Ion Air Jet Applications

While writing my blog last week on all of the features & benefits of the Gen4 Ion Air Jet, I couldn’t help but think of some of the very interesting and successful uses I’ve seen in my nine years (as of this past Monday) as an Application Engineer at EXAIR Corporation.  In honor of my workaversary, this week’s edition is Russ’ Top 9 Ion Air Jet applications:

  1. A medical device manufacturer uses Ion Air Jets to remove dust from plastic extrusion as it goes through a puller belt.  The small diameter (0.05″ to 0.10″) made the Ion Air Jet a more efficient fit than the Super Ion Air Wipe, which is commonly used for extrusions like this, but is most effective for larger diameters.
  2. A maker of large scale automated machinery has provided Ion Air Jets (as well as other EXAIR quiet, efficient, and safe compressed air products) on machines they’ve been selling their customers for years.  When they started machining their own plastic parts, the Ion Air Jet was their first thought for a solution when plastic chips started sticking to their drill bits.
  3. A commercial printer makes displays, signs, etc. from a variety of static-prone materials such as acrylic, polycarbonate, and styrene.  They use CNC routers to cut them to size & shape, form the edges, and add dimensional detail.  Ion Air Jets blow the dust & shavings away, and keep them away, greatly reducing the prep time between routing and assembly.
  4. A weather sealing/stripping manufacturer uses Ion Air Jets to remove statically charged dust from their rubber & foam product extrusions, allowing for increased line speeds and better cuts for the products they cut for specific seal packages for the residential & commercial door and automotive industries, among others.
  5. A major provider of electrical and electronic contactors uses Ion Air Jets to blow off contact strip as it rolls off large reels to remove protective film and static.
  6. A manufacturer of wire marking machinery installs Ion Air Jets on their machines that are used to print on products with especially static-prone jackets, to ensure clean and crisp markings
  7. A cable manufacturer that caters to the computer & electronic industries uses Ion Air Jets to remove static & dust as foil is applied to PVC coated wire.  This eliminates the static charge that was causing inconsistencies when the adhesive was heated to activate.
  8. A wholesale food equipment distributor uses Ion Air Jets to blow out bottles during the sterilization process, prior to filling.
  9. A maker of specialty polymers uses Ion Air Jets to keep fine powders from accumulating in the entries into their hoppers.
Some applications call for a fixed-in-place solution, like the (above, from left) Super Ion Air Knife, Super Ion Air Wipe, Ion Air Jet, and Ion Air Cannon.) Others are best suited to the hand-held convenience of the Ion Air Gun.  Whatever your static problem is, though, EXAIR has a solution for you!

If you have a problem with static, the Ion Air Jet is just one of the solutions EXAIR Corporation can provide.  If you’d like to find out more about how we can help, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Static Eliminators: Ion Air Jet

Static charge causes a variety of problems & challenges in industrial applications:

  • It “zaps” operators who have to handle statically charged materials.
  • It makes sheets and films cling to each other.
  • It can cause tearing or jamming of those sheets and films as well.
  • Objects with high static charges can cause sensors or sensitive electronics to malfunction, and it the charge is high enough, even damage them.
  • It makes dust cling to parts and material that you want to keep clean.
  • It can lead to uneven or spotty coverage if the statically charged piece is to be painted, coated, printed on, etc.

Good news is, static charge is pretty easy to dissipate, and EXAIR Corporation offers a number of solutions that are simple to install and easy to operate.  Among them is the Gen4 Ion Air Jet.

The Gen4 Ion Air Jet generates a concentrated flow of ionized air, which is ideal when you need to focus on a specific spot without disturbing anything in the surrounding area.  They’re quiet, efficient, and OSHA compliant.  They are also available with a number of options to further simply installation & operation:

If you can hard plumb an air pipe directly, the Gen4 Ion Air Jet is ready to go, right out of the box.

Ion Air Jet

The Gen4 Stay Set Ion Air Jet includes a Magnetic Base and 12″ Stay Set Hose, for quick setup and easy aiming of the ionized air flow, exactly where you want it.

The Magnetic Base and Stay Set Hose make it a breeze to mount & aim your Ion Air Jet.

The Gen4 Instant Static Elimination Station adds a foot pedal and two 10ft compressed air hoses, perfect for hands-free on/off operation.

For a total hands-free solution, look no further than the Model 8910 Instant Static Elimination Station.

The Gen4 Deluxe Stay Set Ion Air Jet Kit adds an Automatic Drain Filter Separator and Pressure Regulator so you can keep your air supply clean & moisture free, and dial in the flow & force of the ionized air stream, from a breeze to a blast, or anywhere in between, depending on the needs of your application.

The Model 8495-9362 Deluxe Stay Set Ion Air Jet Kit has everything you need, right out of the box.

We offer two Power Supply options: the Model 7960 has two ports, which will operate any two EXAIR Static Eliminator Products, and the Model 7961 has four ports, to operate up to four Static Eliminators.  They’re switchable for operation with either 115VAC or 230VAC, and come with both cables for your convenience.

