COATING HUMIDIFICATION SYSTEM

Described herein is a coating system comprising an applicator head that is configured to apply a coating to a surface of a workpiece, a shroud comprising a housing and an internal cavity located inside of the housing, and a humidifying apparatus comprising an output that is fluidly coupled to the shroud, wherein the humidifying apparatus configured to introduce a quantity of humid air to the internal cavity of the shroud.

BACKGROUND

Edge-coating a workpiece as it moves along in a direction generally parallel to its edge is generally known. Systems have been developed that spray the passing edge with a liquid and then vacuum the excess liquid off the edge in order to obtain a smooth and uniform coating of the liquid on edge of the workpiece. Problems with these previous attempts exist, however, in that the coating composition requires low solids contents to avoid clumping. Therefore, a need exists for improved edge-coating systems capable of applying coating composition having higher solids contents.

BRIEF SUMMARY

Described herein is a coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising a housing and an internal cavity located inside of the housing; and a humidifying apparatus comprising an output that is fluidly coupled to the shroud, wherein the humidifying apparatus configured to introduce a quantity of humid air to the internal cavity of the shroud.

Other embodiments of the present invention include a coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising a housing and an internal cavity located inside of the housing; and a humidifying apparatus comprising an output that is fluidly coupled to the shroud, wherein the shroud can be altered between a first state and a second state, wherein in the first state the applicator head is at least partially located inside of the interval cavity and in the second state the applicator head is located outside of the internal cavity, and wherein in the first state the humidifying apparatus is configured to introduce a quantity of humid air to the internal cavity of the shroud that contacts the applicator head.

Other embodiments of the present invention include a coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising: a housing; an internal cavity located inside of the housing; and a baffle located within the internal cavity; a humidifying apparatus comprising an output that is fluidly coupled to the shroud, wherein the humidifying apparatus is configured to introduce a quantity of humid air to the internal cavity of the shroud that contacts the applicator head.

Other embodiments of the present invention include a coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising: a housing; and an internal cavity located inside of the housing; a humidifying apparatus comprising an output that is fluidly coupled to the shroud, the humidifying apparatus comprising: an air-moving device configured to move air; a steam generator configured to generate steam; a mixing apparatus comprising a mixing chamber configured to blend the steam with the air to form humid air; and wherein the humidifying apparatus is configured to introduce the humid air to the internal cavity of the shroud that contacts the applicator head.

Other embodiments of the present invention include a method for coating a workpiece, the method comprising: a) supplying humid air to a coating assembly, the coating assembly comprising: an applicator head; and a shroud comprising an internal cavity whereby the applicator head is at least partially disposed inside of the internal cavity and the humid air is supplied to the internal cavity of the coating assembly; b) moving the workpiece relative to the coating assembly; and c) directing a coating composition onto a surface of the workpiece using the applicator head and exposing the surface of the workpiece to the humid air.

Other embodiments of the present invention include a method for coating a workpiece, the method comprising: a) supplying humid air to a coating assembly, the coating assembly comprising: an applicator head; and a shroud comprising an internal cavity whereby the applicator head is at least partially disposed inside of the internal cavity and the humid air is supplied to the internal cavity of the coating assembly; b) moving the workpiece relative to the coating assembly; c) directing a coating composition onto a surface of the workpiece using the applicator head and exposing the surface of the workpiece to the humid air.

Other embodiments of the present invention include a method for coating a workpiece, the method comprising: a) supplying humid air to a coating assembly by a gravity feed, the coating assembly comprising: an applicator head comprising an applicator nozzle; and a shroud comprising an internal cavity and a baffle located inside of the internal cavity; whereby the applicator head is at least partially disposed inside of the internal cavity and the humid air is supplied to the internal cavity of the coating assembly; b) contacting the applicator head with the humid air as a coating composition is applied onto a surface of the workpiece using the applicator head, where by a condensation product of the humid air is directed away from the applicator nozzle by the baffle.

Other embodiments of the present invention include a shroud for coating a work piece, the shroud comprising a housing and an internal cavity located inside of the housing, the housing comprising: a top plate having an upper major surface opposite a lower major surface; a port located on the top plate and extending continuously from the upper major surface to the lower major surface of the top plate; a first side plate having a first major surface opposite a second major surface; the first side plate extending downward from the top plate; a second side plate having a first major surface opposite a second major surface; the second side plate extending downward from the top plate; a third side plate having a first major surface opposite a second major surface; the third side plate extending downward from the top plate; a baffle located within the internal cavity, wherein at least a portion of the baffle overlaps with the port in a vertical direction; and wherein each of the lower major surface of the top plate, the second major surface of the first side plate, the second major surface of the second side plate, and the second major surface of the third side plate face the internal cavity.

DETAILED DESCRIPTION

Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar 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. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material. According to the present application, the term “about” means+/−5% of the reference value. According to the present application, the term “substantially free” less than about 0.1 wt. % based on the total of the referenced value.

Referring toFIG.1, the present invention is directed to a coating system1comprising a coating assembly10, a humidifying apparatus300, and a steam generating apparatus400. The coating assembly10may comprise a shroud100and an applicator head200. Referring toFIGS.1,10, and11, the coating system1may further comprise comprising a support apparatus500. The support apparatus500may comprise a frame510and a conveyor520.

The steam generating apparatus400may comprises a reservoir and a heating element. The reservoir may be configured to store a quantity of liquid water, and the heating element may be configured to heat the liquid water inside of the reservoir thereby transitioning the water from liquid to vapor (also referred to as “water vapor”). The steam generating apparatus400may be further configured to modify the internal pressure of the reservoir to affect the generation of water vapor. The water vapor may be pure water vapor. The term “pure water vapor” refers to a volume or quantity of water that is about 100% in the gaseous phase.

The steam generating apparatus400may comprise a first output405that is fluidly coupled to the reservoir such that the water vapor may exit the steam generating apparatus400via the first output405. The first output405of the steam generating apparatus400may be fluidly coupled to the humidifying apparatus300by a first supply line21. The first supply line21may be directly coupled to the first output405of the steam generating apparatus400. The first supply line21may be a pipe. Non-limiting examples of the first supply line21include insulated copper pipe. In other embodiments, an ultrasound element may generate humid air.

The humidifying apparatus300may comprise a mixing device310and an air-moving device350. The mixing device310may comprise a mixing chamber320that is an elongated cavity within the mixing device310. The mixing device310may comprise a first input311. The mixing device310may further comprise a second input312. The first output405of the steam generating apparatus400may be fluidly coupled to the first input311of the mixing device310. The water vapor generated by the steam generating apparatus400may be delivered to the mixing chamber320of the mixing device310via the first supply line21and the first input311of the mixing device310. The mixing chamber320of the mixing device310may be fluidly coupled to the output405of the steam generating apparatus400via the first supply line21and the first input311of the mixing device310.

The air-moving device350may comprise a housing351and an air-moving element355that is configured to move air into the mixing chamber320of the mixing device310. In a non-limiting embodiment, the air-moving element355may be a fan. The air-moving device350may comprise an input352and an output353. The air-moving element355may be configured to pull air from the surrounding environment that is up-stream from the air-moving element355and through the input352, whereby the air is subsequently pushed through the output353of the air-moving device350when down-stream from the air-moving element355. Each of the input352and the output353of the air-moving device350may be located on the housing351—whereby the air-moving element355is located inside of the housing351.

The output353of the air-moving device350may be fluidly coupled to the second input312of the mixing device310. The air moved by the air-moving element355may be delivered to the mixing chamber320of the mixing device310via the output353of the air-moving device350and the second input312of the mixing device310. The mixing chamber320of the mixing device310may be fluidly coupled to input352of the air-moving device350via the output353of air-moving device350and the second input312of the mixing device310.

The steam generating apparatus400may deliver water vapor to the humidifying apparatus300at a rate ranging from about 6 lb./hr. to about 16 lb./hr.—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the steam generating apparatus400may deliver water vapor to the humidifying apparatus300at a rate ranging from about 7 lb./hr. to about 15 lb./hr.—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the steam generating apparatus400may deliver water vapor to the humidifying apparatus300at a rate ranging from about 8 lb./hr. to about 14 lb./hr.—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the steam generating apparatus400may deliver water vapor to the humidifying apparatus300at a rate ranging from about 9 lb./hr. to about 13 lb./hr.—including all sub-ranges and specific rates there-between.

The air-moving device350may deliver air to the mixing chamber320at a rate ranging from about 500 CFM to about 700 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the air-moving device350may deliver air to the mixing chamber320at a rate ranging from about 525 CFM to about 675 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the air-moving device350may deliver air to the mixing chamber320at a rate ranging from about 550 CFM to about 650 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the air-moving device350may deliver air to the mixing chamber320at a rate ranging from about 575 CFM to about 625 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the air-moving device350may deliver air to the mixing chamber320at a rate ranging of about 600 CFM.

The air delivered to the mixing chamber320via the air-moving device350and the water vapor delivered to the mixing chamber320via the steam generator device may be blended together to form humid air40. The mixing device310may comprise a static mixing element330located inside of the mixing chamber320to promote mixing of the water vapor and air.

