respectively. In the illustrated example, air manifolds 14A and 14B may each have inlets (40A and 40B) configured for hose connections, so the fluid conduits 36 and 38 can be provided as hoses such as flexible hoses. In other examples, the pipe may be positioned between the split section 32 and one of the air manifolds 14A or 14B, in which case an adapter (not shown) is coupled to each end of the pipe to facilitate fluid connection between a hose extending from the outlet of the split section 32 (e.g., 33 or 34) and a hose extending from the inlet of one of the air manifolds (e.g., 14A or 14B) (e.g., 40A or 40B). In some examples, the system 10 may consist of only a single air manifold (e.g., 14A) and therefore may not have a split section 32. In such examples, the fluid conduit 22 may be directly coupled to the air manifold 14A.

[0043] As shown in Figure 1, the airflow 44 exiting the air manifolds 14A and 14B can be directed to the respective applications 48 and 50 of the processing system 10. For example, the applications 48 and 50 can be transported through the system 10 along a conveyor belt 52 or other suitable type of transport mechanism. As can be understood, the system 10 can utilize the airflow 44 provided by the air manifolds 14A and 14B for a variety of functions, including, but not limited to, drying products, removing dust or debris, coating control, cooling, leak detection, surface impregnation, and corrosion prevention. For example, in a particular example, the system 10 may be used to dry food or beverage containers such as cans or bottles, or it may be a system for removing dust and other debris from highly sensitive electronic products such as printed circuit boards (PCBs). In addition, in some examples of the system 10, the airflow 44 may be used to clean and / or remove debris from the conveyor belt 52.

[0044] Figures 2 and 3 show an exemplary air manifold 14 used in the system 10 of Figure 1. The air manifold 14 comprises a body or housing 56 having an axial length (e.g., measured along the longitudinal axis L) of about 0.15 to 1.2 meters (about 0.15, 0.30, 0.46, 0.61, 0.76, 0.91, 1.1, or 1.2 meters) (about 0.5 to 4 feet (e.g., 0.5, 1, 1.5, 2, 2.5, 3, 3.5, or 4 feet)) or less or more) or more, although other axial lengths of the body 56 may be used as well. For example, in some examples, the length may be greater than about 1.2 meters (4 feet) (e.g., about 1.5, 1.8, 2.1, 2.4 meters (5, 6, 7, 8 feet)) or less or more, etc.

[0045] In the illustrated example, the body 56 is generally cylindrical (for example, having a generally circular cross-section). In other examples, the body 56 may have an elliptical, rhombic, triangular, square, or rectangular cross-section, etc. The first end of the body 56 is open and forms an inlet 40. As described above, air supplied by the air source 12 is guided through the inlet 40 to the air manifold 14 and can be discharged through a plurality of nozzles 42. For example, the inlet 40 can be coupled to a fluid conduit (for example, conduit 36). The second end of the body 56 (closed end) opposite the inlet 40 can be sealed by an end cap 58. In certain examples, the end cap 58 may have a shape that is generally the same as the cross-sectional shape of the body 56 (for example, circular). The end cap 58 may be joined to the body 56 by welding (for example, tungsten inert gas (TIG) welding), or it may be fixed to the body 56 using one or more screws, bolts, or any other suitable type of fastener, adhesive, etc.

[0046] In some examples, the body 56 of the air manifold 14 may be provided with one or more mounting brackets 60 for attaching the air manifold 14 to an assembly line. The mounting brackets 60 may be welded to the body 56, or they may be fixed to the body 56 using other connection methods such as adhesives or mechanical fasteners. In the illustrated example, each mounting bracket 60 is formed by a plate 61 extending radially outward from the body 56, and each has a plurality of through holes 62 for receiving mounting screws (not shown) or similar mechanical fasteners for fixing the plate 61 to a support (not shown). Other types of mounting brackets 60 may be used, including those that allow movement of the body 56 relative to the support, including rotational motion, sliding motion, etc.

[0047] The inlet 40 and the body 56 are illustrated in Figures 2 and 3 as having diameters that can be equal. In one example, the diameters of the inlet 40 and the body 56 are approximately 2.5 to 15 centimeters (approximately 1 to 6 inches). In other examples, the diameters of the inlet 40 and the body 56 may be of different sizes. Furthermore, in some examples, the diameter of the body 56 may vary along its length L. For example, the diameter of the body 56 may gradually decrease or increase from the end of the inlet 40 to the sealed end (e.g., having an end cap 58).

[0048] The nozzles 42 extend radially outward from the body 56. The body 56 has a plurality of openings 70 (Figure 3), each of which corresponds to each of the nozzles 42. The inlet ends of the nozzles 42 may be welded to the body 56 by TIG welding or a similar mounting process so that air flowing into the body 56 of the air manifold 14 through the inlets 40 can flow into each nozzle 42 through the openings 70 of the body 56. In other words, each nozzle 42 on the body 56 and its respective opening 70 define a flow path through which air in the body 56 can be discharged from the air manifold 14.

[0049] While the illustrated examples in Figures 2 and 3 feature 10 nozzles 42, it should be understood that any appropriate number of nozzles may be provided in various examples. For example, in a particular example, there may be 2 to 20 or more nozzles. The nozzles 42 can be spaced axially along the length L of the body 56 such that each nozzle 42 is axially separated. The distance between adjacent nozzles 42 may be the same or vary, as shown in Figure 2, and is approximately 2.5 to 30 centimeters (approximately 1 to 12 inches) each, although other distances are considered within the scope of this disclosure. Furthermore, the length of the nozzles extending from the outer surface of the air manifold body 56 can be adjusted to suit a particular environment and / or application (e.g., housing size, object dimensions, processing speed, etc.).

[0050] Referring to Figures 3, 6, and 7, an ionizer bar 100 is presented for generating ions that enter an airflow 44 directed toward the applications 48, 50, and is inserted into a main body 56. The ionizer bar 100 comprises a housing 102 made of an insulating material, polytetrafluoroethylene (PTFE), reinforced plastic, etc. The housing 102 comprises at least one hollow channel 104 extending along the length of the ionizer bar 100. The hollow channel 104 is sized and shaped to receive a power cable 106, which can be an insulated cable having a conductive core.

[0051] In some examples, the power supply 98 is connected to the ionizer bar 100 via a power cable 106. The power supply 98 can be a low-voltage power supply that provides a voltage over a range of values. For example, the low voltage supplied to the ionization bar 100 can be lower than 50V DC (e.g., from 12V DC to 48V DC), and may be a 24V DC supply voltage or approximately 24V DC supply voltage. Although the low-voltage power supply is illustrated as being located remotely from the air manifold 14 and connected to the ionizer bar 100 via a power cable 106, in some examples it may be located adjacent to the housing 56 and / or integrated into the housing 56. In such a configuration, the power supply may be connected to a power source that provides a direct current (DC) or alternating current (AC) input (e.g., a commercial power supply, a generator, an energy storage system, etc.) that can be located remotely from the air manifold 14. In one example, the system 10 and power supply 98 provide a 24V DC supply voltage. Therefore, the wiring to the ionizer bar 100 can be configured to receive input from a 24V DC power supply and / or power converter. Advantageously, the power transmitted to the system 10 and / or the ionizer bar 100 can be carried by cabling suitable for low-voltage power, allowing for a choice of wiring that may be better suited to specific applications and / or environments (e.g., rather than cabling for high-voltage power).

[0052] The power supply 98 may include and / or use a voltage converter. For example, the voltage converter may include a circuit, switch, transformer, etc., which changes the input voltage to a desired output voltage, and the converter converts the input voltage accordingly. This may include conversion from a DC source or an AC source, and conversion from high voltage to low voltage, or low voltage to high voltage. Furthermore, the power supply for converting and / or adjusting the voltage for output to the ionizer bar 100 may be installed inside the ionizer bar itself (and / or inside the manifold 14, inside a junction in the manifold 14, or inside a junction adjacent to the manifold 14, etc.), thus avoiding a remote and / or separate high-voltage power supply. This allows the power supply 98 and / or the ionizer bar 100 to be protected from the working environment (e.g., shock, chemicals, fluids, etc.) by mounting them inside the manifold, thereby reducing the overall footprint of the air manifold 14 and / or the larger system 10.

[0053] While some examples focus on low-voltage power supplies, in some examples the power supply 98 may include circuitry configured to provide a voltage range greater than 1kV (e.g., a higher voltage output).

