Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD FOR ICE BLASTING
This is a divisional of Canadian patent application 2,257,384 filed
June 5, 1997.
Field of the Invention
The invention provides an apparatus and method for blasting small ice
particulates onto surfaces, for cleaning, decontaminating, debarring, or
smoothing the
surfaces. More particularly, the invention provides ice particulates within a
narrow
range of size distribution sc:pplied through an apparatus that makes these
particulates
and motivates them to a required velocity, without intermediate storage of the
particulates.
Backeround of the Invention
In recent years there has been increasing interest in the use of ice blasting
techniques to treat surfaces. For certain applications, ice blasting provides
significant
advantages over chemical surface treatment, blasting with sand or other
abrasive
materials, hydro-blasting, and blasting with steam or dry ice. The technique
can be
used to remove loose material, blips and buns from production metal
components,
1 S such as transmission channel plates after machining, and even softer
material, such as
organic polymeric materials, including plastic and rubber components. Because
water in either frozen or liquid form is environmentally safe, and
inexpensive,. ice
blasting does not pose a waste disposal problem. The technique can also be
used for
cleaning surfaces, removing paint or stripping contaminants from a surface,
without
the use of chemicals, abrasive materials, high temperatures, or steam.
Because of these apparent advantages, ice blasting has generated significant
commercial interest which lead to the development of a variety of technologies
designed to deliver a high pressure spray containing ice particuiates for
performing
particular surface treatment procedures.. Some of these technologies are
shown, for
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example, in U.S. Patent Nos. 2,699,403; 4,389,820; 4,617,064; 4,703,590;
4,744,181;
4,96S,968; 5,203,794; and 5,367,838. Despite all the effort devoted to ice-
blasting
equipment, the currently available equipment still suffers significant
shortcomings
that lead to job interruption and downtime for equipment maintenance. This is
a
particular disadvantage in using ice blasting in a continuous automated
production
line to treat surfaces of machined parts.
In general, in the prior art equipment, the ice particulates are mechanically
sized, a process that can cause partial thawing of ice partieulates so that
they adhere
together, producing larger particulates. As a result, there is not only a wide
l0 distribution in the size of ice particulates produced, and the velocity at
which these
particulates are ejected from a nozzle onto the surface to be treated, but
also frequent
blockages that necessitate equipment downtime for clearing the blocked area.
Moreover, in the available equipment, the ice particulates are retained in
storage
hoppers, where they are physically at rest, while in contact with each other.
This
results in ice particulates cohering to form Larger ice blocks that ultimately
cause
blockages with resultant stoppage of the ice blasting operation due to an
insufficient
supply of ice particulates to the blasting nozzle. In other equipment, the ice
particulates flow along a path with abruptly varying cross-sectional area for
flow.
This frequently causes the accumulation of fine ice parti:culates in certain
low
pressure areas. This accumulation also ultimately results in , blockage of the
apparatus, causing the ice blasting operation to come to an unscheduled stop.
There yet exists a need for ice-blasting apparatus, and a method of ice
blasting, that can be carried out continuously, with minimal risk of
unscheduled
stoppages due to ice blockages forming in the apparatus. Such an ~xpparatus,
and
method of its operation, will allow more efficient ice-blasting operations,
reducing
labor costs for unscheduled stoppages, labor casts incurred in freeing the
equipment
of blockages, and permit more ready integration of ice blasting into an
automated
production line.
Summary of the Invention
The invention provides an apparatus for producing ice particulates within a
narrow size distribution, and delivering these ice.particulates at a
predetermined
velocity onto a substrate, thereby treating the surface of the substrate to
taemove
contaminants, to deburr, or to otherwise produce a smooth, clean surface. The
apparatus of the invention may be operated continuously, with significantly
reduced
3 5 risk of blockage by accumulated ice, as compared to currently-available
ice-blasting
equipment.
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In general, the invention provides an ice particulate-making apparatus that
has
a curved, refrigerated surface on which a thin ice sheet is formed, which is
then
fragmented into ice particulates that are fluidized and carried in a conduit
of flowing
air to impact onto the surface to be treated, The conduit is preferably
smooth, and of
substantially uniform cross-sectional area for flow, to minimize or eliminate
ice
particulate agglomeration and consequent clogging of the apparatus.
