Electromagnetic cleaning process and device

Abstract

The present invention discloses a process for cleaning oxides, slurry, dirt, impurities, organics and volatile matter, rust and other scales from substrates. This cleaning and surface preparation action is affected by abrasion, shaving or dry machining of the substrate material as caused by dry magnetic abrasive particles, either in powder or granule form, which engage the substrate material in a magnetic field. The passage of input current through a motor generates a magnetic field, which creates a “coupling” between two surfaces, the driving (stator) surface and the driven (rotor) surface. The magnetic coupling between the surfaces is provided by stiffening of the particles, which allows the mechanical abrasion that is necessary for the cleaning action on the substrate.

Description

FIELD OF THE INVENTION

[0002] The present invention is directed to the field of electromagnetic cleaning and more particularly to an apparatus and method for utilizing magnetic abrasive particles in a generated magnetic field to clean substrates such as wire.

BACKGROUND OF THE INVENTION

[0003] The use of magnetic fields containing magnetic abrasive particles for engraving and machining workpieces is known in the art. (See, for example, U.S. Pat. Nos. 6,036,580 to Igelshteyn et al.; 5,419,735 to Imahashi et al.; 5,197,234 to Gillenwater; 4,821,466 to Kato et al.; 4,306,386 to Sakulevich et al.; and 4,170,849 to Sakulevich et al., the teachings of all of which are incorporated herein by reference). However, it is has not been previously recognized that magnetic abrasive particles introduced between magnetically coupled surfaces can be used to clean substrates.

SUMMARY OF THE INVENTION

[0004] The present invention discloses a process for cleaning oxides, slurry, dirt, impurities, organics and volatile matter, rust and other scales from substrates. This cleaning and surface preparation action is effected by abrasion, shaving or dry machining of the substrate material as caused by dry magnetic abrasive particles, either in powder or granule form, which engage the substrate material in a magnetic field. A magnetic field generator generates the magnetic field, which creates a “coupling” between two surfaces, the driving (stator) surface and the driven (rotor) surface. The magnetic coupling between the surfaces is provided by stiffening of the particles, which allows the mechanical abrasion that is necessary for the cleaning action on the substrate.

BRIEF DESCRIPTION OF THE DRAWING

[0005] The invention is described with reference to the several figures of the drawing, in which:

[0006] FIG. 1 is a cross-sectional illustration of a substrate being cleaned by magnetic abrasive particles in a generated magnetic field according to one embodiment of the invention;

[0007] FIGS. 2A and 2B are isometric illustrations of drive surfaces according to various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0008] Referring now to the figures of the drawing, the figures constitute a part of this specification and illustrate exemplary embodiments to the invention. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.

[0009] The present invention discloses a process for cleaning oxides, slurry, dirt, impurities, organics and volatile matter, rust and other scales from substrates. This cleaning and surface preparation action is affected by abrasion, shaving or dry machining of the substrate material as caused by dry magnetic abrasive particles, either in powder or granule form, which engage the substrate material in a magnetic field. In a preferred embodiment, the substrate material is an elongate material. In another preferred embodiment, the elongate material is in coiled form or in short lengths and is metallic in nature (with the ductility and machinability characteristic of metallic materials). In another preferred embodiment, the metallic material is substantively a metal alloy based on aluminum, copper, or magnesium (or other non-ferrous metals) or iron (e.g. steel). In another preferred embodiment, the elongate material is a wire of circular cross section that is paid off a coil wound on a drum.

[0010] A magnetic field generator generates a magnetic field which creates a “coupling” between two surfaces, the drive (stator) surface and the driven (rotor) surface. In a preferred embodiment, the passage of input current through a motor with special laminations generates the magnetic field. FIG. 1 is a cross-sectional illustration of a driven surface being cleaned by dry magnetic abrasive particles 30 in a magnetic field generated by a motor 40. The dry magnetic abrasive particles 30, either in powder or granule form, fill the gap 24 formed by the configuration of the drive surface 20 and is adapted to receive the driven surface. In a preferred embodiment, the driven surface is the substrate 10 that is to be cleaned. In another embodiment, the gap 24 between the surfaces could potentially comprise a fluid other than air. The magnetic coupling between the surfaces is provided by stiffening of the particles 30, which allows the mechanical abrasion that is necessary for the cleaning action on the substrate 10. The coupling creates an engagement between the substrate 10 and the dry magnetic abrasive particles 30 on the substrate. As shown in by the arrows in FIG. 1, the substrate 10 may be moved by a mechanism 14 that grips the substrate and moves it in a translational, oscillatory or rotational motion in order to effect and enhance the cleaning action of the magnetic abrasive particles.

[0011] In preferred embodiments, the input currents to the motor 40 are square or sinusoidal waveforms. In order to improve the response time, increase cleaning efficiency, and alleviate over-heating problems, the motor 40 can be operated in a “big bang” mode. This allows the application of larger input power for short bursts of time without damaging the motor. To further prevent over-heating, oil or water cooling can be used independently with both the drive system and on the substrate material. Substrate cooling mechanisms 12 and drive cooling mechanisms 22 are illustrated in FIG. 1.

[0012] FIGS. 2A and 2B are schematic illustrations of drive surfaces according to various embodiments of the invention. FIG. 2A illustrates an embodiment in which the drive surface comprises two plates 50. FIG. 2B illustrates an embodiment in which the drive surface comprises a slotted cylinder 52. Other configurations for the drive surface will be apparent to those of ordinary skill in the art.

[0013] The invention can be used independently or in conjunction with a combination of one or more other cleaning techniques employed in industry today including chemical (low or high temperature), electrochemical, mechanical abrasion (e.g. mechanical rotors), and rinsing (ultrasonic, hot water, etc . . . ).

[0014] The present invention offers various advantages. The substrate to be cleaned needs not be ferromagnetic as the cleaning action is effected by the stiffening of the magnetic abrasive particles in the magnetic field. The invention is mobile and allows for the cleaning or polishing of substrates which must undergo pre-processing or post-processing, for example in the application of a coating.

[0015] Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.

Claims

1. An apparatus for electromagnetic cleaning, comprising: at least one drive surface, wherein said at least one drive surface is arranged so as to form a gap that is adapted to receive a substrate; magnetic abrasive particles residing in said gap; and a magnetic field generator, wherein said generator generates a magnetic field so as to magnetically couple said drive surface with said substrate when said substrate is introduced into said gap, and wherein said magnetic field causes said magnetic abrasive particles to engage said substrate.

2. The apparatus of claim 1, further comprising at least one cooling mechanism attached to said drive surface.

3. The apparatus of claim 1, further comprising at least one cooling mechanism attached to said substrate.

4. The apparatus of claim 1, wherein said magnetic field generator is a motor adapted to receive an input current.

5. The apparatus of claim 4, wherein said input current is a sinusoidal waveform.

6. The apparatus of claim 4, wherein said input current is a square waveform.

7. The apparatus of claim 4, wherein said input current is large and said motor is operated for multiple short periods of time.

8. The apparatus of claim 1, wherein said at least one drive surface comprises two plates.

9. The apparatus of claim 1, wherein said at least one drive surface comprises a cylinder.

10. The apparatus of claim 1, further comprising: means for moving said substrate.

11. The apparatus of claim 1, wherein said magnetic abrasive particles are in powder form.

12. The apparatus of claim 1, wherein said magnetic abrasive particles are in granule form.

13. A method for electromagnetic cleaning, comprising the steps of: generating a magnetic field so as to magnetically couple two surfaces, wherein said surfaces comprise a drive surface and a substrate and wherein said drive surface is arranged to form a gap adapted to receive said substrate; introducing magnetic abrasive particles into said gap, wherein said magnetic field causes said magnetic abrasive particles to engage said substrate.

14. The method of claim 13, wherein said magnetic abrasive particles are stiffened by said magnetic field.

15. The method of claim 13, further comprising moving said substrate so as to effect cleaning by said magnetic abrasive particles.

16. The method of claim 13, wherein said magnetic field generator is a motor adapted to receive an input current.

17. The apparatus of claim 16, wherein said input current is a sinusoidal waveform.

18. The apparatus of claim 16, wherein said input current is a square waveform.

19. The apparatus of claim 16, wherein said input current is large and said motor is operated for multiple short periods of time.

20. A system for electromagnetic cleaning, comprising: a substrate at least one drive surface arranged so as to form a gap that is adapted to receive said substrate; magnetic abrasive particles residing in said gap; and a magnetic field generator, wherein said generator generates a magnetic field so as to magnetically couple said drive surface with said substrate when said substrate is introduced into said gap, and wherein said magnetic field causes said magnetic abrasive particles to engage said substrate.

21. The system of claim 20, wherein said substrate is an elongate member of circular cross section.

22. The system of claim 20, wherein said substrate is a non-ferrous metal alloy.