[0054] The housing 102 of the ionizer bar 100 also has a pin slot 108 on its bottom surface that extends along a hollow channel 104 and is accessible from there. Multiple pins 110 are electrically coupled to the power cable 106 and extend within the pin slot 108. The pins 110 may be directly connected to the low-voltage power supply 98, resistively connected via the power cable 106, or connected capacitively. While some examples target low-voltage power supplies, high-voltage power supplies are also considered in some examples. In the example shown in the drawings, the pins 110 penetrate the insulator of the power cable 106 to establish a physical and electrical connection to the conductive core. However, in other examples, the pins 110 may be coupled to the power cable 106 via terminals, conductive traces, etc. The pins 110 can be spaced in a regular pattern along the length of the housing 102 of the ionizer bar 100 to provide a uniform distribution of ions. For example, the pins 110 can be placed about 2.5 centimeters (1 inch) apart from each other along the power cable 106. The pin 110 can be formed from a metallic material such as copper, aluminum, tungsten, titanium, stainless steel, silicon, or silicon carbide, or from a semiconductor material.

[0055] The ionizer bar 100 can be installed inside the body 56 of the air manifold 14, with the free end of the power cable 106 positioned close to the end cap 58. To prevent a short circuit due to accidental contact between either the power cable 106 or the pin 110 and the body 56, the end portion 112 of the housing 102 of the ionizer bar 100 can be filled with an inert or non-conductive material 114, which may be a polyolefin-based hot-melt adhesive. Alternatively, the inert or non-conductive material 114 may be an epoxy, polyurethane, or silicone compound.

[0056] In some examples, the power supply 98 may include a controller 99 and / or be operably connected to the controller 99. The controller 99 may include, in a non-limiting list of examples, a control circuit unit 101 for processing data and / or a user interface 103 that allows the user to provide instructions, make selections, adjust operating parameters and / or receive feedback. The controller 99 may be located adjacent to the power supply 98 and / or the ionizer bar 100 (e.g., within the processing environment) and / or in a separate location (e.g., outside the processing environment). The controller 99 may be communicatively coupled to the power supply 98 and / or the ionizer bar 100 via a wired or wireless connection. The user interface 103 may include, in a non-limiting list of examples, knobs, dials, buttons, touch-operable surfaces, and voice and / or motion sensors for receiving and / or presenting information.

[0057] Although a single ionizer bar 100 is shown in some examples, two or more ionizer bars may be used in some examples. Multiple ionizer bars may be placed side by side (e.g., in a single air manifold) and / or housed in separate air manifolds and connected via conduits and / or power cables. Multiple ionizer bars may be connected in parallel or in series and may be controlled together and / or separately (e.g., via controller 99 or other suitable controller).

[0058] In some cases, the process may require increased ionization, and therefore multiple ionizer bars are used. For example, ionization treatment for materials being processed at high speed may use juxtaposed ionizer bars and / or multiple ionizer bars placed in or near the process environment.

[0059] In some cases, the low-voltage ionizer bars disclosed herein can be retrofitted to existing systems. Therefore, the bracket and housing configuration, as well as the supply of low-voltage power, can replace components of existing processing systems. For example, a high-voltage ionizer bar may be removed and replaced with a low-voltage ionizer bar mounted and powered as disclosed herein.

[0060] Referring to Figures 4A and 4B, in some examples, the ionizer bar 100 may be mounted within the body 56 of the air manifold 14 by a bracket 78. The bracket 78 may be permanently connected to the body 56 by welding or the like, but the bracket 78 may instead be releasably mounted to the body 56 to facilitate easier access to the ionizer bar 100 for maintenance and / or replacement. Thus, the bracket 78 can be mounted to the body 56 via bolts 82 or other mechanical fasteners extending from the outside of the body 56 into the bracket 78. However, other releasable mounting methods for the bracket 78, such as latches or hook-and-loop fasteners, may be used. In some examples, the bracket 78 is rigidly mounted to the body 56 to prevent the bracket 78 and the ionizer bar 100 from moving as a result of the force of the air flowing through the body 56.

[0061] Referring to Figures 5A and 5B, in some examples, the ionizer bar 100 may be mounted within the body 56 of the air manifold 14 by a cartridge 80. The exemplary cartridge 80 can be used in applications using various voltages, such as those exceeding 1 kV. The cartridge 80 may be in the form of a hollow bar having two side plates 84, 85 that, when installed, extend parallel to each other along the length L of the body 56 of the air manifold 14. The side plates 84, 85 are spaced apart from each other to form a channel 86 between them, which may be sized and shaped to hold the ionizer bar 100. The bottom surfaces of each plate 84, 85 may have a lip 88 perpendicular to the plates 84, 85 and extending toward the channel 86. The lip 88 is used to support the ionizer bar 100. For example, the lip 88 may abut against the bottom surface of the housing 102 of the ionizer bar 100, allowing the pin 110 to extend through a slot 90 formed by the lip 88. However, in some examples, the lip 88 engages with each groove 116 (Figure 6) that extends along the housing 102 of the ionizer bar 100. In this way, the corona discharge of the pin 110 is not obstructed by the cartridge 80. This configuration allows for easy insertion and removal of the ionizer bar 100 within the cartridge 80 by sliding the ionizer bar 100 within the channel 86. However, other insertion and removal methods for the cartridge 80, such as clips or other mechanical fasteners, may be used as well.