In accordance with one embodiment of the invention, the apparatus includes a
refrigerated device with a curved surface, such as a cylindrical drum that is
preferably rotatably mounted with outer surfaces adapted to form a thin layer
of ice..
In one embodiment, the drum is horizontally mounted in a basin of water. As
the
drum, that is refrigerated to a surface temperature of at least 0°C,
rotates in the basin,
a thin curved ice sheet forms on the cylindrical outer surfaces of the drum.
An lee
breaking tool, such as a doctor-knife, is mounted near the side of the drum
that is ice-
coated, and extends along the Length of the drum. The knife is oriented to
intercept a
leading edge of the ice sheet and fragment it into ice particulates as the
drum rotates.
An ice-receiving tube is located adjacent, and extends along the length of.
the doctor-
knife and is oriented so that a longitudinal slot in the tube is able to
receive the ice
particulates formed. One end of the tube is coupled to a hose supplying cold
air, and
the other end is coupled Lo an ice delivery hose that applies suction to the
interior
space of the tube. The delivery hose terminates in an ice blasting nozzle. As
ice
particuiates enter into' the ice-receiving tube, the particulates are carried
by a
continuously flowing stream of cold air into the delivery hose and thence into
the iee-
blasting nozzle. The flow conduit of the ice particulates (tube and hoses) has
a
substantially smooth (i.e. free of obstructions and surface irregularities)
inner surface,
and substantially uniform cross-sectional area for flow, thereby avoiding low
velocity
spots where ice particulates may settle, accumulate, and cause blockages.
In another embodiment, the refrigerated drum is sprayed with water to form
the thin ice sheet. The drum may be horizontally mounted, as preferred to form
a
uniform thickness ice-sheet, or may be inclined at an angle. In one such
embodiment
of the invention, the refrigerated drum is vertically-oriented and water is
sprayed
onto the drum to form a thin curved ice sheet. As. explained above, a doctor-
knife
extends along the length of the drum to fragment ice. particuIates from the
sheet into
an adjacent co-extensive ice-receiving tube.
In a further alternative embodiment of the invention, the refrigerated
cylindrical surface is the interior surface of an annulus. At least one spray
nozzle is
mounted to direct water onto the cylindrical walls of the annulus to form a
thin ice
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sheet. As before, a doctor-knife extending along the length
of the cylindrical wall is used to fragment ice particulates
of narrow size distribution from the ice sheet into a slot in
an ice-receiving tube that is adjacent to and co-extensive
with the knife.
In a yet further alternative embodiment of the
invention, the entire apparatus for making ice particulates
is enclosed in a pressurized vessel. The vessel may be
maintained at a pressure in the range from about 20 to
about 150 prig. Moreover, in this embodiment of the
invention pressurized air, or another gas, is supplied to the
apparatus to fluidize the ice particulates, and carry the ice
particulates to a nozzle, or a plurality of nozzles, for
blasting onto a surface.
According to the method of the invention, ice
particulates may be prepared by freezing water into a thin,
curved sheet of ice. This thin, curved ice sheet, already
stressed as a result of the curvature, is relatively easily
fragmented into ice particulates that are sized dependent on
ice sheet thickness and radius of curvature. These ice
particulates are drawn by suction pressure into a stream of
cold, dry air that fluidizes and sweeps the particulates into
a smooth surfaced flow cor~duit having a Substantially
constant cross-sectional area for flow. At a terminal end of
this flow conduit the ice particulates a:re ejected onto a
surface of a substrate through a nozzle at high velocity to
perform deburring, cleaning, or other operations, depending
upon the velocity of the ice particulate:a and air stream.