Model 7960 Gen4 Power Supply (top) has two ports; Model 7961 (bottom) has four, depending on how many Static Eliminators you wish to operate from the same Power Supply

The Gen4 Ion Air Jet is just one of EXAIR Corporation’s eight distinct lines of Static Eliminator Products.  If you’ve got a problem with static charge, we can help.  Give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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The 3 Types of Static Generation

Static electricity is something that we talk about often here at EXAIR, particularly during the colder winter months. When an atom gains or loses an electron from its outer shell, it becomes electrically imbalanced. A material’s propensity to either gain or lose an electron is “ranked” on a list known as the Triboelectric Series. So how does static actually generate, or what causes these atoms to either gain or lose an electron? There are three types of static generation: contact, detachment, and frictional static build up.

Contact static build up is one of the simplest methods of static generation. In this type of static generation, a charge is generated simply from two objects contacting one another and separating. This often results in an instantaneous static charge as the electrons are transferred from one object to another in accordance with the Triboelectric Series.

redplasticbox_peel
As a layer of material is peeled off, electrons are transferred from one sheet to another.

The second type of static generation is known as detachment static buildup. The principle behind the type of static electricity is the same as contact static buildup, but the materials are already in contact with one another and the charge is generated as the surfaces are separated. During the separation, not all of the electrons are able to get back to their original molecule. The amount of static generated in detachment static buildup is generally far greater than contact static buildup due to the large surface area.

BOSE 2

The last type of static generation is frictional static buildup. When two objects have friction between one another, electrons in the outer valences of the molecules can easily pass from one atom to another. If the force pressing the objects together increases, even more molecules come into contact with each other and increase the charge that is generated. Just as detachment static buildup, frictional static buildup generally produces higher charges than contact static buildup.

Gen4 Static
Gen4 Static Eliminators

Regardless of the type of static generation occurring in your process, EXAIR has a Static Eliminator that is suitable for neutralizing that charge and mitigating any issues that you’re having as a result. With a team of Application Engineers standing by to help and our unconditional 30 day guarantee, there’s no reason to not give us a call and try one out!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Static Electricity: What Is It And The Products To Solve Industrial Process Problems

The lower relative humidity associated with the cold, dry air of winter results in a significant increase in customers  with problems related to static. Luckily, EXAIR has a wide-range of Static Eliminators that are designed specifically to address static issues in a wide variety of industries. So, what exactly is static and how is it generated? Let’s take a quick trip down memory lane to elementary school science class….

An atom consists of three basic particles: protons, neutrons, and electrons. The protons (positively charged) and neutrons (neutral charge) form the nucleus. Outside of the nucleus, electrons (negatively charged) are quickly zipping around in orbits at specific distances from the nucleus. These electrons are bound to the nucleus due to electromagnetic force. Opposite charges attract. Since the protons in the nucleus carry a positive charge this acts on the negative charge of the electrons and keeps them in orbit. The closer the electron to the nucleus, the stronger the bond and the more energy required to break that electron from its original orbit.

When an atom gains or loses an electron, it affects the balance that occurs within an atom. If an atom gains an electron, it now has more electrons than protons. This results in a negatively charged atom. The opposite can be said if an atom loses an electron, it now carries a positive charge. This charge imbalance is where static electricity comes from. Both positive and negative charges will remain static until contacted by or in close proximity to a conductive or grounded surface. Materials such as paper, plastic, or textiles will normally contain an equal number of both positive and negative ions. When subjected to friction, this balance can be disturbed if the atoms gain or lose an electron.

The static charge will then exert a force on nearby charged objects or grounded conductors (including personnel). These issues can also manifest in the form of dust clinging to product, product clinging to itself, rollers, machine beds or frames, materials jamming, and sheet feeding problems.

To eliminate these charges, EXAIR’s Static Eliminators produce an equal amount of both positive and negatively charged ions. This allows us to neutralize either charge quickly and effectively.

For applications that allow you to install close (generally within 2”) to the surface of the material, we offer our Ionizing Bar in lengths ranging from 3”-108”. If a wide area of coverage is necessary, but you can’t get close to it, the same Ionizing Bar is installed on the Super Ion Air Knife to help deliver those ions over a greater distance.

gen4 super ion air knife
Gen4 SIAK

The Ionizing Point is another product that can be used without the need for compressed air. A compact, single point ionizer, this product is ideal for winding, rewinding or slitting operations. It can also be mounted through a duct to neutralize static charges due to moving air or materials.

ionpointCUTCARDS_350x
Gen4 Ionizing Point

The Ion Air Gun combines incredibly fast static decay rates with low compressed air consumption. With a 10’ flexible armored cable and ergonomic handle, the Ion Air Gun is best for applications where an operator will perform the blowoff process.

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If the airflow pattern from the Ion Air Gun is conducive to your application, but you’d prefer to automate the blowoff or maintain a continuous usage, both the Ion Air Jet and the Stay Set Ion Air Jet provide an identical airflow pattern. The Stay Set Ion Air Jet comes with a magnetic base and Stay Set Hose, allowing you to precisely position the static eliminating ions in your process.

staysetiaj_559x

The Ion Air Cannon delivers a quit, efficient, and concentrated flow of ionized air. It is ideal for hard to reach spaces or confined areas that necessitate a solution to static problems. Designed with a sturdy stand, the pre-drilled holes can be wall, bench, or machine mounted. It incorporates a swivel adjustment for directing the airflow.

Our Gen4 Static Eliminators have all undergone independent laboratory tests to certify that they meet the rigorous safety, health, and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. If there’s a process in your facility that could benefit from a solution to static problems, please give us a call. Any of our Application Engineers will be happy to help select the best option for your process.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD