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Beware of Humidification,
Electric Leakage, Fire, and Assist Air !

Various types of ionizers  |  Correct understanding  |  Attention!  |  Key points for ionizer selection  |  Application examples of TRINC

Beware of anti-static measure using humidification!

Humidification has long been used as a means of static electricity. Since static electricity is hard to generate in an environment with high humidity during the rainy season, it has been often attempt to solve the problem of static electricity by making air hot and humid. The representative measures using humidification is as follows.

  • ・Textile miles, paper mills, paper and plastic film printing factories
  • ・Some electronics or semiconductor factories
  • ・Painting process in automobile factory
Humidification can cause several problems.
Several problems of humidification
1. Soldering failure

Rust on the leads and terminals of electronic components causes soldering defects.

2. Electrical contact failure

Due to oxidization of metal surfece caused by condensation, electric contasts are failed in relays, breaker, etc.

3. Rust on metal surface

In plastic molding, sheet metal pressing, forging, and die casting, metal molds rust due to condensation.
Since rusted metal molds cannot be used, many attentions are paid to prevent condensation.

4. Rust on machinery

Metal parts such as the housing of equipment rust from condensation due to high humidity.

5. Degeneration of material

The surface of optical components such as plastic lenses is degenerated and get fogged.
The lifetime of organic EL parts deteriorates.

6. Paint unevenness in painting process

Paint unevenness occurs because of condensation on the surface of the object to be painted.

7. Increase of dust-related defects

To prevent condensation, it is necessary to prevent the humidity from rising to high throughout the factory. To keep temperature inside the factory uniform and stable, the air is stirred by a fan, warm air near the ceiling is blown down toward the floor, whereas cold air near the floor is blown up to the ceiling. Since stirring air scatters dust, so that the dust adhesion to the product is increased. As a result, the humidifacation increases dust-related defects, on contrary to the original aim of their decreasing.

8. Difficulty in handling paper by machine

Since the paper becomes soft and limp due to the high humidity, paper handling tends to fail because of wrincle generation, etc.

9. Mold growning on fiber and paper

The high temperature and humidity environment causes mold to grow on the fibers and paper, resulting in defective products.

10. Tend to be unsanitaly

Since bacteria can easily grow in such high temperature and humidity environment, quality of foods is prone to be deteriorated.

11. Possibility to adversely affect worker's skin disease

High temperature and high humidity working envitonment has a possibility to exacerbate skin disease.
12. High capital investment

Capital investment and construction costs hare high. For example, they are required for pure water production equipment, pipes for pure watere, large numbers of sprayers distributed in the factory, etc.

13. High running cost

It requires high electricity cost to generate pure water.
    On the other hand, in a paintign factory using solvent, it is necessary to constantly ventilate. This is equivalent to dehumidification, so humidification must be further enhanced to maintain humidity. As a result, power wasting is accerated.

14. High maintenance cost of equipment

To prevent water leaks from pipe connection part, it is necessary to take measures at all times.

A new measure to get out of annoying humidification
"Phased array ionizer"

Phased array ionizer can fill a large space with ions w/o air blow. The amount of ions with positive and negative polarities are cotrolled to be equal. So, all of static electricity existing in the target space is neutralized. Here, "all" means static electricity on all things such as not only products, parts, equipment, humanbody, but also dust floating in the air.
    Conventional ionizers are used to remove static electricity on the object, and are not able to remove that on dust floating in the air. This feature of phased array ionizer decrease the dust-related defects dramatically. Since the adhesion of dust to object is caused by the Coulomb's attractive force, static electricity on both object and dust must be removed to prevent it.
    Traditionaly, dust-related defects haven't been prevented because only the static electricity on object have been considered. Even if this fact were noticed, dust problem wouldn't be solved because there are no practical tool to realize it.

Principle of static elimination using "Phased Array Ionizer"

Here, we explain how the phased array ionizer can nuetralize the static electricity on dust floating in the air.

