Patent Grant
7947218
This is a U.S. patent application of U.S. provisional application 60/811,925, filed Jun. 8, 2006 for a Apparatus and Method for Coil Cooling, which is hereby fully incorporated by reference.
The present invention relates to a portable cooling device including an air source, such as a fan, that provides air flow, and a shroud for directing air flow from the air source at an article, particularly (a) a coil of material or (b) a non-coil metal article such a sheet, plate or ingot, having a temperature greater than the ambient room temperature. The cooling device provides cooling efficiency by directing the air from the air source at an increased velocity to a desirable area or areas on a surface of the object, thereby increasing heat transfer from the object. The cooling device shroud includes an air directing surface that influences the direction of air flow across the object in a desired pattern. Methods for preparing cooling devices and for cooling objects, particularly coils, are also described.
In the metallurgical or metalworking field, sheets or pieces of a metal or metal alloy are processed in any number of ways that can raise the temperature of the sheet above the temperature of the ambient room temperature. The processed sheets are subsequently rolled into a coil. For example, sheets that have been treated using a cold rolling process can reach temperatures above 200° C. during the process. Heat treatments utilized to treat sheets include, but are not limited to, continuous annealing/solution heat treatment (SHT) and batch annealing. During a continuous annealing/SHT process, the sheet is uncoiled and then first passed through a furnace section and then a quench section. For some metals or alloys, the sheet comes off the quench at higher than room temperature. During batch annealing, the entire coil is placed in a furnace where it is heated to a predetermined temperature and held for a predetermined period of time, such as several hours, after which the coil is removed and allowed to cool.
Following a procedure such as, but not limited to, one of the above described procedures, it is often necessary to cool the sheet coils to ambient room temperature either as a final step prior to storing/shipping or the like, or in preparation for a subsequent step in a manufacturing sequence.
One current practice in the art is to provide forced air cooling by positioning an axial flow fan adjacent a coil and directing air flow at the coil. The air flow is generally perpendicular to the horizontal axis of the coil at the surface of the coil end, and the velocity of air is limited by the air exit velocity of the fan. When the coil has a hollow core or center, some of the air passes through the coil center and therefore does not contribute significantly to coil cooling. Furthermore, some of the air passes along the outside of the coil diameter and also does not provide efficient heat transfer.
The cooling device of the present invention comprises an air source and a shroud connected to the air source. The shroud includes an air directing surface having one or more apertures in an arrangement adapted to direct air from the air source at a predetermined area or areas on a surface of an article, such as a coil or a non-coil article, preferably of a metal or metal alloy. The shroud is utilized to direct air flow across a surface of the article to achieve more efficient cooling when compared to using the air source alone. In one embodiment, the shroud design increases the air velocity to a value greater than the velocity exit value from the air source such as a fan. In a further embodiment, the shroud includes an adaptor that allows the device to be utilized on a coil without a core, on a coil with a core, or with a coil having a mill spool which extends out beyond the plane of the coil sidewall or end. The adaptor prevents air from passing through the center of the coil.
In one embodiment, a cooling device having an air source is provided. A shroud of the device is positioned adjacent one lateral end of a coil, wherein air from the air source is directed through one or more apertures of an air directing surface of the shroud onto a surface of the coil, preferably near the inner diameter of the coil. The air flows in a gap between the surface of the coil and the air directing surface of the shroud toward the outer diameter of the coil, escaping along the end of the shroud or outer diameter of the coil. In another embodiment, the shroud air directing surface has an outer perimeter formed as an annulus, preferably having a diameter similar to the diameter of the coil. In a preferred embodiment, the adaptor of the shroud prevents air from flowing through the center of the coil.
It is, therefore, an object of the present invention to provide a cooling device that is mobile, portable, and can be easily positioned in relation to a coil in order to cool the coil for further handling or processing or a combination thereof.
A further object of the present invention is to provide a cooling device and method for utilizing the cooling device that improves heat transfer and cooling efficiency when compared to the prior art practice of providing forced air cooling by directing air from an axial flow fan at the lateral end of a coil.
Yet another object of the present invention is to provide a cooling device that is adapted to be utilized on a coil free of a core, on a coil with a core, or on a coil having a mill spool which extends out beyond the plane of an end of a coil.
Still another object of the present invention is to provide a shroud that can be easily retrofitted to an existing fan.
It is a further object of the present invention to provide a cooling device that utilizes air from an air source, increases the velocity of the air exiting the air source, and directs the air at a location near the inner diameter of a coil and subsequently along the surface of the coil.
Accordingly, one aspect of the present invention is a cooling device for use in cooling an article, comprising an air source that provides air flow, and a shroud that receives air flow from the air source and is adapted to direct the air onto a surface of the article, wherein the shroud includes a receiver that is connected to an air exhaust outlet of the air source, wherein the shroud includes an air directing surface having one or more apertures through which air flows out of the shroud, and wherein the one or more apertures have a total cross-sectional area that is less than a cross-sectional area of the air exhaust outlet.