The humid air40exiting the humidifying apparatus300may have a relative humidity ranging from about 60% to about 100%—including all relative humidity and sub-ranges there-between—as measured under normal atmospheric conditions. In some embodiments, the humid air40exiting the humidifying apparatus300may have a relative humidity ranging from about 60% to about 90%—including all relative humidity and sub-ranges there-between—as measured under normal atmospheric conditions.

The humidifying apparatus300may comprise an output305that is fluidly coupled to the mixing chamber320such that the humid air40generated inside of the mixing chamber320may exit the humidifying apparatus300at the output305. The output305of the humidifying apparatus300may comprise a y-joint that separates the humid air stream into a first stream and a second stream.

The humidifying apparatus300may be fluidly coupled to one or more coating assembly10by one or more second supply lines22. The second supply line22may be directly coupled to the second output305of the humidifying apparatus300and directly coupled to the one or more coating assembly10. The second supply line22may be a conduit. Non-limiting examples of the second supply line22include a duct. The humid air40may be delivered from the humidifying apparatus300to the at least one coating assembly10via the one or more second supply lines22.

The humidifying apparatus300may deliver humid air40to the one or more coating assembly10at a rate ranging from about 100 CFM to about 160 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humidifying apparatus300may deliver humid air to the one or more coating assembly10at a rate ranging from about 110 CFM to about 150 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humidifying apparatus300may deliver humid air to the one or more coating assembly10at a rate ranging from about 120 CFM to about 140 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humidifying apparatus300may deliver humid air to the one or more coating assembly10at a rate of about 130 CFM.

The humidifying apparatus300, the one or more coating assembly10, and the one or more second supply lines22may be configured such that the humid air40reaches the one or more coating assembly10via gravity feed through the one or more second supply lines22.

The humid air40that enters the coating assembly10may have a relative humidity ranging from about 20% to about 90%—including all relative humidity and sub-ranges there-between—as measured under normal atmospheric conditions. The change in relative humidity between the state at which the humid air exits the humidifying apparatus300and the state at which the humid air enters the coating assembly10may be due to condensation. In some embodiments, the humid air40that enters the coating assembly10may have a relative humidity ranging from about 20% to about 50%—including all relative humidity and sub-ranges there-between—as measured under normal atmospheric conditions. In some embodiments, the humid air40that enters the coating assembly10may have a relative humidity ranging from about 60% to about 90%—including all relative humidity and sub-ranges there-between—as measured under normal atmospheric conditions.

The humid air40when it enters the internal cavity101may have a temperature ranging from about 70° F. to about 120° F.—including all temperatures and sub-ranges there-between. The humid air40when it enters the internal cavity101may have a temperature ranging from about 80° F. to about 110° F.—including all temperatures and sub-ranges there-between. The humid air40when it enters the internal cavity101may have a temperature ranging from about 85° F. to about 105° F.—including all temperatures and sub-ranges there-between.

The humid air40when it enters the internal cavity101may have a temperature ranging from about 70° F. to about 120° F.—including all temperatures and sub-ranges there-between. The humid air40when it enters the internal cavity101may have a temperature ranging from about 80° F. to about 110° F.—including all temperatures and sub-ranges there-between. The humid air40when it enters the internal cavity101may have a temperature ranging from about 85° F. to about 105° F.—including all temperatures and sub-ranges there-between.

Referring now toFIGS.2-11, the coating assembly10may comprise a shroud100and an applicator head200. The shroud100comprises a housing110and an internal cavity101located inside of the housing110. The housing110may include a top plate120and a first side plate130extending downward from the top plate120. The housing110may include a second side plate140extending downward from the top plate120. The housing110may include a third side plate150extending downward from the top plate120.

The top plate120may be elongated. The top plate120may comprise an upper major surface121that is opposite a lower major surface122. The top plate120may comprise a first edge123that is opposite a fourth edge126and a second edge124that is opposite a third edge125. The first edge123and the fourth edge126may be substantially parallel. The first edge123and the fourth edge126may form longitudinal edges of the elongated top plate120. The second edge124and the third edge125may be substantially parallel. The second edge124and the third edge125may form lateral edges of the elongated top plate120. The first edge123and fourth edge126may intersect the second edge124and the third edge125. The first edge123and fourth edge126may be substantially orthogonal to the second edge124and the third edge125.

The top plate120may have a plate thickness to as measured between the upper major surface121and the lower major surface122. The plate thickness to of the top plate120may be substantially uniform. The plate thickness to may range from about 0.0239 inch (24 gauge) to about 0.1793 inch (7 gauge)—including all thicknesses and sub-ranges there-between.

The first side plate130may comprise a first major surface131that is opposite a second major surface132. The first side plate130may comprise a first bottom edge133that is opposite a first top edge134. The first side plate130may comprise a first bottom edge133that is opposite a first top edge134. The first side plate130may comprise a first side edge135that is opposite a second side edge136.

The first side edge135of the first side plate130may extend between the first top edge134of the first side plate130and the first bottom edge133of the first side plate130. The first side edge135of the first side plate130may intersect the first top edge134of the first side plate130and the first bottom edge133of the first side plate130. The second side edge136of the first side plate130may extend between the first top edge134of the first side plate130and the first bottom edge133of the first side plate130. The second side edge136of the first side plate130may intersect the first top edge134of the first side plate130and the first bottom edge133of the first side plate130.

The first bottom edge133of the first side plate130and the first top edge134of the first side plate130may be substantially parallel. The first side edge135of the first side plate130and the second side edge136of the first side plate130may be substantially parallel. The first bottom edge133of the first side plate130and the first top edge134of the first side plate130may be substantially orthogonal to each of the first side edge135of the first side plate130and the second side edge136of the first side plate130.

The first side plate130may extend downward from the top plate120spanning from the first top edge134of the first side plate130to the first bottom edge133of the first side plate130. The first side plate130may extend a first height H1as measured between the first top edge134of the first side plate130to the first bottom edge133of the first side plate130. The first height H1may range from about 1.25 inches to about 2.0 inches—including all heights and sub-ranges there-between. In some embodiments, the first height H1may be about 1.625 inches.

The first side plate130may have a first width W1as measured between the first side edge135and the second side edge136of the first side plate130. The first width W1may range from about 12 inches to about 13 inches—including all widths and sub-ranges there-between.

The first side plate130may have a first thickness t1as measured between the first major surface131and the second major surface132of the first side plate130. The first thickness t1of the first side plate130may be substantially uniform. The first thickness t1may range from about 0.0239 inch (24 gauge) to about 0.1793 inch (7 gauge)—including all thicknesses and sub-ranges there-between. The first thickness t1of the first side plate130may be substantially equal to the plate thickness to of the top plate120.

The first side plate130may comprise a first securing element137. The first securing element137may extend from the first major surface131to the second major surface132of the first side plate130. In the embodiment shown inFIGS.2-5, the first securing element137may be an open-ended slot comprising an opening137athat is opposite a slot ceiling137b, whereby slot walls137cextend between the opening137aand the slot ceiling137b.

The slot ceiling137band the opening137amay be spaced apart by a first offset height H1A(also referred to as “slot depth”). The first offset height H1Aof the vertical slot137may range from about 1.0 inch to about 1.5 inches—including all heights and sub-ranges there-between—provided that the first offset height H1Ais less than the first height H1. The slot walls137cmay include two parallel walls that are offset from each other by a first offset width W1A(also referred to as “slot width”). In a non-limiting embodiment, the first offset width W1Amay range from about ⅛ inch to about ½ inch—including all distances and sub-ranges there-between.

A ratio of the first height H1of the first side plate130and the first offset height H1Aof the vertical slot137may range from about 1.1:1.0 to about 1.4:1.0—including all distances and sub-ranges there-between. A ratio of the first offset height H1Aof the vertical slot137and the first offset width W1Aof the vertical slot137may range from about 2:1 to about 12:1—including all ratios and sub-ranges there-between.

The first edge123of the top plate120may transition into the first top edge134of the first side plate130. The first edge123of the top plate120may directly transition into the first top edge134of the first side plate130. The first edge123of the top plate120may seamlessly transition into the first top edge134of the first side plate130. The first edge123of the top plate120may transition into the first top edge134of the first side plate130at a first bend106comprising the first edge123of the top plate120and the first top edge134of the first side plate130.

The second side plate140may comprise a first major surface141that is opposite a second major surface142. The second side plate140may comprise a second bottom edge143that is opposite a second top edge144. The second side plate140may comprise a first side edge145that is opposite a second side edge146.

The first side edge145of the second side plate140may extend between the second top edge144of the second side plate140and the second bottom edge143of the second side plate140. The second side edge146of the second side plate140may extend between the second top edge144of the second side plate140and the second bottom edge143of the second side plate140. The first side edge145of the second side plate140may intersect the second top edge144of the second side plate140and the second bottom edge143of the second side plate140. The second side edge146of the second side plate140may intersect the second top edge144of the second side plate140and the second bottom edge143of the second side plate140.

The second bottom edge143of the second side plate140and the second top edge144of the second side plate140may be substantially parallel. The first side edge145of the second side plate140and the second side edge146of the second side plate140may be substantially parallel. The second bottom edge143of the second side plate140and the second top edge144of the second side plate140may be substantially orthogonal to each of the first side edge145of the second side plate140and the second side edge146of the second side plate140.