Thus, in a broad aspect the invention provides an
apparatus for supplying and accelerating particulates, the
apparatus comprising: (a) a refrigerated drum, the drum
mounted to rotate about a central axis, the refrigerated drum
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able to cool a cylindrical surface of the drum to at
least 0°C to cause an ice sheet to form on the cylindrical
surface when water contacts the surface; (b) a doctor-knife
mounted in close proximity to the cylindrical surface of the
drum, the doctor-knife extending along the length of the
cylindrical surface of the drum, the doctor-knife oriented to
enable fragmenting of ice particulates from a thin ice sheet
formed on the cylindrical surface when water contacts the
cylindrical surface; (c) an ice-receiving tube adjacent to
the doctor-knife, the tube having a longitudinal slot
oriented to receive ice particulates formed by the doctor-
knife when the knife fragments a thin icc=_ sheet from the
cylindrical surface of the drum, the ice-receiving tube
having a first end, the first end in fluid communication with
a supply hose for supplying cold air to t:he tube to sweep ice
particulates from the tube, and the tube having a second end,
the second end in fluid communication with a delivery hose
for carrying away ice particulates and a~_r from the ice-
receiving tube; and (d) a nozzle at a tez-minal end of the
hose for carrying away ice particulates from the outlet end
of the ice-receiving tube, the nozzle able to control flow of
ice particulates therethrough.
In another broad aspect the invention provides an
apparatus for delivering ice particulates, the apparatus
comprising: (a) a rotatable refrigerated device, the device
able to cool a cylindrical surface thereof to at least 0°C;
(b) a doctor-knife mounted near the cylin.drioal surface of
the device and extending along a length of the surface, the
doctor-knife oriented and positioned to fragment ice
particulates from an ice sheet on the cylindrical outer
surfaces of the refrigerated device formed when water freezes
on the cylindrical surface of the device; (c) an ice-
receiving tube adjacent to the doctor-knife, the tube having
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a longitudinal slot oriented to receive ice particulates when
the doctor-knife fragments particulates from an ice sheet,
the ice-receiving tube having a first end, the first end in
fluid communication with a supply hose for supplying cold air
to the tube to sweep ice particulates from the tube, and the
tube having a second end, the second end in fluid
communication with a delivery hose for carrying away ice
particulates and cold air from the ice-receiving tube; and
(d) a nozzle at a terminal end of the delivery hose, the
nozzle able to control a rate of flow of ice particulates
therethrough.
In another aspect the invention provides a method
of continuously producing a stream of ice particulates, the
method comprising: a) continuously freezing water on a curved
surface into a thin, curved sheet of ice,, a curvature of the
surface causing fragmenting of the curved sheet of ice to
form ice particulates; (b) continuously separating fragmented
ice particulates from the curved surface by continuously
sweeping the separated ice particulates directly into a
stream of air sufficient to fluidize the particulates; (c)
maintaining the ice particulates in a fluidized state; and
(d) continuously ejecting the fluidized i.ce particulates
under controlled velocity from a nozzle.
In another aspect the invention provides a method
of continuously producing a stream of ice: particulates, the
method comprising: (a) freezing water on a curve of surface
into a thin, curved sheet of ice, the curved sheet having a
radius of curvature, the curvature causing sufficient
internal stress in the curved sheet to result in self-
fracture of the ice sheet; (b) harvesting self-fractured ice
particulates directly from the curved surface; (c)
maintaining the harvested ice particulates in a fluidized
state, thereby preventing significant agglomeration of ice
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particulates; and (d) blasting the harvested, fluidized ice
particulates from a nozzle at a controlled velocity onto a
substrate.
In another aspect the invention provides a method
for producing and accelerating ice particulates, the method
comprising: (a) forming a thin curved sheet of ice on a
surface of a rotating cylindrical drum, the ice sheet having
a radius of curvature sufficient to induce self-fracturing of
the ice sheet; (b) continuously harvesting the self-fractured
ice particulates directly from the surfar_e of the drum into
an ice-receiving tube adjacent to the surface of the drum, by
supplying the tube with a sufficient amount of air to
fluidize said harvested ice particulates, and sweeping the
particulates into an ice-delivery conduit in fluid
communication with the tube; and (c) expelling the ice
particulates from a terminal end of the conduit, under
controlled conditions, onto the surface of a substrate.
