Fluid application device having a modular contact nozzle with a fluidic oscillator

A fluid application device having a contact nozzle assembly with a fluidic oscillator is provided. The fluid application device includes an applicator head and a nozzle assembly. The nozzle assembly includes a first conduit configured to receive a first fluid from the applicator head, a second conduit configured to receive a second fluid from the applicator head and an application conduit including a receptacle and first and second branches. The receptacle is fluidically connected with the first conduit and configured to receive the first fluid. The first and second branches are fluidically connected to the second conduit and receptacle and are configured to receive the second fluid. The nozzle assembly further includes an orifice fluidically connected to the application conduit and configured to discharge the first fluid for application onto a strand of material, and a guide slot extending from the orifice and configured to receive the strand of material.

BACKGROUND

The following description relates to a fluid application device for applying a fluid onto a strand of material, and in particular, a fluid application device having a modular contact nozzle with a fluidic oscillator so as to apply the fluid onto the strand of material in a non-linear pattern.

Nonwoven fabrics are engineering fabrics that provide specific functions such as absorbency, liquid repellence, resilience, stretch, softness, strength, flame retardant protection, easy cleaning, cushioning, filtering, use as a bacterial barrier and sterility. In combination with other materials, nonwoven materials can provide a spectrum of products with diverse properties and can be used alone or as components of hygiene apparel, home furnishings, health care, engineering, industrial and consumer goods.

A plurality of elasticated strands may be positioned on and bonded to the nonwoven materials to, for example, allow for flexibility fitting around an object or a person. The strands may be bonded to the nonwoven fabric with an adhesive, such as glue. In one configuration, the strands are fed past a nozzle on an adhesive application device. The nozzle may include a plurality of outlets through which the glue may be discharged. A second fluid, such as air, may be discharged through separate outlets to control the application of the glue such that the glue is oscillated across the respective strands as the strands pass by the nozzle. In such a configuration, the glue may be discharged as a fiber, and the fiber is oscillated by the air.

An adhesive application device may apply the glue to the strands with either a contact nozzle or a non-contact nozzle. A contact nozzle discharges a volume of substantially stationary glue while a substrate, such as the strand, is fed by the glue. The strand is in contact with the glue and the glue adheres to the strand as a result of the contact. In a non-contact nozzle, the glue may be discharged from an outlet as a fiber. The glue fiber is discharged over a gap between the outlet and the strand, and is ultimately received on the strand. Discharging of the glue fiber may be controlled by a second fluid, such as air, discharged from adjacent outlets, to oscillate the glue fiber during application onto the strand.

A non-contact nozzle may be beneficial for applying the glue fiber on the strand in a desired pattern, for example, in a substantially sinusoidal pattern. However, a line speed, i.e., a speed at which the strand is fed past the nozzle, typically cannot exceed about 400 meters per minute (mpm) to achieve the desired pattern using a non-contact nozzle. A higher line speed may be achieved with a contact nozzle. However, a contact nozzle is limited to applying the glue onto the strand in a substantially linear pattern.

Accordingly, it is desirable to provide a fluid application device having a contact nozzle configured to apply the fluid onto the strand in a non-linear pattern such that the fluid may be applied over a wider area of the strands.

SUMMARY

According to one embodiment, there is provided a fluid application device having an applicator head and a nozzle assembly fluidically coupled to, i.e., in fluid communication with, the applicator head. The nozzle assembly includes a first conduit configured to receive a first fluid from the applicator head, a second conduit configured to receive a second fluid from the applicator head and an application conduit including a receptacle, a first branch and a second branch. The receptacle is fluidically connected with the first conduit and is configured to receive the first fluid, and the first branch and the second branch are fluidically connected to the second conduit and the receptacle and are configured to receive the second fluid. The nozzle assembly further includes an orifice fluidically connected to the application conduit. The orifice is configured to discharge the first fluid for application onto a strand of material. A guide slot extends relative the orifice and is configured to receive the strand of material.

According to another embodiment there is provided a fluid application device including an applicator head and a nozzle assembly fluidically coupled to the applicator head. The nozzle assembly includes a first conduit configured to receive a first fluid from the applicator head and an application conduit including a first branch and a second branch fluidically connected with the first conduit and configured to receive the first fluid. The nozzle assembly further includes an orifice fluidically connected to the application conduit, and configured to discharge the first fluid for application onto a strand of material, and a guide slot extending relative to the orifice, the guide slot configured to receive the strand of material.

According to yet another embodiment, there is provided a nozzle assembly for a fluid application device. The nozzle assembly includes a first conduit configured to receive a first fluid, a second conduit configured to receive a second fluid and an application conduit including a receptacle, a first branch and a second branch. The receptacle is fluidically connected with the first conduit and is configured to receive the first fluid and the first branch and the second branch are fluidically connected between the second conduit and the receptacle and are configured to receive the second fluid. The nozzle assembly further includes an orifice fluidically connected to the application conduit. The orifice is configured to discharge the first fluid for application onto a strand of material. A guide slot extends relative to the orifice and is configured to receive the strand of material.

According to still another embodiment, there is provided a nozzle assembly for a fluid application device. The nozzle assembly includes a first conduit configured to receive a first fluid from the applicator head and an application conduit including a first branch and a second branch fluidically connected with the first conduit and configured to receive the first fluid. The nozzle assembly further includes an orifice fluidically connected to the application conduit and configured to discharge the first fluid for application onto a strand of material, and a guide slot extending relative to the orifice, the guide slot configured to receive the strand of material.

Other objects, features, and advantages of the disclosure will be apparent from the following description, taken in conjunction with the accompanying sheets of drawings, wherein like numerals refer to like parts, elements, components, steps, and processes.