Another aspect of the present invention is a cooling device for use in cooling a coil of material, comprising an air source that provides air flow through an air exhaust outlet, and a shroud connected to the air source that receives air from the air source exhaust outlet and is adapted to expel the air through one or more apertures of an air directing surface of the shroud, wherein the shroud includes an adaptor connected to the air directing surface of the shroud and adapted to substantially seal a core of the coil to prevent air flow through the core.
Still another aspect of the present invention is a method for cooling a coil, comprising the steps of providing a coil of material at a temperature above an ambient temperature, providing a cooling device comprising an air source that provides air flow and a shroud that receives air flow from the air source and is adapted to direct the air onto a surface of the coil, wherein the shroud includes a receiver that is connected to an air exhaust outlet of the air source, wherein the shroud includes an air directing surface having one or more apertures through which air flows out of the shroud, positioning the air directing surface of the cooling device adjacent an end of the coil, and directing air from the cooling device onto the coil end to cool the coil, wherein a velocity of the air exiting the one or more apertures is greater than a velocity of the air exiting the air exhaust outlet.
Yet another aspect of the invention is a cooling device for use in cooling an article, comprising an air source that provides air flow; and a shroud that receives air flow from the air source and is adapted to direct the air onto a surface of the article, wherein the shroud includes a receiver that is connected to an air exhaust outlet of the air source, wherein the shroud includes an air directing surface having one or more apertures through which air flows out of the shroud, wherein the air directing surface is substantially planar radially outward of an adaptor connected to the air directing surface and wherein the air directing surface is adapted to be positioned substantially parallel to a plane formed by an end of the article.
The invention will be better understood and other features and advantages will become apparent by reading the Detailed Description of the Invention, taken together with the drawings, wherein:
This description of preferred embodiments is to be read in connection with the accompanying drawings, which are part of the entire written description of this invention. In the description, corresponding reference numbers are used throughout to identify the same or functionally similar elements. Relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and are not intended to require a particular orientation unless specifically stated as such. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or other axis, as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship.
Referring now to the drawings, the cooling device 10 of the present invention includes an air source 20 operatively connected to a base 50 in one embodiment as shown in
An impeller or propeller 26 is operatively connected to an output shaft of motor 25. Propeller 26 includes one or more fan blades utilized to draw air into air intake 23 and expel the same through air exhaust outlet 24. The described air source 20 is known to those of ordinary skill in the art and is commercially available from sources such as Universal Fan and Blower of Bloomfield, Ontario, Canada and Continental Fan of Buffalo, N.Y., USA. There are generally no limitations regarding the horsepower of the fan, so long as the desired air flow is provided to cool a coil 100. A fan having a horsepower of less than 10 is utilized in this application in one embodiment to maintain ease of portability. In a preferred embodiment, an air source is utilized that is capable of maintaining relatively low flow rates at medium to high pressure without stalling or overloading, with an appropriate shroud design.
During use, a motor switch is actuated and motor 25 is energized, thereby producing rotation of propeller 26. The rotation of propeller 26 draws air inwardly through air intake 23 and discharges the air through exhaust outlet 24.
While the air source 20 described hereinabove is generally known in the art as an axial flow fan, any other air source such as a blower, a pump such as a rotary or centrifugal pump, a compressor, centifugal-blower or fan, tube-axial fan, or mixed flow fan, or the like can be utilized to provide a desired volume of air at a desired velocity to shroud 30 of cooling device 10.
Shroud 30 is connected to air source 20 and receives air expelled from exhaust outlet 24, as shown in
Shroud 30 includes a body 36 that extends between receiver 32 to the shroud air directing surface 40 as shown in
In a preferred embodiment, the direction of air flow 60 is changed from horizontal, i.e. the direction of air flow entering outlet 24 from air source 20, towards a direction substantially perpendicular or perpendicular thereto, such as shown in
In a preferred embodiment, several straight or curvilinear vanes 43, preferably of the same width as projection 46, are attached to the air directing surface 40 and extend from the edge of the air exit openings towards the outer diameter or perimeter 48 and cause the air to take a curving path across the coil face. Also, the distance maintained between the coil 100 and the shroud 30 is very important in the process for cooling a coil 100, and depends on the fan characteristics, i.e. pressure vs. flow, generally known as the fan characteristics curve. Accordingly, the distance between the coil 100 and shroud 30, such as at air directing surface 40, can be varied depending on the application.