■Conventional ionizers using fan air or compressed air (Air-assisted ionizer)
In order to neutralize the static electricity of dust floating in space, air must be blown toward the target space. Since the effective range of air-assisted ionizer is within only 1.5m, a large numbers of ionizers must be used side by side. However, dust is scattered in the space by air blow from ionizers, resulting in an increase in dust-related defects. Like this, conventional air-assisted ionizers are adverse rather than ineffective for anti-dust mesures.

■Phased array ionizer
Ions are spread widely by using Coulomb's repulsive force working between ions without air flow. Its capability to nuetralize static electricity is powerful. We evaluated its ability compared to humidification. In the experiment with humidification, the static electricity on nyrlon resin wasn't removed even after 5 minutes. The residual static potential is 10kV. On the other hand, with phased array ionizer, the static electricity was neutralized to be 0kV only in 20 seconds.

Conventional explosion-proof ionizers can be a cause of fire!?

If the foreign-matter adheres to high voltage part of conventional explosion-proof ionizer, there is a risk of fire or explision.

1. Problems of conventional explosion-proof ionizers!
1) Spark when touching to high voltage part

If the high voltage part such as discharge needle is exposed, there is a risk of spark in the flammable atmosphere when the human hand or jig touches to the high voltage part, resulting in fire disaster.

2) Foreign matter adhering to high voltage part causes electric leakage

If the conductive foreign matter adheres to the insulator around high vlotage part, the electric leakage occurs and it lead to accidents of fire and explosion.

2. TRINC' explosion-proof ionizer has safety structure!
1) Safety structure

The main body of the static eliminator is housed in a triple container, and the outermost part is covered with aluminum to ensure mechanical strength. Despite its robust housing, the maintenance is very easy because of the equipped one-touch cleaner to clean discharge needles. In addition, the needles can be replaced without disassembly.

2) Double safety measures

TRINC's explosion-proof ionizer has double safety measures.
The main body with explosion-proof structure is palced in the explosion-proof area, while the control panel is palaced in the safety area and always monitor the current. If an error is detected, the current is cut off immediately.

Please don't use ionizers that are prone to electric leakage!

If ionizer that has the high voltage part to generate ions and the air flow channel are placed in the same area is used, there is a risk of fire accident caused by electric leakage.

Why does electric leakage occure?
1. Leakage structure (high voltage part and air flow channel are placed in same space)

When compressed air is released from the pressure, the adiabatic expansion of air is occur. Here, the air temperature drops instantly, so that the moisture contained in the air condenses and forms mist. Although the discharge needles are hold by the insulator not to occur electric leakage by high voltage. However, if the mist adheres to the surface of the insulator, the insulation capability deteriorates, resulting in occuring electric leakage.
This leads to not only degradation of ionizer performance but also fire disaster. We call this types of structure prone to electric leakage as "leakage structure". while TRINC's safe ionizers is named as "No-leak structure".
Example of leakage structure Enlarged view
2. Electric leakage and carbonization of plastic

If the electric leakage occurs and current flows, the plastic is burnt and turn black. This indicates that the insulator is carbonized, where the current flows easily. Once the insulator is carbonized, leakage current flows at an increasing tempo. Then, the voltage drops and the corona discharge that generates ions stops. Furthermore, if the device continues to be used, it will eventually leads to a fire. There is a fact that, at a automobile painting factory, a smoke accident occured by an ionizer with leakage structure in flammable thinner atomosphere, so the power was turned off in a hurry.

The clean environment is destroyed by foreign matter emit from carbonized part.

3. Fire due to electric leakage

The high voltage on the discharge needle always wants to leak along the surface of the insulator. If the dust adheres to the insulator, electric leakage occurs, that is, tracking phenomenon which leads to a fire.
Actually, in a printing factory, when the low insulation ink invaded to the inside of device, the electric leakage occurred in ink atomosphere containing the solvent caused a fire.

Tracking phenomonen

No-leak structure

There is a fundamental rule in the electric engineering that "Air flow channel and high voltage parts should not exist in the same space". Even with a 100V power supply, we are afraid of a tracking phenomenon, that is a electric leakage occured by dust. So, of course, the static eliminator that generates ions using a high voltage of several kilo-volt must be serpareted with easily fog-containing air to avoid electric leakage. Unfortunately, even now, many static eliminator with leakage structure are used.
    TRINC's ionizers have the structure in which the high voltage part and the air flow channel are separeted each other, that is "no-leak structure". This no-leak structure makes it possible to extend the lifetime of TRINC's ionizers and realize the overwhelming record of toughness free from abnormality even after using 10 years.