DETAILED DESCRIPTION

While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more embodiments with the understanding that the present disclosure is to be considered illustrative only and is not intended to limit the disclosure to any specific embodiment described or illustrated.

FIG. 1is a side perspective view of a fluid application device10according to an embodiment described herein. The fluid application device10may be used to apply a first fluid onto an article. For example, the fluid application device10may apply a first fluid onto an article. The first fluid may be a viscous fluid that is a liquefied material heated or non-heated between about 10 and 50,000 centipoise (cps). The first fluid may be, for example, an adhesive, and the article may be, for example, an elastic or non-elastic strand12of material. That is, in one embodiment, the fluid application device10is part of a strand coating system. The adhesive may be applied to the strand12so that the strand12may be adhered to a substrate14, such as a nonwoven material. The strand12, in one embodiment, may be made from an elastic material and may be in either a stretched condition or a relaxed condition as the first fluid is applied. The strand12of material may be, for example, spandex, rubber or other similar elastic material.

According to one embodiment, the fluid application device10includes an applicator head16. The applicator head16may include a first fluid supply unit18and a second fluid supply unit20. The fluid application device10also includes a nozzle assembly22fluidically coupled to the applicator head16. The first fluid supply unit18is configured to receive the first fluid F1from a first fluid source (not shown) and the second fluid supply unit20is configured to receive a second fluid F2from a second fluid source (not shown). The nozzle assembly22is fluidically coupled to, i.e., is in fluid communication with, the first fluid supply unit18. The nozzle assembly22may also be fluidically coupled to, i.e., may be in fluid communication with, the second fluid supply unit20. Accordingly, the nozzle assembly22may receive the first fluid F1from the first fluid supply unit18and the second fluid F2from the second fluid supply unit20.

In some embodiments, the applicator head16may also include an adapter24secured to at least one of the first fluid supply unit18and second fluid supply unit20. The adapter24is positioned adjacent to the nozzle assembly22and is fluidically coupled to, i.e., is in fluid communication with, the nozzle assembly22. In addition, the adapter24is fluidically coupled to one of or both of the first fluid supply unit18and second fluid supply unit20, such that the nozzle assembly22may receive the first fluid and the second fluid via the adapter24. That is, the adapter24is in fluid communication with at least one of the first fluid supply unit18and the second fluid supply unit20and also the nozzle assembly22. The adapter24is configured to have the nozzle assembly22secured thereto such that the nozzle assembly22may be properly positioned and oriented relative the applicator head16and/or a path along which the strands12travel.

The applicator head16may also include a flow control module26. The flow control module26may include a valve or series of valves to regulate a flow of the first fluid and second fluid from the first fluid supply unit18and second fluid supply unit20, respectively, to the nozzle assembly22. The flow control module26and the adapter24may be integrated such that the adapter24and the flow control module26are one and the same. That is, in some embodiments, the adapter24and flow control module26are implemented as the same unit. This unit provides an adhesive path between one of or both of the first and second fluid supply units18,20and the nozzle assembly22. This unit, i.e., the combined adapter24and flow control module26may also include valving to start and stop the flow of adhesive.

FIG. 2is a front perspective view of the fluid application device10according to an exemplary embodiment. With reference toFIGS. 1 and 2, the nozzle assembly22may be removably secured to the adapter24or other adjacent component of the applicator head16. The nozzle assembly22may be a contact nozzle assembly22. The nozzle assembly22includes an orifice28, through which the first fluid F1(seeFIG. 4) may be applied directly on the strand12. There may be at least one orifice28associated with each strand12of material. In some embodiments, there is one orifice28associated with each strand12. That is, each orifice28may discharge the first fluid directly to a respective strand12. Each orifice28may have a width of approximately 0.016-0.020 inches (in.), but is not limited thereto. For example, the width of the orifices28may be varied to accommodate different sizes of strands12. In addition, in an embodiment of the present contact nozzle assembly, the second fluid F2(seeFIG. 4) may also be discharged adjacent to or at the orifice28as described further below. The second fluid F2may be used to control the application of the first fluid on the strand12, for example, by moving the first fluid F1back and forth across a width of, or at least partially around an outer circumference of, the strand12as the first fluid F1is applied.

As noted above, the first fluid F1may be an adhesive, such as a hot melt adhesive. The adhesive may be discharged from the orifice28, for example, as a bead that is contacted directly by the strand12. The applicator head16may be heated to either melt the first fluid or maintain the first fluid F1in a melted condition. For example, the first fluid supply unit18, the second fluid supply unit20, and/or the nozzle assembly22may be heated, and thus, may also radiate heat outwardly. The applicator head16may also include a heater.

The second fluid F2may be, for example, air, and may be used to control the discharge of the first fluid F1at the orifice28of the nozzle assembly22and onto the strand12as described above. In a non-limiting example, there are two branches174a,174b(seeFIGS. 3 and 4) configured to discharge the second fluid F2adjacent to each orifice28that discharges the first fluid F1as described further below. It is understood, however, that the number of branches174a,174bassociated with each orifice28may vary. The second fluid may be alternately discharged from the outlets adjacent to each orifice28to cause the first fluid F1to fluctuate and during application to the strand12.

The fluid application device10further includes a strand engagement device30. The strand engagement device30may be formed integrally with the applicator head16. Alternatively, the strand engagement device30may be secured to the applicator head16or other component of the fluid application device10with a suitable fastener, including, but not limited to, bolts, screws, rivets, adhesives, welds and the like. The strand engagement device30is configured to engage the strands12and move the strands12toward or away from the applicator head16and nozzle assembly22based on a line condition (active or static) of the fluid application device10, as described further below.