The second side plate140may extend downward from the top plate120spanning from the second top edge144of the second side plate140to the second bottom edge143of the second side plate140. The second side plate140may extend a second height H2as measured between the second top edge144of the second side plate140to the second bottom edge143of the second side plate140. The second height H2may range from about 4.25 inches to about 6.25 inches—including all distances and sub-ranges there-between. In some embodiments, the second height H2may be about 5.25 inches.

The second side plate140may have a second width W2as measured between the first side edge145and the second side edge146of the second side plate140. The second width W2may range from about 3 inches to about 5 inches—including all distances and sub-ranges there-between. In some embodiments, the second width W2may be about 4 inches.

The second side plate140may have a second thickness t2as measured between the first major surface141and the second major surface142of the second side plate140. The second thickness t2of the second side plate140may be substantially uniform. The second thickness t2may range from about 0.0239 inch (24 gauge) to about 0.1793 inch (7 gauge)—including all thicknesses and sub-ranges there-between. The second thickness t2of the second side plate140may be substantially equal to each of the plate thickness to of the top plate120and/or the first thickness t1of the first side plate130.

The first side edge145of the second side plate140may comprise a first portion145a, a second portion145b, and a third portion145c. The first portion145aof the first side edge145of the second side plate140may be an upper portion located adjacent to the second top edge144of the second side plate140. The third portion145cof the first side edge145of the second side plate140may be a lower portion located adjacent to the second bottom edge143the second side plate140. The second portion145bof the first side edge145of the second side plate140may be located between the first portion145aand the third portion145cof the first side edge145of the second side plate140.

The first portion145aof the first side edge145of the second side plate140may extend vertically between the second top edge144of the second side plate140and the second portion145bof the first side edge145of the second side plate140. The second portion145bof the first side edge145of the second side plate140may extend transverse to the first portion145aof the first side edge145of the second side plate140. The second portion145bof the first side edge145of the second side plate140may extend horizontally between the first portion145aand the third portion145cof the first side edge145of the second side plate140. The third portion145cof the first side edge145of the second side plate140may extend vertically between the second portion145bof the first side edge145of the second side plate140and the second bottom edge143of the second side plate140.

The first portion145aof the first side edge145of the second side plate140and the third portion145cof the first side edge145of the second side plate140may be substantially parallel. The second portion145bof the first side edge145of the second side plate140and the third portion145cof the first side edge145of the second side plate140may be substantially orthogonal. The second portion145bof the first side edge145of the second side plate140and the first portion145aof the first side edge145of the second side plate140may be substantially orthogonal.

The first potion145aof the first side edge145of the second side plate140and the second side edge146of the second side plate140may be spaced apart by a distance that is substantially equal to the second width W2of the second side plate140. The first potion145aof the first side edge145of the second side plate140and the third portion145cof the first side edge145of the second side plate140may be horizontally offset from each other by a second offset width W2A—whereby the second offset width W2Aranges from about 0.125 inches to about 0.375—including all widths and sub-ranges there-between. In some embodiments, the second offset width W2Amay be about 0.25 inches.

The third portion145cof the first side edge145of the second side plate140and the second side edge146of the second side plate140may be spaced apart by a distance that is equal to the difference between the second width W2and the second offset width W2A.

The second potion145bof the first side edge145of the second side plate140and the second bottom edge143of the second side plate140may be vertically offset from each other by a second offset height H2A—whereby the second offset height H2Aranges from about 1.75 inches to about 2.75 inches—including all distances and sub-ranges there-between. In some embodiments, the second offset height H2Amay be about 2.25 inches.

The second portion145bof the first side edge145of the second side plate140and the second top edge144of the second side plate140may be spaced apart by a distance that is equal to the difference between the second height H2and the second offset height H2A.

The combination of the second portion145band third portion145cbeing inset from the first portion145aof the first side edge145creates a stepped edge profile147on the second side plate140.

The stepped edge profile147of the second side plate140may have a stepped width ratio of the second width W2to the second offset width W2Aranging from about 12:1 to about 20:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped width ratio of the second side plate140may range from about 14:1 to about 18:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped width ratio of the second side plate140may be about 16:1.

The stepped edge profile147of the second side plate140may have a stepped height ratio of the second height H2to the second offset height H2Aranging from about 1.66:1 to about 3.33:1including all ratios and sub-ranges there-between. In some embodiments, the stepped edge profile147of the second side plate140may have a stepped height ratio of the second height H2to the second offset height H2Aranging from about 2:1 to about 2.66:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped height ratio of the second height H2to the second offset height H2Amay be about 2.33:1.

The second edge124of the top plate120may transition into the second top edge144of the second side plate140. The second edge124of the top plate120may directly transition into the second top edge144of the second side plate140. The second edge124of the top plate120may seamlessly transition into the second top edge144of the second side plate140. The second edge124of the top plate120may transition into the second top edge144of the second side plate140at a second bend107comprising the second edge124of the top plate120and the second top edge144of the second side plate140.

The third side plate150may comprise a first major surface151that is opposite a second major surface152. The third side plate150may comprise a third bottom edge153that is opposite a third top edge154. The third side plate150may comprise a first side edge155that is opposite a second side edge156.

The first side edge155of the third side plate150may extend between the third top edge154of the third side plate150and the third bottom edge153of the third side plate150. The second side edge156of the third side plate150may extend between the third top edge154of the third side plate150and the third bottom edge153of the third side plate150. The first side edge155of the third side plate150may intersect the third top edge154of the third side plate150and the third bottom edge153of the third side plate150. The second side edge156of the third side plate150may intersect the third top edge154of the third side plate150and the third bottom edge153of the third side plate150.

The third bottom edge153of the third side plate150and the third top edge154of the third side plate140may be substantially parallel. The first side edge155of the third side plate150and the second side edge156of the third side plate140may be substantially parallel. The third bottom edge153of the third side plate150and the third top edge154of the third side plate150may be substantially orthogonal to each of the first side edge155of the third side plate150and the second side edge156of the third side plate150.

The third side plate150may extend downward from the top plate120spanning from the third top edge154of the third side plate150to the third bottom edge153of the third side plate150. The third side plate150may extend a third height H3as measured between the third top edge154of the third side plate150to the third bottom edge153of the third side plate150. The third height H3may range from about 4.25 inches to about 6.25 inches—including all distances and sub-ranges there-between. In some embodiments, the third height H3may be about 5.25 inches.

The third side plate150may have a third width W3as measured between the first side edge155and the second side edge146of the third side plate150. The third width W3may range from about 3 inches to about 5 inches—including all distances and sub-ranges there-between. In some embodiments, the third width W3may be about 4 inches.

The third side plate150may have a third thickness t3as measured between the first major surface151and the second major surface152of the third side plate150. The third thickness t3of the third side plate150may be substantially uniform. The third thickness t3may range from about 0.0239 inch (24 gauge) to about 0.1793 inch (7 gauge)—including all thicknesses and sub-ranges there-between. The third thickness t3of the third side plate150may be substantially equal to each of the plate thickness to of the top plate120and/or the first thickness t1of the first side plate130and/or the second thickness t2of the second side plate140.

The first side edge155of the third side plate150may comprise a first portion155a, a second portion155b, and a third portion155c. The first portion155aof the first side edge155of the third side plate150may be an upper portion located adjacent to the third top edge154of the third side plate150. The third portion155cof the first side edge155of the third side plate150may be a lower portion located adjacent to the third bottom edge153the third side plate150. The second portion155bof the first side edge155of the third side plate150may be located between the first portion155aand the third portion155cof the first side edge155of the third side plate150.

The first portion155aof the first side edge155of the third side plate150may extend vertically between the third top edge154of the third side plate150and the second portion155bof the first side edge155of the third side plate150. The second portion155bof the first side edge155of the third side plate150may extend transverse to the first portion155aof the first side edge155of the third side plate150. The second portion155bof the first side edge155of the third side plate150may extend horizontally between the first portion155aand the third portion155cof the first side edge155of the third side plate150. The third portion155cof the first side edge155of the third side plate150may extend vertically between the second portion155bof the first side edge155of the third side plate150and the third bottom edge153of the third side plate150.

The first portion155aof the first side edge155of the third side plate150and the third portion155cof the first side edge155of the third side plate150may be substantially parallel. The second portion155bof the first side edge155of the third side plate150and the third portion155cof the first side edge155of the third side plate150may be substantially orthogonal. The second portion155bof the first side edge155of the third side plate150and the first portion155aof the first side edge155of the third side plate150may be substantially orthogonal.

The first portion155aof the first side edge155of the third side plate150and the second side edge156of the third side plate150may be spaced apart by a distance that is substantially equal to the third width W3of the third side plate150. The first potion155aof the first side edge155of the third side plate150and the third portion155cof the first side edge155of the third side plate150may be horizontally offset from each other by a third offset width W3A—whereby the third offset width W3Aranges from about 0.125 inches to about 0.375—including all widths and sub-ranges there-between. In some embodiments, the third offset width W3Amay be about 0.25 inches.

The third portion155cof the first side edge155of the third side plate150and the second side edge156of the third side plate150may be spaced apart by a distance that is equal to the difference between the third width W3and the third offset width W3A.