[0062] In some examples, the slot 90 does not extend along the entire length of the cartridge 80, but rather does not reach the edge of the cartridge 80 adjacent to the inlet 40 of the air manifold 14 at the installed position. The lip 88 may approach at this position of the cartridge 80 to form part of the spacer 92. The tops of each plate 84, 85 may also approach at this position to form another part of the spacer 92. The spacer 92 may also be equipped with an end cap 91. The spacer 92 seals the end of the cartridge 80 adjacent to the inlet 40 of the air manifold 14 to prevent air from accessing the power cord 106 of the ionizer bar 100.

[0063] Specifically, the power cord 106 is held by the mounting fixture 69 and can be inserted into the air manifold 14 through a cord opening 68 located at the top of the main body 56, close to the inlet 40. The channel 86 of the cartridge 80 is aligned with the cord opening 68 so that when the mounting fixture 69 is secured inside the cord opening 68, the power cord 106 is immediately received into the channel 86 of the cartridge 80 and is not exposed to the pressurized air entering the main body 56 through the inlet 40. However, the mounting fixture 69 and the cord opening 68 may be positioned at other locations on the air manifold 14.

[0064] Multiple nut plates 72 may be provided on the top of the cartridge 80, each of which is welded to plates 84, 85 or otherwise mechanically secured. Each nut plate 72 may have a threaded hole 74 that is at least partially through. The threaded holes 74 can be spaced apart on the cartridge 80 to align with corresponding bolt holes formed on the top of the body 56. Bolts 82 are positioned through the bolted holes and screwed into the threaded holes 74 of the nut plates 72 to secure the cartridge 80 to the body 56 of the air manifold 14.

[0065] Referring again to Figure 1, the filter 24 prevents debris in the airflow from entering the applications 48 and 50 and contaminating them. The filter 24 also prevents the accumulation of debris on the pins 110 of the ionizer bar 100, thereby maximizing the ionization efficiency of the pins 110 over extended periods. The filter 24 also prevents contamination and / or damage in the event of an upstream failure. For example, the air blower 12 often has an aluminum impeller, which can produce shavings that can enter the airflow if a catastrophic failure occurs that results in aluminum-to-aluminum contact, and the filter 24 will capture these shavings.

[0066] The filter 24 may have a housing made of stainless steel or a similar corrosion-resistant material. Furthermore, the filter 24 may include a medium (not shown) that meets the High-efficiency particulate air (HEPA) standard (i.e., 99.97% of particles larger than 0.3 micrometers are removed). However, a medium with 99.99% efficiency at 0.5 micrometers (nominal) has been found to allow for better airflow (e.g., only 10% pressure drop when using a HEPA filter) and is more than sufficient for food and beverage container applications 48, 50. The filter 24 may further include a gauge (not shown) to notify the user when replacement is needed.

[0067] In Figure 1, only one filter 24 is shown positioned between the blower 12 and the split section 32. Alternatively or additionally, one or more additional filters 24 may be positioned between the split section 32 and the air manifolds 40A and 40B. This configuration is useful, for example, in a system 10 where the airflow pressure is very high. The filter 24 may also be positioned at the inlet (not shown) of the blower 12.

[0068] In an alternative example of the present disclosure, the air manifold 14 may be replaced by an air knife 14', as shown in Figure 8. The air knife 14' is configured similarly to the air manifold 14, including the use of an inlet 40' to receive blown air from the air supply source 12, but instead of the nozzle 42 of the air manifold 14, the air knife 14' has an exhaust slot 42' that extends along most of the length of its body 56'. The body 56' has a tapered portion 57' to push air through the exhaust slot 42'. The ionizer bar 100 can be mounted inside the air knife 14' using a cartridge 80 in the same manner as described above.