Referring toFIGS. 1 and 2, the contact nozzle assembly22further includes a depending guide section32to assist in positioning of the strands12relative to the orifices28and branches174a,174b(seeFIGS. 3 and 4) of the nozzle assembly22. The guide section32also includes at least one guide slot34through which the strand12may be fed. The guide slot34includes an open end36and a closed end38. In one embodiment, the closed end38is positioned immediately adjacent to the orifice28. The open end36may be formed in a substantially inverted v-shape, while the closed end38may be rounded or curved so that it substantially matches a profile of the strand12. The guide slot34may have a substantially constant width between the open end36and closed end38. The closed end38may act as a limit or stop for the strands12to position the strands12at the desired position relative the orifices28and branches174a,174b(seeFIGS. 3 and 4) for application of the first fluid F1. In one embodiment, the strand12contacts the closed end38. Alternatively, the strand12may be spaced from, but in close proximity to the closed end38.

According to one embodiment, the at least one guide slot34may include three guide slots34. However, it is understood that the number of guide slots34may vary, and is not limited to the example above. Each guide slot34is associated with a corresponding orifice28of the nozzle assembly22. That is, each guide slot34is substantially aligned with a corresponding orifice28of the nozzle assembly22. For example, the closed end38of respective guide slots34may be aligned with respective orifices28.

With further reference toFIGS. 1 and 2, the strand engagement device30includes an engagement arm44configured to support and/or guide the strand or strands12. The engagement arm44is adjustable to move the strands12within, or relative to, respective guide slots34to position the strands12relative to the respective orifices28and outlets.

FIG. 2shows the engagement arm44in a first position. The engagement arm44is adjustable between a first position, as shown inFIG. 2, and a second position (not shown). The first position corresponds to a position where the engagement arm44is spaced a first distance from the applicator head16. The first distance is sufficient to prevent or limit damage, such as burn through, to the strands12caused from heat radiating from the applicator head16and/or nozzle assembly22. For example, the engagement arm44, in the first position may space the strands12approximately 3-5 mm from a heat source of the applicator head16. It may be desirable to maintain the engagement arm44in the first position when the fluid application device is in a static line condition, i.e., when the strands12are not being fed past respective orifices28.

The second position (not shown) corresponds to a position where the engagement arm44is spaced a second distance, less than the first distance, from the applicator head16, such that the strands12are moved closer to the applicator head16and the respective orifices28. In one example, the second position of the engagement arm44positions the strands approximately at or partially within the orifices28. That is, the second position of the engagement arm44generally corresponds to a position where the first fluid F1may be applied directly on the strand12. Moving the engagement arm44to, and maintaining the engagement arm in, the second position may be beneficial when the fluid application device10is in an active line condition, i.e., when the strands12are being fed past respective orifices28, so that the first fluid F1may be efficiently applied on the strands12and overspray may be reduced.

Referring still toFIGS. 1 and 2, the engagement arm44may be adjusted by an actuating assembly48. The actuating assembly48may be, for example, a pneumatically controlled piston50and cylinder52. For example, the piston50may be movable within the cylinder52in response to air or another gas being introduced into the cylinder52. The piston50may be connected directly or indirectly to the engagement arm44such that movement of the piston50in and out of the cylinder52causes the engagement arm44to move toward or away from the applicator head16.

Referring still toFIGS. 1 and 2, the nozzle assembly22may be formed as a modular unit. That is, the nozzle assembly22may be selectively removed from and secured to the fluid application device10. For example, the nozzle assembly22may be selectively removed from and secured to the applicator head16, and more specifically, in some embodiments, the adapter24. Accordingly, the nozzle assembly22may be replaced in the event a new or different nozzle assembly is desired or required. The nozzle assembly22is selectively removable from and securable to the fluid application device10by way of at least one securing element74(FIG. 2). In one embodiment, the nozzle assembly22includes at least one securing opening76extending therethrough, each securing opening76configured to receive a respective securing element74.

With further reference toFIGS. 1 and 2, the nozzle assembly22may include two securing openings76, each configured to receive a respective securing element74. It is understood that the number of securing openings76is not limited to the example above, however. Individual securing openings76may be formed as an opening or slot extending through the nozzle assembly22. The opening or slot may be closed about its periphery or include an open side along an edge of the nozzle assembly22. The securing elements74extend through the securing openings76and are received in corresponding bores (not shown) in the fluid application device10to secure the nozzle assembly22to the applicator head16. This allows for a modular design of the fluid application device10and nozzle assembly22to facilitate maintenance, replacement or the like.

FIG. 3is a plan view of contact nozzle assembly components according to an embodiment described. With reference toFIG. 3, the nozzle assembly22may be formed by a plurality of laminated or stacked plates122a-h. In the example shown inFIG. 3, the nozzle assembly includes first plate122a, second plate122b, third plate122c, fourth plate122d, fifth plate122e, sixth plate122f, seventh plate122gand eighth plate122h. It is understood, however, that the number of plates122in the nozzle assembly22may vary and is not limited to the example shown inFIG. 3.FIGS. 4A-4Hare enlarged views of the first through eighth plates,122a-122h, respectively, shown inFIG. 3.

Referring toFIGS. 3, 4B, 4E and 4F, in one embodiment the nozzle assembly22includes a fluidic oscillator configured to control application of the first fluid F1onto the strand12such that the first fluid F1may be applied in a non-linear pattern. For example, the fluidic oscillator may discharge a second fluid F2at opposite sides of the orifice28, via first and second branches174a,174b, to cause the first fluid F1to be applied in a non-linear pattern across a width or at least a portion of the outer circumference, of the strand12.