Brief Description of the Drawings
The foregoing aspects and many of the attendant
advantages of this invention will become more readily
appreciated as the same becomes better understood by
reference to the following detailed description, when taken
in conjunction with the accompanying drawings, wherein:
FIGURE 1 is an illustration of a worker blasting a
surface with ice particulates from an ice blasting device of
the invention;
FIGURE 2 is a simplified schematic of the ice
particulate-making equipment of the invention;
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FIGURE 3 is a schematic perspective view of an
embodiment of an iceblasting apparatus in accordance with the
invention;
FIGURE 4A is an end view of an embodiment of the
invention showing details of the ice removal tool and ice-
receiving tube of the invention;
FIGURE 4B is an end view of an embodiment of the
invention including water spray nozzles for forming an ice
sheet on a cylindrical surface of a rotating refrigerated
drum;
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FIGURE 4C is a schematic perspective view of an embodiment of the ice-
receiving tube of the invention, equipped with an optio~'al window;
FIGURE 5 is a schematic diagram showing another embodiment of the ice
particulate-making apparatus of the invention wherein the rotating
refrigerated drum
is vertically oriented and receives a water spray to form an ice sheet on the
outer
surfaces of the drum;
FIGURE b is yet another preferred embodiment of the ice particulate-making
device of the invention wherein the rotating drum has a cylindrical internal
surface
on which a thin ice sheet is formed and fragmented into an ice-receiving tube;
IO FIGURE 7 is a schematic cross-sectional illuistration of an ice-particulate
receiving tube, divided into two sections, for supplying two streams of
fluidized ice
particulates;
FIGURE $ is a schematic representation of an embodiment of the apparatus
of the invention enclosed in a pressure vessel, and supplied with cornpr~essed
air.
Detailed Description of the Preferred l~mbodiment
The invention provides an apparatus, and method, of continuously producing
ice particulates, and continuously delivering these ice particulates at a
controlled high
velocity .onto a substrate. Tlae ice particulates are forrned from fragmenting
a "thin
curved sheet" of ice. In the specification and claims, this means a sheet of
such
curvature and thickness that, as a result, the sheet has residual stresses and
a thermal
gradient so that it is predisposed to ready fragmentation. An example of such
a
cylindrical sheet is-a sheet about 1.5 mm thick and with a radius of curvature
of about
100 mm. Preferably, this sheet is from about I .U to albout 2.U mm thick, and
has a
radius of curvature of about 50 mm to about 150 rnm. Clearly, larger or
smaller
apparatus are also useful and are within the scope of the invention.
The ice particulates are kept in constant motion (and are
°'fluidfz~ed"),
according to the invention, so that they do not come to rest relative to any
part of the
apparatus and do not come into stationary contact with ~:ach other to cohere
and form
larger ice particulate blocks that may cause blockages in the apparatus.
Moreover,
the flow path along which the ice particulates are carried by a fluidizing
gas, such as
cold air, is smooth and devoid of such abrupt changes in flow cross-sectional
area as
may lead to the deposition and subsequent accumulation of ice particulates to
form
blockages. Preferably, the flow conduit has a diameter of about 2S to about 30
mm.
In order to minimize any melting of the ice particulates that may lead to
subsequent
coherence or adherence and blockage, components of 'the apparatus that come
into
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contact with ice particulates are preferably fabricated from materials that
are smooth
and have low thermal conductivity. Plastic materials are preferred, especially
non-
stick plastics such as TEFLON, that may be used as an inner coating.
The apparatus of the invention may be better understood with reference to the
accompanying figures that schematically represent preferred embodiments 'of
the
apparatus for making ice particulates and delivering these through a nozzle
onto the
surface of a substrate. Clearly, other embodiments are also within the scope
of the
invention, but reference to the preferred embodiments of the figures
facilitate an
explanation of aspects of the invention.
FIGURE 1 schematically illustrates the ice-bhisting operation. In accordance
with the invention, a unique ice maker 10 that produces ice particulates with
controlled dimensions, as will be described later, sub~plies fluidized ice
partieulates
into an ice and air medium delivery hose 52 to which is connected a nozzle 54
attached to a high pressure hose 56 that receives pressured air from device
58, either
a compressor or a pressurized cylinder. The high pressure air is supplied,
through
hose ~6 to the nozzle 54 and creates a suction behind its entry point in the
nozzle that
draws ice particulates into the delivery hose 52, as will be explained later,
and
accelerates the speed of travel of the ice particulates so that they may be
ejected from
the nozzle 54, under the control of an operator (or under automated control),
onto a
surface 80 that is to be treated by ice-blasting. As vvill become apparent
later, the
unique ice maker 10 of the invention is not necessarily itself pressurized
(although it
may be in some embodiments), but in the illustrated embodiment air is-drawn
into it
through hose 50,. and an air-ice particulate mixture is delivered from it
through .
delivery hose ~2 to the nozzle 54. it is imporwnt to maintain a sufficient
pressure
drop between the air inlet 30a of tube 30 and air outlet 30b to cause
sufficient air
flow to fluidize the ice particulates formed and acxelerate the particulates
(see
FIGURE 2).