[0069] Figures 9 to 11 show another example of the present disclosure, specifically designed for use in wash bottles (not shown) typically having small openings. The air manifolds in Figures 9 to 11 are similar to those in the examples shown in Figures 1 to 7, with similar elements being referred to by the same numerals, except that the examples in Figures 9 to 11 use numerals in the 200s. Therefore, a complete description of the examples in Figures 9 to 11 is omitted, and only the differences are described.

[0070] As can be seen in Figures 10 and 11, an elongated cylindrical shaft 243 having a constant inner diameter dI can be connected to each outlet of nozzles 242A through 242H. The elongated cylindrical shaft 243 does not further compress the airflow through each nozzle 242A through 242H, but rather maintains the pressure of the airflow 44 relatively constant. The elongated cylindrical shaft 243 is used, for example, to guide the airflow 44 to a small opening in a bottle. The outer diameter do of the elongated cylindrical shaft 243 can be constant along its length. In some examples, the inner diameter dI for bottle washing applications may be maximized for air delivery into the bottle, and the outer diameter dO is minimized so that air exiting the bottle opening can escape over the elongated cylindrical shaft 243. In one example, the inner diameter dI is approximately 7.9 millimeters (approximately 5 / 16 inch) and the outer diameter dO is approximately 9.5 centimeters (approximately 3 / 8 inch), but a variety of diameters are within the scope of this disclosure.

[0071] The elongated cylindrical shaft 243 may be friction-fitted and / or welded to the corresponding air nozzles 242A to 242H. However, other mounting methods such as adhesives and mechanical fasteners may also be used. The elongated cylindrical shaft 243 may also be made removable for replacement and / or use of nozzles 242A to 242H without the shaft 243.

[0072] Furthermore, Figures 9 and 10 show alternative configurations for attaching the power cable 206 to the air manifold 214. The cord opening 268 is located on the sealed end of the body 256 opposite the inlet 240, rather than on the top or radial surface of the body 256. Also, Figure 9 shows a slightly different configuration of the bracket 260. As described above, these modifications can be made to adapt to the mounting requirements of the air manifolds 14, 214 and are not limited by this disclosure.

[0073] When introducing elements of the various embodiments described below, the non-limiting words ("a," "an," "and," "the") are intended to mean that one or more of the elements exist. The terms "comprising," "including," and "having" are inclusive and are intended to mean that there may be further elements other than those listed. Furthermore, while the term "exemplary" may be used in this application in reference to certain examples of aspects or embodiments of the subject matter of this disclosure, these examples are illustrative in nature, and it should be understood that the term "exemplary" in this application is not used to indicate a preference or requirement regarding the disclosed aspects or embodiments. In addition, when referring to "one embodiment," "one embodiment," "several embodiments," etc., it should be understood that this is not intended to be interpreted as excluding the existence of further embodiments that similarly incorporate the disclosed features.

[0074] As used in this application, the terms “first” and “second” may be used to enumerate different components or elements of the same type and do not necessarily imply a specific order.

[0075] As used in this application, the terms "coupled," "coupled to," and "coupled with" mean structural and / or electrical connections, whether mounting, attachment, connection, joining, fastening, linking, and / or other fastening. As used in this application, the term "attach" means to attach, join, connect, join, fasten, link, and / or other fasten. As used in this application, the term "connect" means to attach, attach, join, join, fasten, link, and / or other fasten.

[0076] As used in this application, the terms “circuit” and “circuit section” refer to any analog and / or digital components, power and / or control elements, such as a microprocessor, digital signal processor (DSP), software, etc., separate and / or integrated components, or parts and / or combinations thereof, including physical electronic components (i.e., hardware) and any software and / or firmware ("code") that can constitute the hardware, can be executed by the hardware, and / or can be otherwise associated with the hardware. As used in this application, for example, a particular processor and memory may include a first “circuit” when executing one or more first lines of code, and a second “circuit” when executing one or more second lines of code. As used in this application, whenever a circuit section includes hardware and / or code (if either is required) necessary to perform a certain function, the circuit section is “operable” and / or “configured” to perform that function, regardless of whether the performance of that function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).

[0077] The terms “control circuit,” “control circuit section,” and / or “controller,” as used in this application, may include digital and / or analog circuit sections, discrete and / or integrated circuit sections, microprocessors, digital signal processors (DSPs), and / or other logic circuit sections, and / or associated software, hardware, and / or firmware. A control circuit or control circuit section may be located on one or more circuit boards that form part or all of a controller and is used to control a welding process, equipment such as a power supply or wire feeder, and / or any other type of welding-related system.