Referring toFIGS. 3 and 4A-4H, in one example, the nozzle assembly22includes a first conduit130in which the first fluid F1may flow. The fluidic oscillator of the nozzle assembly22may be formed by a second conduit132within the nozzle assembly22, an oscillator conduit134in fluid communication with the second conduit132, and an application conduit136, fluidically connected to the first conduit130and second conduit132.

The first conduit130is configured to a deliver the first fluid F1to the application conduit136. The first conduit130includes a first inlet138configured to receive the first fluid F1from the first fluid supply module18. It is understood that the inlet138may be formed in a side of plate of the nozzle assembly22facing toward the applicator, i.e., away from remaining plates of the nozzle assembly, such that the first fluid F1may be received in the first conduit130. For example, the first inlet138may be formed on a side of the first plate configured to abut the applicator head16, or other adjacent component, from which the first fluid is discharged. In one embodiment, the first conduit130may be generally triangular in cross-section, with rounded corners. The first conduit130may also include a width and height. In one example, the width is greater than the height. However, it is understood that these configurations are described for purposes of example only, and the present disclosure is not limited thereto. For example, the first conduit may be formed in different suitable cross-sectional shapes and have varying relative dimensions of width and height.

The second conduit132is formed in the nozzle assembly22and is configured to deliver the second fluid F2to the application conduit136. The second conduit132includes a second inlet140configured to receive the second fluid F2from the second fluid supply module20. It is understood that the second inlet140may be formed in a plate of the nozzle assembly22, for example, first plate122a, so that the second fluid F2is received in the second conduit132from the second inlet140.

Referring toFIG. 3, andFIGS. 4A-4F, in one embodiment, the second conduit132may include one or more flow-splitting sections142(FIGS. 4C and 4D), as described further below, where the second conduit132may be split so as to deliver the second fluid F2to first and second branches174a,174bof the application conduit136. In one embodiment, the flow-splitting section142may include a first branch feed hole144aand a second branch feed hole144b(FIG. 4C). The first branch feed hole144aand second branch feed hole144bmay be in direct fluid communication with the application conduit136so as to supply the second fluid F2to the application conduit136(FIG. 4B).

With further reference to the examples inFIGS. 3 and 4A-4F, the second conduit132may include a first portion146(FIGS. 4B-4E), a second portion148(FIGS. 4C-4E) and a reservoir150(FIG. 4F) spacing apart and fluidically connecting the first portion146and the second portion148. The first portion146extends between the second inlet140and the reservoir150generally in a first direction D1(FIG. 5). In one embodiment, the first portion146may be formed as an elongated opening, having a generally inverted “v,” or “u,” shape in cross-section. However, other angled or curved elongated shapes, or non-angled or non-curved shapes that do not interfere with fastening openings80(described further below) may be suitable as well.

The second portion148extends between the reservoir150and the application conduit136generally in a second direction D2(FIG. 5). In one embodiment, the first direction D1and second direction D2are generally opposite to one another. In one example, the reservoir150extends generally perpendicularly between the first portion146and the second portion148, but is not limited to this configuration.

It is understood that the terminology “generally in a first direction D1” refers to the direction from the second inlet140to the reservoir150, and may include variations in the direction as a result of the specific geometry and configuration of the first portion146. Similarly, it is understood that the terminology “generally in a second direction D2” refers to the direction from the reservoir150to application conduit136, and may include variations in the direction as a result of the specific geometry and configuration of the second portion148.

The reservoir150is configured to receive the second fluid F2, flowing in the first direction D1, from the first portion146of the second conduit132. In one non-limiting embodiment, for example, as shown inFIGS. 3 and 4F, the reservoir150may be formed substantially in a U-shape. The reservoir150may include first and second receiving legs152a,152bconfigured to receive the second fluid F2from the first portion146of the second conduit132. The reservoir150may further include a cross-leg154fluidically connected to the first and second receiving legs152a,152band configured to receive the second fluid F2from the first and second receiving legs152a,152b. In this example, the cross-leg154is fluidically connected to the second portion148of the second conduit132and is configured to deliver the second fluid F2to the second portion148such that the second fluid F2may flow in the second direction D2to the application conduit136. It is understood that various other shapes and configurations for the reservoir150are envisioned that allow for the second fluid F2to flow from the first portion146to the second portion148of the second conduit132.

The second portion148of the second conduit132may include one or more body feed holes156fluidically connected to the reservoir150and configured to receive the second fluid F2from the reservoir150. In the example shown inFIGS. 3 and 4E, the body feed hole156is configured to receive the second fluid F2from the cross-leg154of the reservoir150. The body feed hole156is fluidically connected to the flow-splitting section142.

Referring toFIGS. 3 and 4D, in one embodiment, the flow-splitting section142may include a generally body-shaped portion. The body-shaped portion may include a head160, first and second arms162a,162band first and second legs164a,164b. The head160of the flow-splitting section142is fluidically connected to the body feed hole156and is configured to receive the second fluid F2therefrom. The second fluid F2, received in the head160of the flow-splitting section142may then to the first and second arms162a,162band first and second legs164a,164bof the flow-splitting section142.

As noted above, the flow-splitting section142is configured to split the flow of the second fluid F2. Referring to the non-limiting example shown inFIGS. 3, 4C and 4D, the first leg164a(FIG. 4D) of the flow-splitting section142may be aligned with and fluidically connected to the first branch feed hole144a(FIG. 4C) and the second leg164b(FIG. 4D) of the flow-splitting section142may be aligned with and fluidically connected to the second branch feed hole144b(FIG. 4C). Accordingly, the first and second branch feed holes144a,144bmay receive the second fluid F2from the first and second legs164a,164b, respectively, of the flow-splitting section142. The first and second branch feed holes144a,144bare fluidically connected to the application conduit136and are configured to deliver the second fluid F2to the application conduit136as described further below.