A ratio between the third width W3and the second offset width W3Amay range from about 12:1 to about 20:1—including all ratios and sub-ranges there-between. In some embodiments, the ratio between the third width W3and the third offset width W3Amay range from about 14:1 to about 18:1—including all ratios and sub-ranges there-between. In some embodiments, the ratio between the third width W3and the second offset width W3Amay be about 16:1.

The second portion155bof the first side edge155of the third side plate150and the third bottom edge153of the third side plate150may be vertically offset from each other by a third offset height H3A—whereby the third offset height H3Aranges from about 1.75 inches to about 2.75 inches—including all distances and sub-ranges there-between. In some embodiments, the third offset height H3Amay be about 2.25 inches.

The second portion155bof the first side edge155of the third side plate150and the third top edge154of the third side plate150may be spaced apart by a distance that is equal to the difference between the third height H3and the third offset height H3A.

The combination of the second portion155band third portion155cbeing inset from the first portion155aof the first side edge155creates a stepped edge profile157on the third side plate150.

The stepped edge profile157of the third side plate150may have a stepped width ratio of the third width W3to the third offset width W3Aranging from about 12:1 to about 20:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped width ratio of the third side plate150may range from about 14:1 to about 18:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped width ratio of the third side plate150may be about 16:1.

The stepped edge profile157of the third side plate150may have a stepped height ratio of the third height H3to the third offset height H3Aranging from about 1.66:1 to about 3.33:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped edge profile157of the third side plate150ranging from about 2:1 to about 2.66:1—including all ratios and sub-ranges there-between. In some embodiments, the stepped height ratio of the third side p[late 150 may be about 2.33:1.

The third edge125of the top plate120may transition into the third top edge154of the third side plate150. The third edge125of the top plate120may directly transition into the third top edge154of the third side plate150. The third edge125of the top plate120may seamlessly transition into the third top edge154of the third side plate150. The third edge125of the top plate120may transition into the third top edge154of the third side plate150at a third bend108comprising the third edge125of the top plate120and the third top edge154of the third side plate150.

The steeped edge profile157of the third side plate150may mirror the stepped edge profile147of the second side plate140.

In some embodiments, the second width W2and the third width W3may be substantially equal. In some embodiments, the second offset width W2Aand the third offset width W3Amay be substantially equal. In some embodiments the stepped width ratio of the second side plate140may be substantially equal to the stepped width ratio of the third side plate150.

In some embodiments, the second height H2and the third height H3may be substantially equal. In some embodiments, the second offset height H2Aand the third offset height H3Amay be substantially equal. In some embodiments the stepped height ratio of the second side plate140may be substantially equal to the stepped height ratio of the third side plate150. The second height H2may be greater than the first height H1. The third height H3may be greater than the first height H1.

Collectively, the lower major surface122of the top plate120, the second major surface132of the first side plate130, the second major surface142of the second side plate140, and the second major surface152of the third side plate150may face inward towards the internal cavity101. Stated otherwise, the internal cavity101may be defined by the lower major surface122of the top plate120, the second major surface132of the first side plate130, the second major surface142of the second side plate140, and the second major surface152of the third side plate150. The internal cavity101may be open-ended towards the first bottom edge133of the first side plate130, the second bottom edge143of the second side plate140, and the third bottom edge153of the third side plate150. As discussed further herein, the open-ended internal cavity101may be configured to receive the applicator head200.

The top plate120may comprise a port105. The port105may be an opening having an opening diameter D1that is centered about an opening axis B-B that extends in a direction between the upper major surface121and the lower major surface122of the top plate120. The opening diameter D1may range from about 2 inches to about 4 inches—including all diameters and subranges there-between. In some embodiments, the opening diameter D1may be about 3.56 inches.

The opening may extend continuously from the upper major surface121to the lower major surface122of the top plate. The port105may provide a fluid pathway from external the shroud100to inside the internal cavity101.

The housing110of the shroud100may further comprise an attachment element160located atop the upper major surface121of the top plate120. The attachment element160may be centered about opening axis B-B. In a non-limiting embodiment, the attachment element160may have an open ended tube having a first open end165opposite a second open end166and a tube wall161extending between the first and second open ends165,166. The tube wall161may comprise an outer surface162opposite an inner surface163.

According to the embodiments where the open ended tube has a circular cross-sectional shape, the tube wall161may be a cylindrical wall having an inner surface163that defines an inner diameter of the attachment element160and the outer surface162of the cylindrical wall may define an outer diameter of the attachment element160. In some embodiments, the inner diameter of the attachment element160may be substantially equal to the opening diameter D1of the opening defined by the port105. The attachment element160may be configured to be coupled to the second supply line22, which is fluidly coupled to the output305of the humidifying apparatus300. The port105fluidly couples the internal cavity101to the output305of the humidifying apparatus300via the second supply line22.

The shroud100may further comprise a baffle170. The baffle170may be located within the internal cavity101of the housing110. The baffle170may comprise an upper major surface171that is opposite a lower major surface172. The baffle170may extend between a proximal edge173and a distal edge174. The proximal edge173may be located adjacent to the first bend106. The proximal edge173may contact the lower major surface122of the top plate120. The proximal edge173may contact the second major surface132of the first side plate130.

The baffle170may comprise a first lateral edge176that is opposite a second lateral edge177. The first lateral edge176may extend between the proximal edge173and the distal edge174. The second lateral edge177may extend between the proximal edge173and the distal edge174. The first lateral edge176and the second lateral edge177may be substantially parallel. Each of the first lateral edge176and the second lateral edge177may be substantially orthogonal to the proximal edge176and the distal edge177.

The baffle190may comprise a baffle plate170that extends longitudinally along a longitudinal axis A-A (also referred to as an “elongated baffle plate”170), whereby the proximal edge173and the distal edge174extend substantially parallel to the longitudinal axis A-A. Each of the first and second lateral edges176,177may extend substantially orthogonal to the longitudinal axis A-A.

The top plate120may extend transversely along a transverse axis C-C that is orthogonal to the longitudinal axis A-A. The second and third edges124,125may extend parallel to the transverse axis C-C, and the first and fourth edges123,126may extend substantially orthogonal to the transverse axis A-A.

The opening axis B-B may be substantially orthogonal to both of the longitudinal axis A-A and the transverse axis C-C.

The baffle plate170may be positioned within the internal cavity101such that the baffle plate170is oriented at an oblique angle to the top plate120. In some embodiments, a first angle θ1may be measured between the upper major surface171of the baffle plate170and the lower major surface122of the top plate120, whereby the first angle θ1is an acute angle. In some embodiments, the first angle θ1may range from about 10 to about—including all angles and sub-ranges there-between. In some embodiments, the first angle θ1may be about 5°.

The internal cavity101may comprise an upper region102and a lower region103. The upper region102of the internal cavity101may be the volume occupied above the baffle plate170and below the top plate120. The upper region102of the internal cavity101may be the volume occupied above the upper major surface171of the baffle plate170and below lower major surface122of the top plate120. The lower region103of the internal cavity101may be the volume occupied below the baffle plate170. The lower region103of the internal cavity101may be the volume occupied below the lower major surface172of the baffle plate170and above the second bottom edge143of the second side plate140and the third bottom edge153of the third side plate150.

The baffle190may be positioned within the internal cavity101such that the baffle plate170at least partially overlaps with the port105in a vertical direction. The baffle190may be positioned within the internal cavity101such that the baffle170at least partially overlaps with the port105in a direction that is substantially parallel to the opening axis B-B. The baffle190may be positioned within the internal cavity101such that the baffle plate170comprising an overlapping portion178that at least partially blocks a line of sight between the upper region102and the lower region103of the internal cavity when viewing the internal cavity101through the port105in a downward direction that is parallel to the opening axis B-B.

The baffle plate170may comprise a cutout section175. The cutout section175may be formed into the distal edge174of the baffle plate170. The cutout section175may be a void formed into the distal edge174of the baffle plate170. Although not limited to, the cutout section175may be semi-circular in shape having a cutout diameter D2. The cutout diameter may be smaller than the opening diameter D1. The cutout diameter D2may range from 1.75 inches to about 3.75 inches—including all diameters and subranges there-between. In some embodiments, the opening diameter D1may be about 3.25 inches.

The opening diameter D1of the opening of the port105may be greater than the cutout diameter D2of the cutout section175of the baffle plate170. The width of the overlapping portion178of the baffle plate170may be substantially equal to the difference in the opening diameter D1of the opening of the port105and the cutout diameter D2of the cutout section175of the baffle170. A ratio of the opening diameter D1to the cutout diameter D2may range from about 1.05:1 to about 1.25:1—including all ratios and subranges there-between. In some embodiments, the ratio of the opening diameter D1to the cutout diameter D2may range from about 1.05:1 to about 1.15:1—including all ratios and subranges there-between. In some embodiments, the ratio of the opening diameter D1to the cutout diameter D2may range from about 1.05:1 to about 1.1:1—including all ratios and subranges there-between.

The baffle190may be positioned within the internal cavity101such that the cutout section175of the baffle plate170at least partially overlaps with the port105in a vertical direction. The baffle190may be positioned within the internal cavity101such that the cutout section175at least partially overlaps with the port105in a direction that is substantially parallel to the opening axis B-B.