In a further embodiment, shroud 30 is a substantially solid structure, but can include flexible elements in order to provide a desired air flow to a coil 100. Portions of the shroud 30 can be formed of generally any suitable material offering a desired rigidity or form, including, but not limited to, a polymer, a rubber, or an elastomer, either thermoplastic or thermoset, such as PVC; or any suitable metal. A requirement of shroud 30 is that the material chosen must be suitable in order to withstand and substantially not deform, degrade or the like, at the temperature of the coil 100 to be cooled, for a period of time.
As stated herein above, shroud 30 includes air directing surface 40 connected to body 36. Air directing surface 40 is adapted to be placed in close proximity to a coil 100 as illustrated in
Air directing surface 40 includes one or more apertures 42. As illustrated in
In a preferred embodiment, a plurality of apertures 42 are spaced around the circumference of adaptor 44. In this alignment, the air flowing out of apertures 42 is directed onto the interior portion of lateral end surface 102 of coil 100 adjacent to spool 104 thereof. As illustrated in
Perimeter 48 of air directing surface 40 is preferably annular although it is to be understood that other shapes or designs can be utilized. Annular perimeter 48 is utilized as the same is complimentary to the shape of lateral end surface 102 of coil 100 which is also typically annular. In one embodiment, an annular perimeter 48 has a diameter that is about 5% less than the diameter of a coil 100, and at a minimum, is about 66% of the distance between the coil inner diameter and the coil outer diameter. The cooling device is situated adjacent the coil in one embodiment such that the area of the imaginary annular cylinder extending between the coil and the shroud at the outer diameter of the apertures 42 is preferably about 20% to about 60% of the area of exhaust outlet 24.
Base 50 or other suitable mount is utilized to support air source 20 and shroud 30. The structure of base 50 is not critical, so long as the air source 20 and shroud 30 are supported and allowed to perform their intended functions. In one embodiment as illustrated in
In one embodiment such as shown in
Flexible shroud 230 includes a receiver 232 that is connected to air exhaust outlet 224 of axial fan 220 to receive air therefrom and direct air into interior 234 of shroud 230. As described above, axial fan 220 includes an air inlet 223, motor 225 and propeller 226. The end of flexible shroud 230 generally opposite axial fan 220 is detachably connected to an air directing surface 240 via a locking mechanism 245 that permits quick disassembly for ease of handling. Air directing surface includes an adaptor 244 and one or more projections 246 of adaptor 244 that can be operatively attached to a spool plug component that optionally extends outwardly from the coil. The adaptor 244 can be moved towards or away from the coil to make a desired seal with the spool 104. As also described hereinabove, air directing surface 240 includes one or more apertures 242 that direct air into the coil 100. Air directing surface 240 can include one or more air directing vanes as described hereinabove.
Adaptor 244 in one embodiment as shown in
Adaptor 244 provides support for air directing surface 240 and can rest on mill spool 104 or otherwise be operatively connected thereto.
The flexible shroud 230 advantageously allows the cooling device 210 to be utilized on coils having different core heights above a ground surface. For example, in one embodiment, air directing surface 240 is operatively connected to a core of a coil to be cooled such as shown in
Cooling device 210 includes a base 250 that supports air source 220. In one embodiment, base 250 includes one or more wheels 256 operatively connected to frame 254 or leg 252 such as shown in
In order to utilize cooling device 10 of the present invention, cooling device 10 is moved into a desired position in relation to a coil 100, such as illustrated in
Articles that can be cooled by the present invention include any material, such as a coil or a non-coil article, preferably a metal or metal alloy. Non-coil metal articles include examples such as a sheet, plate, or ingot. Sheet material utilized to form coil 100 can have any thickness. However, in general air cooling of the type desired herein is most efficient with thinner material due to the larger number of windings per coil. Air gaps and surface roughness between laps tend to provide an insulating effect. The more of these discontinuities there are, the more heat movement and thus cooling is favored in the axial direction. In a preferred embodiment, coil 100 is aluminum or an aluminum alloy. Generally any of the numerous one or more 1xxx through 9xxx series alloy articles such as, but not limited to, sheets, plates, coils, and ingots according to the Aluminum Association Designation for Wrought Aluminum Alloys can be utilized. Coil 100 preferably has a side surface 106 having a perimeter that is circular, although side surfaces of other configurations which are not circular, but are substantially circular, oval, or the like can also be utilized. As described herein, coil 100 can have a center or core comprising a spool 104 that is hollow or solid. Coil 100 can be wound upon a mill spool 104 which can be of any suitable composition such as steel, aluminum or fiber. While coil 100 can generally have any diameter, typical diameters range from about 76.2 cm (30 inches) to about 25.40 cm (100 inches), and spools typically vary between about 20.3 cm (8 inches) to about 122 cm (48 inches), but can be smaller or larger.
In accordance with the patent statutes, the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
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| Number | Date | Country | |
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| 20080029191 A1 | Feb 2008 | US |
| Number | Date | Country | |
|---|---|---|---|
| 60811925 | Jun 2006 | US |