With reference toFIGS. 3, 4E and 4F, the oscillator conduit134may be formed in the nozzle assembly22. In the example shown inFIG. 3, the oscillator conduit134is fluidically connected to the second conduit132, for example, at the flow-splitting section142and is configured to vary a pressure of the second fluid F2flowing through the flow-splitting section142, in part, by creating or amplifying a turbulent flow in the second fluid F2.

In one embodiment, the oscillator conduit134includes one or more pairs of arm feed holes, each pair of arm feed holes including first and second arm feed holes166a,166band one or more pairs of leg feed holes, each pair of leg feed holes including including first and second leg feed holes168a,168b. The first and second arm feed holes166a,166bare aligned with and fluidically connected to the first arm162aand second arm162b, respectively, of the flow-splitting section142. Likewise, the first and second leg feed holes168a,168bare aligned with and fluidically connected to the first leg164aand second leg164b, respectively, of the flow-splitting section142. The oscillator conduit134further includes one or more pairs of oscillator slots, each pair including first and second oscillator slots170a,170b. The first oscillator slot170ais aligned with and fluidically connected to the first arm feed hole166aand the first leg feed hole168a. Likewise, the second oscillator slot170bis aligned with and fluidically connected to the second arm feed hole166band the second leg feed hole168b. Accordingly, the first oscillator slot170ais configured to receive the second fluid F2from the first leg feed hole168aand discharge the second fluid F2through the first arm feed hole168b. Similarly, the second oscillator slot170bis configured to receive the second fluid F2from the second leg feed hole168band discharge the second fluid F2through the second arm feed hole166b.

Referring still to the example inFIG. 3, and with further reference toFIG. 4B, the application conduit136includes a receptacle172, the first branch174aand the second branch174b. The receptacle172is fluidically connected to the first conduit130, and thus, is configured to receive the first fluid F1from the first conduit130. The first branch174aand the second branch174bare aligned with and fluidically connected to the first branch feed hole144aand second branch feed hole144b, respectively. Accordingly, the first branch174aand the second branch174bare configured to receive the second fluid F2from the first branch feed hole144aand second branch feed hole144b, respectively. The receptacle172, the first branch174aand the second branch174bare fluidically connected to the orifice28.

In the examples above, the second portion148of the second conduit132, the oscillator conduit134, and the application conduit136define a flow path for the second fluid F2between the reservoir150and the orifice28. It is understood that multiple flow paths may be provided in the nozzle assembly22to control the application of the first fluid F1onto additional strands of material12. For example, as shown inFIGS. 3 and 4A-4F, the fluidic oscillator includes three flow-splitting sections142, each flow-splitting section142having a body-shaped portion, first branch feed hole144aand second branch feed hole142b, and three body feed holes156, formed in the second portion148of the second conduit132. Similarly, the oscillator conduit134may include three pairs of arm feed holes166a,166b, three pairs of leg feed holes168a,168band three pairs of oscillator slots170a,170b. Further, the nozzle assembly, as shown inFIG. 4B, for example, may include three application conduits136. Accordingly, the first fluid F1may be applied on three strands via three respective application conduits136. In this example, the first conduit130may be fluidically connected to each application conduit136, and thus, may supply the first fluid F1to respective receptacles of the application conduits136. In addition, the first portion146of the of the second conduit132may supply the second fluid F2to the reservoir150, and in turn, to the second portion148of the second conduit132, the oscillator conduits134and the application conduits136.

It is understood that the configurations shown inFIGS. 3 and 4A-4Fare non-limiting, and that the number of flow-splitting sections142, including the body-shaped portions, first branch feed holes144a, and second branch feed holes144b, body feed holes156, arm feed hole pairs166a,166b, leg feed hole pairs168a,168b, oscillator slot pairs170a,170b, and application conduits136may vary depending on the number of strands of material12the nozzle assembly22is configured to accommodate. The nozzle assembly22may be configured to accommodate, for example, anywhere from one strand to ten strands, but is not limited to this range.

As noted above, and with further reference toFIGS. 3 and 4A-4H, the nozzle assembly22may be formed by a plurality of laminated or stacked plates. In one embodiment, the nozzle assembly22is formed by eight plates122a-h. The first conduit130, second conduit132, oscillator conduit134and application conduit136may be formed in and configured to extend in one or more plates. In a non-limiting example, and with reference toFIG. 4A, the first conduit130may be formed in the first plate122a. The first inlet136may be formed at a side of the first plate122afacing an adjacent component, such as the adapter24. The first conduit130may be formed through a thickness of the first plate122a.

The second inlet140may be formed in the first plate122aas well. The second conduit132, as shown inFIGS. 4A-4F, may extend through the thickness of the first plate122a, the second plate122b, the third plate122c, the fourth plate122d, the fifth plate122eand the sixth plate122f. In one embodiment, the first portion146of the second conduit132extends through the second plate122b, the third plate122c, the fourth plate122dand the fifth plate122e. As described above, the first portion146may be formed as an elongated, angled or curved opening in the second through fifth plates122b-e. These elongated openings may be similarly positioned on the plates122b-eso that they are substantially aligned when the nozzle assembly22is assembled and secured to the adapter24.

Referring toFIGS. 3 and 4F, the reservoir150may be formed in the sixth plate122f. Referring toFIGS. 4C-4E, the second portion148of the second conduit132may be formed in the third plate122c, fourth plate122dand fifth plate122e. For example, the body feed hole156may be formed in the fifth plate122e, the flow-splitting section142may be formed in the fourth plate122dand the first and second branch feed holes144a,144bmay be formed in the third plate122c.