Referring to the preferred embodiment of FIGURES 2, 3, 4A and 4B, an ice
maker 10 includes a housing 12 partially filled with water 13. A cylindrical
drum 14
with an axial shaft 16 is rotatably mounted such that a portion of its outer
cylindrical
surface 15 is covered with water, when the housing contains an operating
volume of
water. The drum is refrigerated, usually by a plurality of channels in the
interior of
the .cylindrical drum that carry a refrigerant (not shown.). As illustrated,
the drum 14
rotates in a counterclockwise direction around its axial shaft 1 S that is
coupled to an
electric drive motor 18 at a rate that allows the formation of a suitably
thick layer of
ice on its surface. As the refrigerated drum rotates, water in contact with
its outer
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cylindrical surface freezes to form a thin sheet of ice ~!0. This sheet of ice
is carried
around to another side of the drum for removal as i.ce particulates 20a. The
ice-
cleared drum surface then continues to rotate and re-enters the water to form
an ice
sheet.
S It should be noted that the thin curved ice sheet is subject to stress as a
result
of its shape and a temperature gradient that extends through its thickness so
that it is
predisposed to fragment into ice particulates. The size distribution of these
ice
particulates is dependent upon the thickness, temperature, and the radius of
curvature
of the ice sheet, which are in turn dependent upon the rate of rotation and
temperature
of the drum, and the radius of the drum 14.
The components of the apparatus that fragment the ice sheet are more clearly
shown in FIGURES 4A and 4B. An ice-removal tool, or doctor-knife 22 is mounted
on a support 24 so that the tip of the tool extends at an angle of about
4S° to intercept
a leading edge of the ice sheet 20. The doctor-knife 22 and its support 24
extend
1 S substantially along the entire length of the cylindrical drum 14, as shown
in
FIGURES 2 arid 3. Thus, as the ice sheet leading edge encounters the tip of
the
doctor-knife 22, the stressed ice sheet fragments into ice particulates 20a.
The ice
particulates 20a then enter a tube of preferably substantially uniform inside
cross-
sectional area for flow, with a smooth inner surface, a:. shown in FIGURES 4A
and
4C. Within these constraints, the tube may have any one of many possible
designs
that may readily occur to one of skill in the art who has read this
disclosure. In the
illustrated embodiment, these ice particulates enter into a slot 28 of an ice-
receiving
tube 30 that extends substantially along the entire length. of the drum 14.
The smooth
inner-surfaced tube 30, shown in more detail in F'1GURE 4C, is mounted so that
one
longitudinal edge 26 of the longitudinal slot is in contact with, and sealed
against an
upper end of the doctor-knife 22 by mechanical pressure. The other
longitudinal
edge 27 of the slot 28 curves over above the ice sheet and backward toward the
leading edge of the ice sheet while extending downward to a position in
touching
relationship with the ice sheet 20. The edge 27 is therefi~re sealed against
the surface
of the ice sheet. Thus, ice particulates 20a are captured m the slot and enter
the ice-
receiving tube 30 where they are immediately fluidized and carried away, as
will be
explained later. In order to allow inspection of the :interior of the ice-
receiving
tube 30, the tube is optionally equipped with a longitudinal glass window 34
held in
a frame 35. This optional glass window 34 extends along a substantial length
of the
upper surface of the ice-receiving tube 30, where a corresponding section of
the tube
has been removed. The ice-receiving tube is affixed to a support bracket 40,
that
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extends along its upper outer surface. The bracket 40 is mounted to the
housing 12
and is interconnected with an optional warning system, described below.