The baffle190may comprise a wall180extending upwards from the baffle plate170in a direction towards the top plate120. The wall180extends vertically between a bottom edge184and a top edge183. The bottom edge184of the wall being adjacent to the upper major surface171of the baffle plate170. The wall180having a height Hwas measured between the top edge183and the bottom edge184of the wall180. The height Hwof the wall180may range from about 0.3 inches to about 0.7 inches—including all heights and sub-ranges there-between.

The top edge183of the wall180may be substantially parallel to the top plate120. The top edge183of the wall180may be substantially parallel to the lower major surface122of the top plate120. The top edge183of the wall180may be substantially parallel to the upper major surface121of the top plate120.

The bottom edge184of the wall180may be substantially parallel to the upper major surface171of the baffle plate170. With the top edge183of the wall180being substantially parallel to the top plate120and the baffle plate170oriented at the first angle θ1as measured between the upper major surface171of the baffle plate170and the lower major surface122of the top plate120, the height Hwof the wall180may vary with distance from the proximal edge173of the baffle plate170to the distal edge174of the baffle plate170. Specifically, the height Hwof the wall180may increase when moving from the proximal edge173of the baffle plate170to the distal edge174of the baffle plate170.

The height Hwof the wall180adjacent to the distal edge174of the baffle plate170may range from about 0.45 inches to about 0.85 inches—including all heights and sub-ranges there-between. In some embodiments, the height Hwof the wall180adjacent to the distal edge174of the baffle plate170may range from about 0.55 inches to about 0.75 inches—including all heights and sub-ranges there-between. In some embodiments, the height Hwof the wall180adjacent to the distal edge174of the baffle plate170may be about 0.64 inches.

The height Hwof the wall180adjacent to the proximal edge173of the baffle plate170may range from about 0.3 inches to about 0.6 inches—including all heights and sub-ranges there-between. In some embodiments, the height Hwof the wall180adjacent to the proximal edge173of the baffle plate170may be about 0.5 inches.

The wall180may extend through and above the port105. According to the embodiments where the shroud100comprises the attachment element160, the wall180may at least partially overlap with the attachment element160in a horizontal direction. The top edge183of the wall180may extend above the top plate120by wall offset height HW1. The wall offset height HW1may range from about 0.1 inches to about 0.4 inches—including all heights and sub-ranges there-between. In some embodiments, the wall offset height HW1may range from about 0.15 inches to about 0.35 inches—including all heights and sub-ranges there-between. In some embodiments, the wall offset height HW1may range from about 0.2 inches to about 0.3 inches—including all heights and sub-ranges there-between. In some embodiments, the wall offset height HW1may be about 0.25 inches. The wall offset height HW1may be measured from the top edge183to the upper major surface121of the top plate120.

The top edge183of the wall may be substantially parallel to the lower surface122of the top plate120.

The wall180may comprise an inner major surface181that is opposite an outer major surface182. The inner major surface181of the wall180may face the cutout section175of the baffle plate170. The wall180may be configured to follow the portion of the distal edge174of the baffle plate170that forms a boundary of the cutout section175of the baffle plate170.

The baffle190may be positioned within the internal cavity101such that the wall180at least partially overlaps with the port105in a vertical direction. The baffle190may be positioned within the internal cavity101such that the wall180at least partially overlaps with the port105in a direction that is substantially parallel to the opening axis B-B.

The baffle190may be positioned within the internal cavity101such that the proximal edge173of the baffle plate170does not overlaps with the port105in a vertical direction. The baffle190may be positioned within the internal cavity101such that proximal edge173of the baffle plate170does not overlap with the port105in a direction that is substantially parallel to the opening axis B-B.

Referring now toFIGS.1and10-18, the coating system1includes the coating assembly10, which includes the applicator head200and the shroud100. The applicator head200may comprise an applicator housing210and an applicator nozzle220, whereby the applicator nozzle220may have a leading edge221. A coating supply line23may be coupled to an input of the applicator head200, whereby the coating supply line23is fluidly coupled to a coating composition reservoir containing a coating composition.

The applicator head200is configured to apply the coating composition to a surface31,32,33,34of a workpiece30—whereby the coating composition may be emitting from the applicator nozzle210to the surface31,32,33,34of a workpiece30—whereby the workpiece comprises a first major surface31opposite a second major surface32and at least a first side surface33opposite a second side surface34, whereby the first and second side surfaces33,34extend between the first and second major surfaces31,32. The coating composition may be supplied to the coating head200via the coating supply line23.

The coating composition may be a liquid-based coating composition. The coating composition may comprise a binder, a particulate, and a liquid carrier. Non-limiting examples of particulate include pigment, filler, and combinations thereof. Non-limiting examples of binder include polymeric binder. The liquid carrier may comprise water. The coating composition may have a high-solids content—the term “high solids content” refers to a liquid based coating composition having a solids content of at least 60 wt. % based on the total weight of the coating composition. The coating composition may have a solids content ranging from about 65 wt. % to about 90 wt. % based on the total weight of the coating composition—including all percentages and sub-ranges there-between.

The support apparatus500may comprise a frame510and a conveyor surface520. The frame may comprise a second securing element516. The second securing element516may be configured to couple to the first securing element137located on the first side plate130of the shroud100.

The frame510may comprise a lower portion511and an upper portion512. The upper portion512may comprise an coupling plate515, whereby the second securing element137is located on the coupling plate515.

The conveyor surface520may be configured to support a first or second major surface31,32of a workpiece30during the coating process of the present invention. In a non-limiting example, the conveyor surface520may be a belt, rollers, or the like. In some embodiments, the conveyor surface520may be located atop the lower portion511of the frame510.

The conveyor surface520may move along a machine direction MD that is substantially parallel to the longitudinal axis A-A of the shroud100. During the coating process of the present invention, the conveyor520may move relative to the coating assembly10—whereby the shroud100and the applicator head200do not move relative to each other.

In other embodiments, the conveyor surface520may be stationary. During the coating process of the present invention, the workpiece30and the coating assembly10may move relative to each other along the machine direction MD—whereby the shroud100and the applicator head200do not move relative to each other. During the coating process of the present invention, the applicator head200and the frame510may not move relative to each other and the shroud100and the applicator head200do not move relative to each other.

The coating assembly10may be alterable between a first state I, as shown inFIGS.10,11,14-18, and a second state II, as shown inFIGS.12,13A, and13B. In the first state I the applicator head200may be at least partially located inside of the internal cavity101of the shroud100. In the second state II the applicator head200may be located outside of the internal cavity101of the shroud100.

As demonstrated byFIGS.12-18, in the first state I, the applicator nozzle220may be at least partially located inside of the internal cavity101of the shroud100. In the first state I, the applicator housing210may be at least partially located inside of the internal cavity101of the shroud100. In the second state II, the applicator nozzle220may be outside (i.e., external to) the internal cavity101of the shroud100. In the second state II, the applicator housing210may be outside the internal cavity101of the shroud100.

In the first state I, the first side plate130may at least partially overlap with the applicator head200in a horizontal direction that is substantially parallel to the transverse axis C-C. In the first state I, the first side plate130may at least partially overlap with the applicator housing210in the horizontal direction that is substantially parallel to the transverse axis C-C. In the first state I, the first bottom edge133may at least partially overlap at least one of the first major surface31and/or the second major surface32of the workpiece30in a vertical direction that is substantially parallel to the opening axis B-B.

In the second state II, the first side plate130and the applicator head200may not overlap in the horizontal direction that is substantially parallel to the transverse axis C-C. In the second state II, the first side plate130and the applicator housing210may not overlap in the horizontal direction that is substantially parallel to the transverse axis C-C. In the second state II, the first bottom edge133may at least partially overlap at least one of the first major surface31and/or the second major surface32of the workpiece30in the vertical direction that is substantially parallel to the opening axis B-B.

In the first state I, the second side plate140may at least partially overlap with the applicator head200in a horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the second side plate140may at least partially overlap with the applicator housing210in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the second side plate140may at least partially overlap with the applicator nozzle220in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the second side plate140may at least partially overlap with the leading edge221of the applicator nozzle220in the horizontal direction that is substantially parallel to the longitudinal axis A-A.

In the second state II, the second side plate140and the applicator head200may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the second state II, the second side plate140and the applicator housing210may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the second side plate140and the applicator nozzle220may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the second state II, the second side plate140and the leading edge221of the applicator nozzle220may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A.

In the first state I, a plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion145aof the first side edge145of the second side plate140and the applicator head200. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion145aof the first side edge145of the second side plate140and the applicator housing210. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect the first portion145aof the first side edge145of the second side plate140and the applicator nozzle220.

In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the first portion145aof the first side edge145of the second side plate140and the applicator head200. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the first portion145aof the first side edge145of the second side plate140and the applicator housing210. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the first portion145aof the first side edge145of the second side plate140and the applicator nozzle220.

In the first state I, a plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect the third portion145cof the first side edge145of the second side plate140and the applicator head200. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect the third portion145cof the first side edge145of the second side plate140and the applicator housing210. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect the third portion145cof the first side edge145of the second side plate140and the applicator nozzle220.

In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the third portion145cof the first side edge145of the second side plate140and the applicator head200. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the third portion145cof the first side edge145of the second side plate140and the applicator housing210. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the third portion145cof the first side edge145of the second side plate140and the applicator nozzle220.