Referring toFIGS. 4E and 4F, the oscillator conduit134may be formed in the fifth plate122eand sixth plate122f. For example, the first and second arm feed holes166a,166band the first and second leg feed holes168a,168bmay be formed in the fifth plate122e. The first and second oscillator slots170a,170bmay be formed in the sixth plate122f.

With reference toFIG. 4B, the application conduit136, including the receptacle172, first branch174aand the second branch174bmay be formed in the second plate122b. The orifice28may be formed in the second plate122bas well. The at least one guide slot34may be formed in the first, second and third plates122a-cas described below and shown inFIGS. 4A-C.

In one embodiment, the depending guide section32is formed on first plate122a, second plate122band third plate122c(FIGS. 4A-4C). The guide slots34are formed on the depending guide section32on the first, second and third plates122a,122b,122cas well. Each guide slot34may include a first guide slot segment34aformed on the first plate122a, a second guide slot segment34bformed on the second plate122b, and a third guide slot segment34cformed on the on the third plate122c.

The first guide slot segment34aincludes an open end36aand a closed end38a. The closed end38amay include a curved surface configured to substantially match a profile of the strand12and act as a stop for the strand12to properly position the strand12relative to the orifice28. The second guide slot segment34bincludes an open end36b. The open end36bmay include a substantially inverted v-shaped portion as described above. The second guide slot segment34bis in communication with the orifice28at an end opposite to the open end36b. The third guide slot segment34cincludes an open end36cand a closed end38c. The open end36cmay include a substantially inverted v-shaped portion as described above. The closed end38cof the third guide slot segment34cmay include a substantially square or rectangular portion having a width greater than the width of an adjacent portion of the guide slot segment34c.

In one embodiment, the nozzle assembly22includes three guide slots34, each guide slot34including first, second and third guide slot segments34a-c. However, it is understood the number of guide slots34may vary to accommodate different number of strands12. The number of guide slots34may correspond to the number of application conduits136. When assembled, the first guide slot segment34a, second guide slot segment34band third guide slot segment34care substantially aligned to form the guide slot34. The strand12may be received through the respective open ends36a,36b,36c, i.e., the open end36of the guide slot34, and moved to the closed end38of the guide slot34. The closed end38of the guide slot34is defined by the first closed end38aand third closed end38c. The orifice28is formed in the second plate122bimmediately adjacent to and between the closed ends38a,38c.

Referring toFIGS. 4G and 4H, the seventh plate122gand eighth plate122hare positioned at an opposite end of the nozzle assembly22from the first plate122a. In one embodiment, the seventh plate122gacts as a seal that forms a boundary for the second conduit132. That is, the seventh plate122gis configured to seal the second conduit132at the reservoir150and oscillator slots170a,170b. The eighth plate122his an end plate for increasing the structural integrity of the nozzle assembly22. The eighth plate122hmay include a beveled edge.

At least one fastening hole80may be formed in each of the plates122a-h. In one embodiment, three fastening holes80are formed in each plate122a-h. However, it is understood that the present disclosure is not limited to this configuration and the number of fastening holes80may vary. The fastening holes80of the plates122a-hare aligned with one another so as to receive a fastener82(FIGS. 1 and 2) through each series of aligned fastening holes80. The fastener82is configured to tightly fasten the plates122a-htogether so that leakage of the first fluid F1and/or second fluid F2between individual plates122a-his limited or prevented.

FIG. 5is an exploded perspective view of the nozzle assembly22according to an embodiment described herein. Referring toFIGS. 2, 4A-4H, and 5, in one example of the nozzle assembly22, the first inlet138is configured to receive the first fluid F1from the first fluid supply module18. The first conduit130is configured to receive the first fluid F1, via the first inlet138and supply the first fluid F1to the application conduit136. In one embodiment, the receptacle172of the application conduit136receives the first fluid F1, and is configured to supply the first fluid F1to the orifice28for application onto the stand of material12. In one embodiment, the nozzle assembly22includes three application conduits136to apply the first fluid on three respective strands12. However, as detailed above, the present disclosure is not limited to this configuration and the number of application conduits136may vary depending on a number of strands12it is desired for the nozzle assembly22to accommodate. Further, each of application conduits136may be fed from a single, common, first conduit130.

The nozzle assembly22is configured to receive the second fluid F2through the second inlet140. The second conduit132is configured to receive the second fluid F2from the second inlet140and feed the second fluid F2through the nozzle assembly22to the application conduit136. In one example, the first portion146of the second conduit132receives the second fluid F2from the second inlet140and supplies the second fluid F2to the reservoir150. The reservoir150is configured to receive the second fluid F2from the first portion146and discharge the second fluid F2to the second portion148of the second conduit132.

In one embodiment, each body feed hole156may receive the second fluid F2from the reservoir150. Each body feed hole156supplies the second fluid F2to a respective flow-splitting section142. The second fluid F2may be received at a respective head160of each flow-splitting section142from the corresponding body feed hole156. The second fluid F2may flow through each flow-splitting section142from the head160to the first and second legs164a,164b. The first and second branch feed holes144a,144bare configured to receive the second fluid F2from respective first and second legs164a,164bfor each flow-splitting section142. Accordingly, the first and second branch feed holes144a,144bmay supply the second fluid F2to corresponding first and second branches174a,174bof a respective application conduit136.