The apparatus of the invention preferably has a warning system for detecting
when the ice-receiving tube has been overfilled, or is being blocked. Under
these
circumstances, the continual rotation of the drum, forcing additional
partieulates into
an already full tube, causes the tube 30 to lift away from the drum 14 thereby
urging
bracket 40 upward. This bracket is held in place, flush with the upper surface
of the
housing 12, by a series of pairs of compression-retaining bolts 42. Each of
these
bolts has a surrounding coil spring 44 that it maintains under compression
between
an upper surface of the bracket 40 and a washer near the top of the retaining
bolt 42.
Thus, as the bracket is urged upward, the springs compress, This compression
is
detected by a sensor 45 and automatically sounds an alarm. This system allows
early
detection of potential or actual blockage so that necessary maintenance can be
performed. As explained, however, such blockage should very rarely occur
because
the ice particulates formed are maintained in a fluidized state, in constant
motion, and
are not allowed to settle and cohere so that blockages are usually not able to
form.
However, blockages can result from inadequate fluidizing air supply or
misaligned
doctor-knife resulting in inadequate fracturing of the ice sheet.
Referring back to FIGURES 2, 3 and 4, an air hose ~0 is connected to an air
inlet end 30a of the ice-receiving tube 30, and a media dice and air) delivery
hose 52
is connected to the other end 30b of the tube. Thus, cold compressed air
supplied in
hose ~0 fluidizes ice particuIates 20a, that are fragmented into tube 30, and
carry
these particulates into the media delivery hose 52. As will be explained
below, the
ice-receiving tube 30 is not subjected to high pressure differentinl between
its inside
and the surroundings but is at close to atmospheric pressure in some
embodiments.
In other embodiments, as explained below, the entire apparatus may be enclosed
in a
pressurized vessel. Of more importance is the difference in pressure between
tube air
inlet and air outlet.
Preferably, there is a smooth transition from tube 30 to delivery hose ~2 so
that there are no intema! obstructions to ice flow that may cause ice
particulates to
settle, adhere, cohere, and forsn blockades. The delivery hose, preferably
with a
smooth inner lining, terminates in an ice-blasting nozzle S4, that can be
manually
controlled by an operator or automatically operated. When the nozzle is shut
off, a
diverter valve 62 reroutes the media through hose b9~ to waste disposal. Thus,
the
3S ice-making apparatus is able to operate continuously without an
accumulation of
particulates 20a when blasting operations cease temporarily. This avoids the
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necessity to restart the apparatus, and the unsteady state operation
associated with
start up, and facilitates recommencing blasting operations.
In.the illustrated embodiment, a high pressure air hose 56 is joined to the
rear
of the nozzle 54 to draw ice into the nozzle by suction and to impel the
particulates at
a controlled velocity through the nozzle 54. The connection to the rear of the
nozzle,
with air directed to the nozzle tip, creates a suction-effect behind the
nozzle so that
ice particulates are drawn from the ice-receiving tube 30 and propelled to the
nozzle S4. Thus, the tube 30 is not pressurized by air entering through hose
50, but
air is drawn in by suction through hose SO air and this air maintains the ice
particulates in constant motion in a fluidized state.
In an alternative embodiment of the invention, illustrated in FIGURE 4B, the
drum 14 does not rotate in a container of water. Instead, the drum 14 is
mounted in a
container along with at least vne spray nozzle that is oriented to spray water
onto
cylindrical surfaces of the drum, and thereby form an ice sheet on the
refrigerated
surface. Thus, as shown in FIGURE 4B, water distributors 72 extend
longitudinally
along the length of the horizontally-oriented drum 1.4, and 'spray water from
nozzle 70 onto the outer surface of the drum. Any excess water collects in the
bottom of the container, and may be drained and recycled to the nozzles 70.
Clearly,
while horizontal orientation of the drum 14 is preferred, to form a thin ice
sheet of
substantially uniform thickness, other orientations are also possible:
An alternative embodiment of the ice-maker apparatus is shown in
FIGURE 5. In this embodiment, the drum i4 is vertically-oriented and rotates
about
a central shaft 16, At least one spray nozzle 70, mounted near the cylindrical
drum,
directs a spray of water onto the cold .(at Least 8° C) cylindrical
outer surfaces 1S of
the drum. This spray of water freezes upon contact with the surfaces into an
ice
sheet. Once again, the curved ice sheet is broken into ice particulates when a
Leading
edge of the sheet impacts against a front edge of a doctor-knife. The knife is
mounted on a support (not shown), and preferably extends substantially along
the
length of the cylindrical surface parallel to the axial shaft of the drum. An
ice-
receiving tube 30 extends along the length of the doctor knife, and a
longitudinal slot
of the tube intercepts ice particulates, directing these into the space within
the
tube 30, as explained before.