In the first state I, the second portion145bof the first side edge145of the second side plate140may at least partially overlap with at least one of the first and/or second major surface31,32of the workpiece30in a vertical direction that is parallel to the opening axis B-B. In the first state I, the third portion145cof the first side edge145of the second side plate140may at least partially overlap with at least one of the first and/or second side surfaces33,33of the workpiece30in a horizontal direction that is substantially parallel to the transverse axis C-C.

In the second state II, the second portion145bof the first side edge145of the second side plate140may at least partially overlap with at least one of the first and/or second major surface31,32of the workpiece30in the vertical direction that is parallel to the opening axis B-B. In the second state II, the third portion145cof the first side edge145of the second side plate140and the first and/or second side surfaces33,33of the workpiece30may not overlap in the horizontal direction that is parallel to the transverse axis C-C.

In the first state I, the second bottom edge143of the second side plate140may be located beneath both of the first major surface31and the second major surface32of the workpiece30. In the first state I, the second bottom edge143of the second side plate140may be located beneath the conveyor520of the support apparatus500.

In the second state II, the second bottom edge143of the second side plate140may be located above both of the first major surface31and the second major surface32of the workpiece30. In the second state II, the second bottom edge143of the second side plate140may be located above the conveyor520of the support apparatus500.

In the first state I, the third side plate150may at least partially overlap with the applicator head200in a horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the third side plate150may at least partially overlap with the applicator housing210in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the third side plate150may at least partially overlap with the applicator nozzle220in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the third side plate150may at least partially overlap with the leading edge221of the applicator nozzle220in a horizontal direction.

In the second state II, the third side plate150and the applicator head200may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the second state II, the third side plate150and the applicator housing210may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the first state I, the third side plate150and the applicator nozzle220may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A. In the second state II, the third side plate150and the leading edge221of the applicator nozzle220may not overlap in the horizontal direction that is substantially parallel to the longitudinal axis A-A.

In the first state I, a plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion155aof the first side edge155of the third side plate150and the applicator head200. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion155aof the first side edge155of the third side plate150and the applicator housing210. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion155aof the first side edge155of the third side plate150and the applicator nozzle220.

In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the first portion155aof the first side edge155of the third side plate150and the applicator head200. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion155aof the first side edge155of the third side plate150and the applicator housing210. In the second state II, a plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the first portion155aof the first side edge155of the third side plate150and the applicator nozzle220.

In the first state I, a plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the third portion155cof the first side edge155of the third side plate150and the applicator head200. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the third portion155cof the first side edge155of the third side plate150and the applicator housing210. In the first state I, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may intersect both the third portion155cof the first side edge155of the third side plate150and the applicator nozzle220.

In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the third portion155cof the first side edge155of the third side plate150and the applicator head200. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the third portion155cof the first side edge155of the third side plate150and the applicator housing210. In the second state II, the plane that is parallel to the longitudinal axis A-A and the transverse axis C-C may not intersect both the third portion155cof the first side edge155of the third side plate150and the applicator nozzle220.

In the first state I, the second portion155bof the first side edge155of the third side plate150may at least partially overlap with at least one of the first and/or second major surface31,32of the workpiece30in a vertical direction that is substantially parallel to the opening axis B-B. In the first state I, the third portion155cof the first side edge155of the third side plate150may at least partially overlap with at least one of the first and/or second side surfaces33,33of the workpiece30in a horizontal direction that is substantially parallel to the transverse axis C-C.

In the second state II, the second portion155bof the first side edge155of the third side plate150may at least partially overlap with at least one of the first and/or second major surface31,32of the workpiece30in the vertical direction that is substantially parallel to the opening axis B-B. In the second state II, the third portion155cof the first side edge155of the third side plate150and the at least one of the first and/or second side surfaces33,33of the workpiece30may not overlap in the horizontal direction that is substantially parallel to the transverse axis C-C.

In the first state I, the third bottom edge153of the third side plate150may be located beneath both of the first major surface31and the second major surface32of the workpiece30. In the first state I, the third bottom edge153of the third side plate150may be located beneath the conveyor520of the support apparatus500.

In the second state II, the third bottom edge153of the third side plate150may be located above both of the first major surface31and the second major surface32of the workpiece30. In the second state II, the third bottom edge153of the third side plate150may be located above the conveyor520of the support apparatus500.

In the first state I, the top plate120may at least partially overlap with the applicator head200in a vertical direction that is substantially parallel to the opening axis B-B. In the first state I, the top plate120may at least partially overlap with the applicator housing210in the vertical direction that is substantially parallel to the opening axis B-B. In the first state I, the top plate120may at least partially overlap with the applicator nozzle220in a vertical direction that is substantially parallel to the opening axis B-B. In the first state I, the top plate120may at least partially overlap with the leading edge221of the applicator nozzle220in a vertical direction that is substantially parallel to the opening axis B-B. In the first state I, the first edge123of the top plate120may at least partially overlap with the first and/or second major surface31,32of the workpiece30a vertical direction that is substantially parallel to the opening axis B-B.

In the second state II, the top plate120may at least partially overlap with the applicator head200in the vertical direction that is substantially parallel to the opening axis B-B. In the second state II, the top plate120may at least partially overlap with the applicator housing210in the vertical direction that is substantially parallel to the opening axis B-B. In the second state II, the top plate120may at least partially overlap with the applicator nozzle220in a vertical direction that is substantially parallel to the opening axis B-B. In the second state II, the top plate120may at least partially overlap with the leading edge221of the applicator nozzle220in a vertical direction that is substantially parallel to the opening axis B-B.

The shroud100may be altered between the first state I and the second state II by moving the shroud100relative to the applicator head200. The shroud100may be altered between the first state I and the second state II by moving the shroud100vertically relative to the applicator head200.

The shroud100may be altered between the first state I and the second state II by moving the shroud100relative to the applicator nozzle220. The shroud100may be altered between the first state I and the second state II by moving the shroud100vertically relative to the applicator nozzle220.

The shroud100may be altered between the first state I and the second state II by moving the shroud100relative to the applicator housing210. The shroud100may be altered between the first state I and the second state II by moving the shroud100vertically relative to the applicator housing210.

The shroud100may be altered between the first state I and the second state II by moving the shroud relative to the support apparatus500. The shroud100may be altered between the first state I and the second state II by moving the shroud vertically relative to the support apparatus500.

The shroud100may be altered between the first state I and the second state II by moving the shroud relative to the frame510of the support apparatus500. The shroud100may be altered between the first state I and the second state II by moving the shroud vertically relative to the frame510of the support apparatus500.

The shroud100may be altered between the first state I and the second state II by moving the shroud relative to the conveyor520of the support apparatus500. The shroud100may be altered between the first state I and the second state II by moving the shroud vertically relative to the conveyor520of the support apparatus500.

The shroud100may be altered between the first state I and the second state II by gripping one or more handle elements108and lifting and/or pulling the shroud100upward and/or downward between the first state I and second state II. The handle elements108may extend upward from the upper major surface121of the top plate120.

In the first state I, with the applicator head200located at least partially within the internal cavity101of the shroud100, the coating system1may be operated such that the humidifying apparatus300feeds humid air40from the output305of the humidifying apparatus300to the internal cavity101via the second supply line22and the opening of the port105. Stated otherwise, the humidifying apparatus300is configured to introduce the humid air40to the internal cavity101of the shroud100. The port105may be fluidly couple the internal cavity101of the shroud100to the second output305of the humidifying apparatus300.

In the first state I, the leading edge221of the applicator nozzle220and the distal edge174of the baffle plate170do not overlap in a vertical direction that is substantially parallel to the opening axis B-B. In the first state I, the leading edge221of the applicator nozzle220may positioned such that the leading edge221of the applicator nozzle220is between the second major surface132of the first side plate130and the outer major surface182of the wall180in a horizontal direction that is substantially parallel to the transverse axis B-B.

As the humid air40enters the internal cavity101of the shroud100when the shroud100is in the first state I, the humid air40inside of the internal cavity101of the shroud100that contacts an applicator head200. As the humid air40enters the internal cavity101of the shroud100when the shroud100is in the first state I, the humid air40inside of the internal cavity101of the shroud100that contacts an applicator housing210. As the humid air40enters the internal cavity101of the shroud100when the shroud100is in the first state I, the humid air40inside of the internal cavity101of the shroud100that contacts an applicator nozzle220. As the humid air40enters the internal cavity101of the shroud100when the shroud100is in the first state I, the humid air40inside of the internal cavity101of the shroud100that contacts the leading edge221of the applicator nozzle220.

The humid air40may be fed to the shroud100via the second supply line22, whereby the humid air40reaches the shroud100by gravity feed. According to this embodiment, the second supply line22is positioned above the shroud100such that the humid40falls through the port105to the internal cavity101under the effects of gravity.

As the humid air40reaches the internal cavity101, the humid air40first enters the upper region102of the internal cavity101and subsequently falls to the lower region103of the internal cavity101under the effects of gravity. As the humid air40is fed to the shroud100, some of the humid air40may condense back into liquid water. In a non-limiting embodiment, the condensation of the humid air40may occur inside of the second supply line22or within the attachment element160. The liquid water formed by condensation will also fall downward under the effects of gravity.