[0078] Although only certain features of the present invention are illustrated and described herein, many modifications and changes will be conceivable to those skilled in the art. Therefore, it should be understood that the appended claims are intended to encompass all such modifications and changes that fall within the true spirit of the present invention.

[0079] While the Method and / or System has been described with reference to certain specific embodiments, those skilled in the art will understand that various modifications and substitutions can be made without departing from the scope of the Method and / or System. In addition, many modifications can be made without departing from the scope of the Disclosure to adapt the teachings of the Disclosure to specific circumstances or materials. Thus, the Method and / or System is not limited to the specific embodiments disclosed, but is intended to include all embodiments that fall within the scope of the appended claims.

[0080] In the context of this application, "and / or" means any one or more items in the list linked by "and / or". For example, "x and / or y" means any element of the set of three elements {(x), (y), (x,y)}. In other words, "x and / or y" means "one or both of x and y". As another example, "x, y and / or z" means any element of the set of seven elements {(x), (y), (z), (x,y), (x,z), (y,z), (x,y,z)}. In other words, "x, y and / or z" means "one or more of x, y and z".

[0081] As used in this application, the term “for example” commences a list of one or more non-limiting examples, cases, or illustrations.

Claims

1. A processing system for an air nozzle manifold, An air manifold comprising a main body, wherein the main body has an inlet coupled to an air blower and a plurality of outlet openings, An ionizer bar disposed within the main body, the ionizer bar being connected to a low-voltage power supply to supply low-voltage power to the ionizer bar, A system equipped with these features.

2. The system according to claim 1, wherein the ionizer bar is connected to the low-voltage power supply via one or more power cables, and the one or more power cables are connected to the air manifold or the ionizer bar via one or more fittings.

3. The system according to claim 2, further comprising an insulating housing that supports the ionizer bar within the main body.

4. The system according to claim 3, wherein one or more emitter pins are electrically coupled to the power cable and electrically coupled to the ionizer bar through the insulating housing.

5. The system according to claim 1, further comprising one or more brackets for mounting the ionizer bar within the air manifold, wherein the ionizer bar is secured to one or more brackets via one or more removable fasteners.

6. The system according to claim 5, wherein one or more brackets are fixed inside the body of the air manifold.

7. The system according to claim 1, wherein each of the outlet openings is coupled to a nozzle that blows ionized compressed air toward an object or the environment.

8. The system according to claim 1, further comprising a second ionizer bar coupled to the low-voltage power supply.

9. The system according to claim 8, wherein the second ionizer bar is located within the air manifold housing.

10. The system according to claim 1, further comprising one or more cartridges having two side plates, the two side plates forming a channel, the ionizer bar being mounted within the channel, and the one or more cartridges being detachably coupled inside the body of the air manifold.

11. A processing system, Low voltage power supply and Air blower and, An air manifold comprising a main body, wherein the main body has an inlet connected to the air blower and a plurality of outlet openings, each of which is connected to a nozzle, An ionizer bar supported by a housing, wherein a power cable is connected to a low-voltage power supply to supply low-voltage power to the ionizer bar, One or more brackets for mounting the ionizer bar within the air manifold, wherein the ionizer bar is secured to one or more brackets via one or more removable fasteners, A system equipped with these features.

12. The system according to claim 11, wherein the low-voltage power supply is located within the air manifold.

13. The system according to claim 11, wherein the low-voltage power supply is located adjacent to the air manifold.

14. The system according to claim 11, wherein the power cable is housed in part of the housing, and a plurality of emitter pins electrically couple the ionizer bar to the power cable.

15. The system according to claim 11, wherein the housing is an insulating housing that surrounds a portion of the ionizer bar.

16. The system according to claim 11, wherein the low-voltage power supply provides 24 volts of direct current (DC) power.

17. The system according to claim 11, wherein the low-voltage power supply is connected to a remote power supply.

18. The system according to claim 11, further comprising a remote control panel / station for providing user control of the processing system, wherein the user control includes controlling the ionization level of the ionizer bar or monitoring feedback of one or more outputs or states related to the ionization process.

19. The system according to claim 11, further comprising a second air manifold housing a second ionizer bar.

20. The system according to claim 19, wherein the remote control panel / station is configured to provide operational control for the ionizer bar and the second ionizer bar.

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