As before, an air hose 50 is attached to an upper open end 30a of the tube 30,
while a media delivery hose 52 is connected to the lower open .end 30b of the
receiving tube 30. Thus, air drawn in through hose ~0 ftuidizes ice
partieulates in the
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tube 30 and carries the fluidized particulates into delivery hose ~2, and
thence to a
delivery nozzle 54, as explained above.
In a yet further embodiment according to the invention shown in FIrGURE 6,
the ice sheet is formed on an internal cylindrical surface of a refrigerated
cylindrical
annulus 17. In this embodiment, the refrigerated annulus 17 has an internal
cylindrical space 75 surrounded by cylindrical walls. The annulus is held, by
friction
between three rotating shafts 80 disposed in a triangular array against its
outer
surfaces so that it rotates at a controlled speed as the shafts rotate. Water,
preferably
from nozzles on a distributor 76, parallel to the central axis of the annulus
17, is
sprayed onto the cold surrounding internal cylindrical waDls of annulus 17.
This
water freezes into an ice sheet that is fragmented by a . longitudinally
extending
doctor-knife tool, that is mounted to intercept the leading edge of the ice
sheet inside
the inner cylindrical space. As explained above, the ice particulates are
captured in
an ice-receiving tube 30 through a longitudinally extending slot in the tu_ be
that
extends substantially along the entire length of the surrounding cylindrical
surface.
An upper end 30a of the tube 30 is in fluid communication with an air supply
hose ~0, while a lower end 30b of the tube is in fluid communication with a
media
delivery hose 56. Thus, air is sucked into the upper open end of the tube,
fluidiz~es
ice particulates within the tube, and carries the fluidized ice parti~culates
into the
delivery hose 52 to an ice-blasting nozzle 54.
The apparatus also optionally includes a diverter valve 62 for diverting ice
particulates into a hose 64 when the nozzle 54 is shut off so that the ice
making
process is continuous.
Clearly, the invention is not limited to the use of a single ice pac~ticulate
receiving tube 30. Instead, a series of tubes may be used, such that each tube
is able
to supply a continuous stream of ice particulates for ice-'blasting, or a
single tube may
be divided into at least two, and possibly a plurality, of tube sections, each
able to
operate relatively independently. Thus, far example, when the front and rear
surfaces
of a substrate must be ice blasted, the invention allows simultaneous blasting
of both
sides. In certain embodiments, nozzles may be mounted on either side of the
substrate, to automatically traverse both surfaces, thereby treating both
front and rear
surfaces of the substrate. In the embodiment shown in FIGtJItE 7, an ice
particulate
receiving tube 30 is divided by a central diaphragm 30c into two tube sections
31
and 33, respectively. Thus, an air supply hose SSa enters into the inlet 31a
of tube
section 31, near the diaphragm 30c. Preferably, the hose SSa is equipped with
a
control valve 57a to assist in controlling the flow of air through tube
section 31. As
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explained above, an ice particulate discharge hose 52b is connected to the
open
end 31 b of tube section 31, so that ice particulates are continuously drawn
from tube
section 31 into hose 52b, and expelled through the nozzle. Similarly, tube
section 33
has an air inlet hose SSb attached to its inlet 33a. The outlet of the tube
section 33b
is coupled to an ice particulate delivery hose S2a, that draws fluidi~ed ice
particulates
to the nozzle for ice blasting. Thus, it is clear, that receiving tube 30 can
be divided
into a series of sections for supplying a series of nozzles with ice
particulates.
Moreover, because the air supply to each nozzle can be individually
controlled, the
velocity of the ice particulates expelled from a nozzle connected to an ice
tube
section, can be individually controlled.