With the overlapping portion178of the baffle plate170at least partially blocking a line of sight between the upper region102and the lower region103of the internal cavity within the port105, and with the baffle plate170oriented at the first angle θ1relative to the top plate120, the overlapping portion178may act as a shield to divert the liquid water away from the applicator nozzle220. Additionally, with the wall180located within the overlapping portion178of the baffle plate170, the wall180may further divert the liquid water away from the applicator nozzle220along the distal edge174of the cutout section175, thereby effectively diverting the liquid water that has collected at a point adjacent to the proximal edge173of the baffle plate170and moving the liquid water to the distal edge174of the baffle plate170outside of the cutout section175.

Under this configuration, the liquid water will be effectively diverted away from the applicator nozzle220of the applicator head200such that the liquid water will not interfere with the application of the coating composition to one or more surfaces31,32,33,34of the workpiece30.

The humid air40may reach the internal cavity101by gravity feed via the second supply line22from the humidifying apparatus300at a rate of about 75 CFM to about 160 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humid air40may reach the internal cavity101by gravity feed via the second supply line22from the humidifying apparatus300at a rate of about 75 CFM to about 150 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humid air40may reach the internal cavity101by gravity feed via the second supply line22from the humidifying apparatus300at a rate of about 110 CFM to about 150 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humid air40may reach the internal cavity101by gravity feed via the second supply line22from the humidifying apparatus300at a rate of about 120 CFM to about 140 CFM—including all sub-ranges and specific rates there-between. In a non-limiting embodiment, the humid air40may reach the internal cavity101by gravity feed via the second supply line22from the humidifying apparatus300at a rate of about 130 CFM.

During operation of the coating system1, a quantity of humid air40may enter the internal cavity101of the shroud100as the coating composition is applied to one or more surfaces31,32,33,34of the workpiece30(referred to herein as the ‘coating stage’) via the applicator nozzle220of the applicator hear200. The presence of the humid air40allows the coating composition to be applied at the high solids content without detrimental effects to coating quality. During the coating stage, the internal cavity101may be subject to a vacuum.

During the coating stage, the humid air40may contact one or more of the first major surface31, the second major surface32, the first side surface33, or the second side surface34of the workpiece30. After the workpiece30is coated with the coating composition, the coating composition may be dried to drive off any liquid carrier—thereby resulting in a 100% solid coating atop the workpiece30.

Exemplary Claim Set

Exemplary Claim1. A coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising a housing and an internal cavity located inside of the housing; and a humidifying apparatus comprising an output that is fluidly coupled to the shroud, wherein the shroud can be altered between a first state and a second state, wherein in the first state the applicator head is at least partially located inside of the interval cavity and in the second state the applicator head is located outside of the internal cavity, and wherein in the first state the humidifying apparatus is configured to introduce a quantity of humid air to the internal cavity of the shroud that contacts the applicator head.

Exemplary Claim2. The coating system according to any one of exemplary claims1to2, wherein the applicator head comprises an applicator nozzle, and wherein in the first state the humidifying apparatus is configured to introduce the quantity of humid air to the internal cavity such that the humid air contacts the application nozzle, whereby the application nozzle configured to apply the coating to the surface of the workpiece.

Exemplary Claim3. The coating system according to any one of exemplary claims1to2, wherein the shroud is altered between the first state and the second state by moving the shroud relative to the applicator head.

Exemplary Claim4. The coating system according to exemplary claim3, wherein the shroud is altered between the first state and the second state by vertically moving the shroud relative to the applicator head.

Exemplary Claim5. The coating system according to any one of exemplary claims1to4, wherein the coating system further comprises a support apparatus comprising a frame and a conveyor, the conveyor configured to support the workpiece and the conveyor and the applicator head are configured to move relative to each other.

Exemplary Claim6. The coating system according to exemplary claim5, wherein the shroud is altered between the first state and the second state by moving the shroud relative to the support apparatus.

Exemplary Claim7. The coating system according to exemplary claim6, wherein the shroud is altered between the first state and the second state by vertically moving the shroud relative to the support apparatus.

Exemplary Claim8. The coating system according to any one of exemplary claims1to7, wherein the internal cavity is not subjected to a vacuum.

Exemplary Claim9. The coating system according to any one of exemplary claims1to8, wherein the shroud comprises a port that is configured to fluidly couple the internal cavity to the output of the humidifying apparatus.

Exemplary Claim10. The coating system according to any one of exemplary claims1to9, wherein the shroud comprises a top plate and a first side plate extending downward from the top plate.

Exemplary Claim11. The coating system according to exemplary claim10, wherein the port is located on the top plate of the shroud.

Exemplary Claim12. The coating system according to any one of exemplary claims10to11, wherein the first side plate comprises a first securing element and the support apparatus comprising a second securing element that is configured to interlock with the first securing element.

Exemplary Claim13. The coating system according to exemplary claim12, wherein the first state, the first securing element and the second securing element are interlocked.

Exemplary Claim14. The coating system according to any one of exemplary claims12to13, wherein the second state, the first securing element and the second securing element are not interlocked.

Exemplary Claim15. The coating system according to any one of exemplary claims11to14, wherein the port and the applicator head at least partially overlap in a vertical direction.

Exemplary Claim16. The coating system according to any one of exemplary claims1to15, wherein the humidifying apparatus comprises: an air moving-apparatus configured to move air; a steam generator configured to generate steam; a mixing apparatus configured to blend the steam with the air to form the humid air.

Exemplary Claim17. The coating system according to exemplary claim16, wherein the mixing apparatus comprises a mixing chamber and a static mixing element positioned within the mixing chamber.

Exemplary Claim18. A coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising: a housing; an internal cavity located inside of the housing; and a baffle located within the internal cavity; a humidifying apparatus comprising an output that is fluidly coupled to the shroud, wherein the humidifying apparatus is configured to introduce a quantity of humid air to the internal cavity of the shroud that contacts the applicator head.

Exemplary Claim19. The coating system according to exemplary claim18, wherein the shroud comprises a top plate and a port located on the top plate, the port configured to fluidly couple the internal cavity to an output of the humidifying apparatus.

Exemplary Claim20. The coating system according to exemplary claim19, wherein at least a portion of the baffle and the port overlap in a vertical direction.

Exemplary Claim21. The coating system according to any one of claims18to20, wherein the baffle comprises an upper major surface opposite a lower major surface, the baffle extending from a proximal edge to a distal edge, and the baffle comprises a cutout section that is formed into the distal edge.

Exemplary Claim22. The coating system according to exemplary claim21, wherein the cutout section at least partially overlaps with the port in a vertical direction.

Exemplary Claim23. The coating system according to any one of exemplary claims18to22, wherein the baffle comprises a wall extending upward from the upper major surface of the baffle.

Exemplary Claim24. The coating system according to exemplary claim23, wherein the wall follows the path of the cutout section of the baffle.

Exemplary Claim25. The coating system according to any one of exemplary claims18to24, wherein the applicator head comprises an applicator nozzle.

Exemplary Claim26. The coating system according to exemplary claim25, wherein the applicator nozzle and the distal edge of the baffle do not overlap in a vertical direction.

Exemplary Claim27. The coating system according to any one of exemplary claims19to26, wherein the baffle and the top plate are oriented at an oblique angle relative to each other.

Exemplary Claim28. The coating system according to any one of exemplary claims21to27, wherein the top plate comprises a lower surface that faces the internal cavity, and the lower surface of the top plate and the upper major surface of the baffle form a first angle ranging from about 10 to about 10°.

Exemplary Claim29. The coating system according to any one of exemplary claims19to28, wherein the shroud further comprises: a first side plate extending downward from the top plate; a second side plate extending downward from the top plate; and a third side plate extending downward from the top plate; wherein the second side plate is opposite the third side plate and the second side plate and the third side plate are substantially orthogonal to the first side plate.

Exemplary Claim30. The coating system according to exemplary claim29, wherein the quantity of humid air has a temperature ranging from about 70° F. to about 120° F.

Exemplary Claim31. The coating system according to any one of exemplary claims29to30, wherein the first side plate extends downward a first distance from the top plate to a first bottom edge, the second side plate extends downward a second distance from the top plate to a second bottom edge, the third side plate extends downward a third distance from the top plate to a third bottom edge, wherein the second and third distance are greater than the first distance.

Exemplary Claim32. The coating system according to exemplary claim30, wherein the quantity of humid air has a temperature ranging from about 85° F. to about 105° F.

Exemplary Claim33. The coating system according to any one of exemplary claims31to32, wherein the second distance and the third distance are equal.

Exemplary Claim34. The coating system according to any one of exemplary claims31to33, wherein the second side plate and third side plate comprise a stepped edge profile located on the respective second and third bottom edges and adjacent to the first side plate.

Exemplary Claim35. The coating system according to exemplary claim34, wherein the stepped edge profile is configured to receive at least a portion of an edge of the workpiece.

Exemplary Claim36. The coating system according to any one of exemplary claims29to35, wherein the coating system further comprises a support apparatus comprising a frame and a conveyor, the conveyor configured to support the workpiece, and the conveyor and the applicator head are configured to move relative to each other.

Exemplary Claim37. The coating system according to exemplary claim36, wherein the frame and the applicator head do not move relative to each other.