A turbulent flow of the second fluid F2in the second portion148of the second channel may result in the second fluid F2being received at the first and second legs164a,164bfrom the head160at the flow-splitting section142at different pressures. In one embodiment, a portion of the fluid at the higher pressure flows into the oscillator conduit134, while fluid at the lower pressure flows to a corresponding branch supply feed hole144aor144b.

For example, the second fluid F2may be initially received at the first leg164aat a higher pressure, and at the second leg164bat a lower pressure relative to the first leg164a. The second fluid F2received in the first leg164a, at the higher pressure, may be at least partially discharged to the first leg feed hole168aof the oscillator conduit134and then into the first oscillator slot170a. The second fluid F2may then flow through the first oscillator slot170aand be discharged from the first oscillator slot170athrough the first arm feed hole166aof the oscillator conduit134. This portion of second fluid F2may then be received in the first arm162aof the flow-splitting section142. Another portion of the higher pressure second fluid F2initially received in the first leg164ais discharged to the first branch feed hole144a, and in turn, to the first branch174aof the application conduit136.

Meanwhile, the second fluid F2initially received in the second leg164b, at the lower pressure, may be discharged from the second leg164bto the second branch feed hole144b. The second fluid F2may flow though the second branch feed hole144band into the second branch174bof the application conduit136.

The second fluid F2received at the first arm162afrom the oscillator conduit134, at a higher pressure, may then flow into the second leg164bof the flow-splitting section142due to the initial lower pressure of the second fluid in the second leg164b. This causes the second leg164bto become the leg having the second fluid F2at the higher pressure, while the first leg164abecomes the leg having the second fluid F2at the lower pressure. That is, the first and second legs164a,164balternate between receiving the second fluid at a higher pressure and a lower pressure by way of the oscillator conduit134.

With the second leg164bcontaining the second fluid F2at a higher pressure than the second fluid F2in the first leg164b, a portion of the second fluid F2may be discharged to the second leg feed hole168bof the oscillator conduit134and then into the second oscillator slot170b. The second fluid F2may then flow through the second oscillator slot170band be discharged through the second arm feed hole166bof the oscillator conduit134. This portion of second fluid F2may then be received in the second arm162bof the flow-splitting section142. Another portion of the higher pressure second fluid F2received in the second leg164bis discharged to the second branch feed hole144b, and in turn, to the second branch174bof the application conduit136.

Meanwhile, the second fluid F2in the first leg164a, now at the lower pressure, may be discharged from the first leg164ato the first branch feed hole144a. The second fluid F2may flow though the first branch feed hole144aand into the first branch174aof the application conduit136.

Accordingly, the second fluid F2may be supplied to the first and second branch feed holes144a,144bat alternating higher and lower relative pressures, and in turn, to the first branch174aand second branch174bat alternating higher and lower relative pressures. The varying pressures of the second fluid F2supplied to the first and second branches174a,174bcause the second fluid F2to be discharged to the orifice28at different pressures, thereby causing the first fluid F1to be fluctuated back and forth across a width of the strand12. In one embodiment, this configuration causes a lateral fluctuation in first fluid F1as it is applied onto the strand12, such that the first fluid F1is applied in an irregular, non-predetermined, and/or non-repeatable pattern.

In the examples shown inFIGS. 1-5, and as described above, the first fluid F1may be an adhesive, such as a hot melt adhesive that is gathered in the receptacle172of the application conduit136and is forced through the orifice28for direct application on the strand12, which is positioned at the orifice28. The first and second branches174a,174bmay be positioned on opposite sides of the orifice28. The second fluid F2may be, for example, air, and may be discharged from the first branch174aand second branch174bat varying pressures causing the first fluid F1to fluctuate across a width of the strand12during application.

Accordingly, in the examples above, a contact nozzle assembly may be provided that applies an adhesive directly to a strand of material in a non-linear pattern. Thus, the fluid application device10may be operated at increased line speeds associated with contact nozzle configurations, while still providing a non-linear pattern of adhesive applied onto the strand. A non-linear adhesive pattern may allow for the strand or strands12to be bonded to the substrate14over a larger rotational range of the strands12compared to a linear application pattern. That is, with a linear adhesive pattern, the strand or strands12must be accurately positioned relative to the substrate so that the linearly applied adhesive contacts the substrate. With the non-linear pattern, the strand or strands12may be rotated, intentionally or unintentionally due to movement of the strand through the device10, and still provide a sufficient bonding surface between the strand12and the substrate14. In addition, the non-linear pattern may allow the strand or strands12to be bonded to the substrate14at points or segments, rather than in a continuous line. This configuration may provide added flexibility, as the strand or strands12are allowed to freely stretch and contract along portions between the bonded segments.

FIG. 6is a front view of the components of a nozzle assembly222according to another embodiment of the present disclosure.FIGS. 7A-7Fare enlarged plan views of the components of the nozzle assembly222ofFIG. 6. Referring to the embodiment inFIGS. 6 and 7A-7F, the first fluid F1may be applied to a strand12of material from opposed first and second branches374a,374bof one or more application conduits336at varying pressures. Accordingly, the first fluid F1may be fluctuated across a width of the strand12during application onto the strand12. In this embodiment, a second fluid F2is not used to control application of the first fluid F2on the strand12. Rather, the first fluid F1is discharged from opposing branches374a,374band is fluctuated as result of varying discharge pressures.

Referring toFIGS. 6 and 7A-7F, the first conduit330may include a first inlet (not shown) at a side of the nozzle assembly222facing the adjacent component, such as the adapter24. The first conduit330is configured to receive the first fluid F1from the first fluid supply module18via the first inlet (not shown). In one embodiment, the first conduit330includes a first portion346that is generally elongated in a width direction. The first conduit330may further include one or more body feed holes356(FIG. 7B) aligned with and fluidically connected to first portion346.