As indicated above, nozzles can be connected to mechanical/electronic
systems to automatically traverse surfaces of a stationary, or moving
substrate. Thus,
the method and apparatus of the invention are not limited to manual operation
of an
ice blast nozzle to treat a surface. instead, the apparatus is ideally suited
for
1 S automated cleaning of a continuous series of parts produced on a
production line,
such as is common in, for example, the automobile industry where the ice
blasting
apparatus of the invention may be used to deburr, or otherwise treat part
surfaces.
The invention provides the significant advantage of continuous operation far
lengthy
periods of time, thereby overcoming a significant problem encountered in prior
art
apparatus and methods.
As indicated before, fluidization of the ice particulates depends upon
maintaining a pressure drop from the air inlet to the air outlet of the tube
30. In
general, for a given tube cross-sectional area for flow, the higher the
pressure drop,
the more the fluidized air that is being supplied. Also, the greater the
amount of
2S fluidized air per unit cross-sectional area for flow, the higher the
pressure at which
the ice particulates leave the tube 30, and the laigher the pressure at tire
delivery
nozzle S4 (for a given length of delivery hose S2).
In accordance with the embodiment of FIGURE 8, an apparatus substantially
as described above, is enclosed in a pressurized vessel 7~ preferably f teed
with a
pressure gauge 74. However, in this instance, air is supplied to tube 30
through a
hose 74, carrying cold compressed fluid, such as.air., Thus, whip the tube 30
is
pressurized, the apparatus is enclosed in 'a pressure vessel, 72, so that the
differential
pressure between the inside and the outside of tube 30 is maintained at a
level that
the tube is able to tolerate, without fracture. As the pressurized cold air is
introduced
3S into the inlet end of the tube, it fluidizes and carries away ice
particulates from the
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outlet end 30b of the tube, which is in fluid communication with the delivery
hose ~2
and thence the nozzle 54.
This particular embodiment of the invention is particularly useful for large
industrial applications. In this event, the discharge end of a compressor
supplies
compressed air to hose 70, and may also be used, . with a control system and
gauge 74, to regulate and maintain the pressure of the pressure vessel 7~. .
The invention also provides a method of ice-blasting surfaces with ice
particulates. In accordance with the method, water is frozen into a thin
curved sheet
of ice, preferably by freezing the water onto a cylindrical surface. The sheet
of ice is
of such a thickness that temperature differences between its opposing~curved
faces
results in stress that predisposes the ice sheet to being fragmented into ice
particulates. This stress-cracked ice sheet is fragmented by impacting,a
leading edge
of the ice sheet with a device, such as a doctor-knife, that extends along the
leading
edge of the ice sheet. The leading edge of the ice sheet is preferably of
substantially
uniform thickness along its length for more uniformly-sized ice particulates.
Fragmented ice particulates are drawn," through suction, into a tube where the
ice
particulates are fluidized in cold air or in an other gas without melting. The
fluidized
ice particulates are then carried away into a delivery hose from which the ice
particulates are e,~ected through a nozzle onto a surface that is being iae-
blasted. In
order to fluidize, carry and accelerate the speed of the ice particulates
entering the
tube, in one embodiment high pressure air is introduced into the nozzle,
thereby .
creating an area of low pressure behind its entry point in the nozzle. The low
pressure area is in fluid communication with the delivery hose and draws, by
suction,
ice particulates from the fragmenting step into the tube and thence into the
delivery
hose. The higher pressure at the vicinity of the nozzle tip, ahead of the
entry point of
the high pressure air, accelerates the ice particulates for the ice-blasting
operation. In
another embodiment, compressed air/gas is used to fluidize the ice
particulates in the
tube and carry the particulates to a nozzle tip.
Although only a few exemplary embodiments of this invention have been
described in detail above, those skilled in the art will readily appreciate
that many
modifications are possible in the exemplary embodiments without materially
departing from the novel teachings and advantages of this invention.
Accordingly,
aII such modifications are intended to be included within the scope of this
invention
as defined in the following claims. In the claims, any means-plus-function
elapses
are intended to cover the structures described herein as performing the
recited
function, and not only structural equivalents, but also equivalent structures.
Thus,
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-1.3-
although a nail and a screw may not be structural equivalents in that a nail
employs a
cylindrical surface to secure wooden workpieces together, whereas a screw
employs
a helical surface, in the environment of fastening wooden workpieces, a nail
and a
screw may nevertheless be equivalent structures.