Exemplary Claim38. The coating system according to exemplary claim37, wherein the first side plate comprises a first securing element and the support apparatus comprises a second securing element that is configured to interlock with the first securing element.

Exemplary Claim39. The coating system according to any one of exemplary claims37to38, wherein conveyor is configured to move relative to the applicator head and the shroud.

Exemplary Claim40. The coating system according to any one of exemplary claims18to39, wherein the humidifying apparatus comprises: an air moving-apparatus configured to move air; a steam generator configured to generate steam; a mixing apparatus configured to blend the steam with the air to form the humid air.

Exemplary Claim41. The coating system according to exemplary claim40, wherein the mixing apparatus comprises a mixing chamber and a static mixing element positioned within the mixing chamber.

Exemplary Claim42. A coating system comprising: an applicator head that is configured to apply a coating to a surface of a workpiece; a shroud comprising: a housing; and an internal cavity located inside of the housing; a humidifying apparatus comprising an output that is fluidly coupled to the shroud, the humidifying apparatus comprising: an air-moving device configured to move air; a steam generator configured to generate steam; a mixing apparatus comprising a mixing chamber configured to blend the steam with the air to form humid air; and wherein the humidifying apparatus is configured to introduce the humid air to the internal cavity of the shroud that contacts the applicator head.

Exemplary Claim43. The coating system according to exemplary claim42, wherein the humid air is gravity fed from the output of the humidifying apparatus to the internal cavity of the shroud.

Exemplary Claim44. The coating system according to any one of exemplary claims42to43, wherein the humid air is supplied to the internal cavity of the shroud at a rate of about 75 CFM to about 150 CFM.

Exemplary Claim45. The coating system according to any one of exemplary claims42to44, wherein the shroud comprises a port that is configured to fluidly couple the internal cavity to the output of the humidifying apparatus.

Exemplary Claim46. The coating system according to anyone of exemplary claims42to45, wherein the air is moved through the mixing chamber to the output of the mixing apparatus under pressure applied by the air-moving device.

Exemplary Claim47. The coating system according to any one of exemplary claims42to46, wherein the mixing apparatus comprises a mixing chamber a static mixing element is position within the mixing chamber.

Exemplary Claim48. The coating system according to any one of exemplary claims42to47, wherein the air-moving device comprises a fan configured to move air at a rate ranging from about 550 CFM to about 650 CFM.

Exemplary Claim49. The coating system according to any one of exemplary claims42to48, wherein the coating system further comprises a support apparatus comprising a frame and a conveyor, the conveyor configured to support the workpiece, and the conveyor and the applicator head are configured to move relative to each other.

Exemplary Claim50. A method for coating a workpiece, the method comprising: a) supplying humid air to a coating assembly, the coating assembly comprising: an applicator head; and a shroud comprising an internal cavity whereby the applicator head is at least partially disposed inside of the internal cavity, and the humid air is supplied to the internal cavity of the coating assembly; b) moving the workpiece relative to the coating assembly; c) directing a coating composition onto a surface of the workpiece using the applicator head and exposing the surface of the workpiece to the humid air.

Exemplary Claim51. The method according to exemplary claim50, wherein steps a), b), and c) are performed concurrently.

Exemplary Claim52. The method according to any one of exemplary claims50to51, wherein the humid air is gravity fed to the internal cavity of the coating assembly.

Exemplary Claim53. The method according to any one of exemplary claims50to52, wherein the internal cavity is not under a vacuum during step c).

Exemplary Claim54. The method according to any one of exemplary claims50to53, wherein the coating composition has a solids content ranging from about 60 wt. % to about 90 wt. % based on the total weight of the coating composition.

Exemplary Claim55. The method according to any one of exemplary claims50to54, wherein the humid air has a relative humidity ranging from about 60% to about 90%.

Exemplary Claim56. The method according to any one of exemplary claims50to55, wherein the humid air is supplied to the internal cavity at a rate of about 100 CFM to about 150 CFM.

Exemplary Claim57. The method according to any one of exemplary claims50to56, wherein the humid air is fed to the internal cavity at a rate ranging from about 8 lb./hr. to about 10 lb./hr.

Exemplary Claim58. The method according to any one of exemplary claims50to57, wherein the humid air in step a) is formed from a humidifying apparatus that comprises a steam generator and a mixing apparatus.

Exemplary Claim59. The method according to any one of exemplary claims50to58, wherein the mixing apparatus comprising a mixing chamber and an air-moving device.

Exemplary Claim60. The method according to exemplary claim59, wherein the air is fed to the mixing chamber from the air-moving device and pure water vapor is fed to the mixing chamber from the steam generator, whereby the air and pure water vapor are blended to form the humid air.

Exemplary Claim61. The method according to exemplary claim60, wherein the air is fed to the mixing chamber at a rate ranging from about 550 CFM to about 650 CFM.

Exemplary Claim62. The method according to any one of exemplary claims60to61, wherein the pure water vapor is fed to the mixing chamber at a rate ranging from about 9 lb./hr. to about 13 lb./hr.

Exemplary Claim63. The method according to any one of exemplary claims50to62, wherein the shroud comprises a baffle located in the internal cavity, and wherein during step c) the baffle redirects condensation from the humid air away from the surface of the workpiece.

Exemplary Claim64. The method according to any one of exemplary claims50to63, wherein during step a) the shroud is in a first state and wherein prior to step a) the shroud is in a second state, wherein in the second state the applicator head is located outside of the internal cavity.

Exemplary Claim65. The method according to exemplary claim64, wherein the shroud moves relative to the applicator head to transition between the first state and the second state.

Exemplary Claim66. The method according to any one of exemplary claims64to65, further comprising a support apparatus configured to support the workpiece, wherein the applicator head and support apparatus move relative to each other.

Exemplary Claim67. A method for coating a workpiece, the method comprising: a) supplying humid air to a coating assembly by a gravity feed, the coating assembly comprising: an applicator head comprising an applicator nozzle; and a shroud comprising an internal cavity and a baffle located inside of the internal cavity; whereby the applicator head is at least partially disposed inside of the internal cavity and the humid air is supplied to the internal cavity of the coating assembly; b) contacting the applicator head with the humid air as a coating composition is applied onto a surface of the workpiece using the applicator head, where by a condensation product of the humid air is directed away from the applicator nozzle by the baffle.

Exemplary Claim68. The method according to exemplary claim67, wherein steps a) and b) are performed concurrently.

Exemplary Claim69. The method according to any one of exemplary claims67to68, wherein the humid air contacts the applicator nozzle during step b).

Exemplary Claim70. The method according to any one of exemplary claims67to69, wherein the humid air contacts the surface of the workpiece during step b).

Exemplary Claim71. The method according to any one of exemplary claims67to70, wherein the internal cavity is not under a vacuum during step c).

Exemplary Claim72. The method according to any one of exemplary claims67to71, wherein the coating composition has a solids content ranging from about 60 wt. % to about 90 wt. % based on the total weight of the coating composition.

Exemplary Claim73. The method according to any one of exemplary claims67to72, wherein the humid air has a relative humidity ranging from about 60% to about 90%.

Exemplary Claim74. The method according to any one of exemplary claims67to73, wherein the humid air reaches the internal cavity at a rate of about 75 CFM to about 150 CFM.

Exemplary Claim75. The method according to any one of exemplary claims67to74, wherein the humid air is fed to the internal cavity at a rate ranging from about 8 lb./hr. to about 10 lb./hr.

Exemplary Claim76. A method for coating a workpiece, the method comprising: a) supplying water vapor and moving air to a mixing chamber of a mixing apparatus, the mixing chamber of the mixing apparatus comprising a static mixer; b) blending the water vapor and moving air in the static mixer to form humid air; c) feeding the humid air from the mixing apparatus to a coating assembly, the coating assembly comprising: a shroud comprising an internal cavity; and an applicator head at least partially located in the internal cavity of the shroud; whereby the humid air reaches the internal cavity of the coating assembly; b) directing a coating composition onto a surface of the workpiece using the applicator head and exposing the surface of the workpiece to the humid air.

Exemplary Claim77. The method according to exemplary claim76, wherein the humid air is fed to the coating assembly in step b) by gravity feed.

Exemplary Claim78. The method according to any one of exemplary claims76to77, wherein the internal cavity is not under a vacuum during step b).

Exemplary Claim79. The method according to any one of exemplary claims76to78, wherein the coating composition has a solids content ranging from about 60 wt. % to about 90 wt. % based on the total weight of the coating composition.

Exemplary Claim80. The method according to any one of exemplary claims76to79, wherein the humid air has a relative humidity ranging from about 60% to about 90%.

Exemplary Claim81. The method according to any one of exemplary claims76to80, wherein the humid air reaches the internal cavity at a rate of about 75 CFM to about 150 CFM.

Exemplary Claim82. The method according to any one of exemplary claims76to81, wherein the humid air is fed to the internal cavity at a rate ranging from about 8 lb./hr. to about 10 lb./hr.

Exemplary Claim83. The method according to any one of exemplary claims76to82, wherein the moving air is fed to the mixing chamber at a rate ranging from about 550 CFM to about 650 CFM.

Exemplary Claim84. The method according to any one of exemplary claims76to83, wherein the water vapor is fed to the mixing chamber at a rate ranging from about 9 lb./hr. to about 13 lb./hr.