TRINC's no-leak structure

Beware of anti-dust/static measures using compressed air!

You may think of a fan-type static eliminator as a typical one, but bar-type or gun-type devices are also widely used in many places.
Conventional bar-type and gun-type static eliminators use compressed air to deliver ions to the object to be neutralized. The structure and operation of conventional static eliminator is as follows.

 (1) Ionizer consits of "high voltage power supply","needles for corona discharge", and "air flow channel".
 (2) Air is ionized by adding high voltage to the discharge needles.
 (3) The generated ions are delivered to charged object by sending air from needle part.

Here, we must note that there are following fundamental problems in using compressed air for ionizer.

 1. Electric leakage occurs.
 2. Annoying maintenance of discharge needles
 3. Dust is blown to the product by air blow.
 4. Surrounding dust is blown to the product with air flow.
 5. Increase of dust-related defects by scattering dust.
 6. Large power consumption of air compressor

Several problems of compressed air
1. Electric leakage occurs.

Moisture contained in the air condenses due to adiabatic expansion, which causes electric leakage from the high-voltage discharge needle. With electric leakage, the generation of ions is stopped, and with further use of it, there is a risk of a fire.

2. Annoying maintenance of discharge needles

Electric leakage tend to occur with using compressed air. Once the surface of the insulator holding discharge needle is burnt and carbonized, the maintenance to remove it is very hard.
3. Dust is blown to the product by air blow.

The dust in the compressed air is removed by a filter.
However, the particles smaller than the filter specification can pass throught the filter, and are blown to the product.

4. Surrounding dust is blown to the product with air flow.

The air blow entrains the surrounding dust and blows it to the product, resulting in increase of defects.

5. Increase of dust-related defects by scattering dust

Air blow scatters dust accumulated on the desk or object, resulting in increase of defects.

6. Large power consumption of air compressor

Power consumption of static eliminators using compressed air is very large.
The anual cost is estimated to be $1,500-3,000 per one bar-type ionizer, since it costs $100 per one discharge needle.

Beware of anti-dust/static measures using fan-type static eliminator!

Fan-type static eliminator causes several problems because it generates strong air flow.

The fundamental problems of conventional fan-type static eliminator are as follows.

 1. Fan type static eliminator blows floating dust to increase defects.
 2. Fan-type static eliminators increases defects by flying up accumulated dust.
 3. Fan-type static eliminator consumes a lot of power.
 4. Fan-type AC pulse static eliminator may destroy product (semiconductor).
 5. Small products and parts such as chip parts is blow off.

Several problems of fan-type static eliminator
1. Fan type static eliminator blows floating dust to increase defects.

The fan-type static eliminator blows dust floating in the space onto the product, resulting in increase of defective products.

2. Fan-type static eliminators increases defects by flying up accumulated dust.

A circulating air flow is generated around the fan-type static eliminator. The dust blown up by the wind circulates on this flow and eventually adheres to the product, resulting in increase of dust-related defects.

3. Fan-type static eliminator consumes a lot of power.

Fan-type static eliminators consume a lot of power because they generate wind to carry ions.

4. Fan-type AC pulse static eliminator may destroy product (semiconductor).

AC-type and pulse-type static eliminators emit strong lines of electric force from the front, which may destroy semiconductors passing nearby and precision electronic devices placed nearby.

5. Small products and parts such as chip parts is blow off.

Chip parts are becoming smaller and smaller, making it difficult to distinguish them from dust.
If the fan-type static eliminator blows wind during mounting with a chip mounter, extremely small electronic components will be blown away.

Phased Array Ionizing”, “No-Blow Ionizing”, “Ion Engine”, “Slight-Air Ionizing” are registered trademark (in Japan) of TRINC Corporation, a forerunner of this field.

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