Efficient and flexible multi spray electrostatic deposition system

An electrostatic flow distribution and charging system, for the spraying of a flowable material by distribution and charging to a suitable high voltage and the spraying of the material by a multiplicity of parallel ligamental streams, wherein said system comprises:

• an assembly of one or more insulated non-conductive flow distribution modules, a conductive surface with electrical connection to such surface, whereby the flowable material is electrically insulated in said system except for said conductive surface and electrical connection, means for application of an electrostatic field, one or more target bars to define the electrostatic field, and one or more catch trays, and grooves in the non-conductive flow distribution flow modules and over the conductive surface, said grooves being parallel with the electrostatic field and are distributed over the width of the flow distribution modules,
• whereby:
• the flowable material is sprayed with minimum loss from electrical currents through said assembly, the flow of material being distributed and guided through said grooves in the non-conductive flow distribution modules and over the electrically conductive part of said assembly substantially parallel with the electrostatic field, the application of the electrostatic field providing a positive force or pressure to move the material that is sprayed, through said grooves, the flow through each groove in a flow distribution module being substantially equal or independent of specific geometry of groove or module, to hydrodynamically distribute the flowable material to be sprayed over a length of a distribution module, while the flow to each distribution module is controlled separately so that long, multiple and shaped spray assemblies can be made with a precise distribution of flow, while different flowable materials can be used in sections of the spray assembly, and wherein the target bars that define the electro static field are separate from any catch trays and shaped to create different spray patterns.

An electrostatic spray system installation comprising:

• one or more vertical members, each having an elongate length with two outside surfaces formed along opposing sides of the length;
• parallel flow distribution modules made from non conductive materials that are clamped relative to each other, the parallel flow distribution modules are positioned adjacent to the two outside surfaces of the one or more vertical members for providing parallel sprays onto a substrate formed of a non conducting material;
• charging strips, each charging strip being mounted to an intermediate portion of one of the two outside surfaces of the one or more vertical members, each charging strip being oriented to face a flow distribution module and maintained at a voltage of a minimum of 20,000 volts;
• sheets formed of a non conductive material, each sheet being disposed over a lower portion of one of the outside surfaces, wherein the charging strips and the sheets collectively space the flow distribution modules away from the outside surfaces of the one or more vertical members, wherein each of the flow distribution modules is supplied by a controlled flow of a flowable material, and wherein the flow distribution modules can be given different dimensions and can be positioned to give various spray configurations, and wherein the sheets extend beyond the flow distribution modules and the one or more vertical members for providing separate parallel sprays spaced 30 to 40 mm from each other;
• and
• a pair of target bars oriented parallel to the one or more vertical members for defining electrostatic fields with the charging strips;
• and grooves in the non-conductive flow distribution flow modules and over the charging strips, said grooves being parallel with the electrostatic field and are distributed over the width of the flow distribution modules.