Referring toFIGS. 6 and 7C, the first conduit330further includes at least one flow-splitting section342. In one embodiment, the flow-splitting section342may be formed as a generally body-shaped portion having a head360, first and second arms362a,362band first and second legs364a,364b.

Referring toFIGS. 6 and 7B, the application conduit336includes the first branch374aand the second branch374bas noted above. In one embodiment, the first and second branches374a,374bare angled relative to one another so as to form a substantially V-shaped cross-section. The first and second branches374a,374bare in fluid communication with and converge at the orifice228, where the first fluid F1may be applied to the strand12. The first branch374aand second branch374bare fluidically connected to the first leg364aand the second leg364b, respectively, of the flow-splitting section342. Accordingly, the first branch374amay receive the first fluid F1from the first leg364aand the second branch374bmay receive the first fluid F1from the second leg364b. In the example shown inFIGS. 6 and 7B, three application conduits336are provided. However, it is understood that the present disclosure is not limited to the configuration, and the number of application conduits336may vary to accommodate a different number of strands12.

With reference toFIGS. 6, 7D and 7E, the nozzle assembly222further includes an oscillator conduit334. The oscillator conduit334is fluidically connected to the first conduit330at the flow-splitting section342and is configured to vary a pressure of the first fluid F1flowing through the flow-splitting section342, in part, by creating or amplifying a turbulent flow in the first fluid F1.

In one embodiment, the oscillator conduit334includes one or more pairs of arm feed holes, each pair of arm feed holes including first and second arm feed holes366a,366band one or more pairs of leg feed holes, each pair of leg feed holes including first and second leg feed holes368a,368b. The first and second arm feed holes366a,366bare aligned with and fluidically connected to the first arm362aand second arm362b, respectively, of the flow-splitting section342. Likewise, the first and second leg feed holes368a,368bare aligned with and fluidically connected to the first leg364aand the second leg364b, respectively, of the flow-splitting section342. The oscillator conduit334further includes one or more pairs of oscillator slots, each pair of oscillator slots including first and second oscillator slots370a,370b. The first oscillator slot370ais aligned with and fluidically connected to the first arm feed hole366aand first leg feed hole368a. Likewise, the second oscillator slot370bis aligned with and fluidically connected to the second arm feed hole366band the second leg feed hole368b. Accordingly, the first oscillator slot370ais configured to receive the first fluid F1from the first leg feed hole368aand discharge the first fluid F1through the first arm feed hole366a. Similarly, the second oscillator slot370bis configured to receive the first fluid F1from the second leg feed hole368band discharge the first fluid F1through the second arm feed hole366b.

In one embodiment, the first fluid F1may be received in the first portion346of the first conduit330via the first inlet (not shown). The body feed hole356is configured to receive the first fluid F1from the first portion346of the first conduit330. In one embodiment, there may be three body feed holes356configured to receive the first fluid F1from the first portion346. However, it is understood that the number of body feed holes356may vary and is not limited to this example. The number of body feed holes356may correspond to the number of application conduits336and the number of strands of material12that may be accommodated by the nozzle assembly222. In addition, those having ordinary skill in the art will appreciate that additional arm feed hole pairs366a,366band leg feed hole pairs368a,368b, along with additional oscillator slot pairs370a,370bmay be provided at the oscillator conduit334to correspond to additional flow-splitting sections342.

The head360of the flow-splitting section342is in fluid communication with the body hole356and is configured to receive the first fluid F1from the body feed hole356. The first fluid F1may flow from the head360to the first and second legs364a,364b. The first and second branches374a,374bof the application conduit336are configured to receive the first fluid F1from the respective first and second legs364a,364bof the flow-splitting section342. In one embodiment, the first conduit330may include three flow-splitting sections342. It is understood, however, that this example is non-limiting, and that the number of flow-splitting sections342may vary. The number of flow-splitting sections342may correspond to the number of body feed holes356, such that each body feed hole356is in fluid communication with a head360of a respective flow-splitting section342.

A turbulent flow of the first fluid F1in the first conduit330may be received at the first and second legs364a,364bfrom the head360at the flow-splitting section342at different pressures. In one embodiment, at least a portion of the fluid at the higher pressure flows into the oscillator conduit334, while fluid at the lower pressure flows to a corresponding first branch374aor to a second branch374bof the application conduit336.

For example, the first fluid F1may be initially received in the first leg364aat a higher pressure, and in the second leg364bat a lower pressure relative to the first leg364a. The first fluid F1received in the first leg364a, at the higher pressure, may be at least partially discharged to the first leg feed hole368aof the oscillator conduit334and then into the first oscillator slot370a. The first fluid F1may then flow through the first oscillator slot370aand be discharged through the first arm feed hole366aof the oscillator conduit334. This portion of first fluid F1may then be received in the first arm362aof the flow-splitting section342. Another portion of the higher pressure first fluid F1initially received in the first leg364ais discharged to the first branch374aof the application conduit336.

Meanwhile, the first fluid F1initially received in the second leg364b, at the lower pressure, may be discharged from the second leg364band received in the second branch374bof the application conduit336.

The first fluid F1received at the first arm362afrom the oscillator conduit334, at a higher pressure, may then flow into the second leg364bof the flow-splitting section342due to the initial lower pressure of the first fluid F1in the second leg364b. This causes the second leg364bto become the leg having the first fluid F1at the higher pressure, while the first leg364abecomes the leg having the first fluid F1at the lower pressure. That is, the first and second legs364a,364balternate between receiving the first fluid F1at a higher pressure and a lower pressure by way of the oscillator conduit334.

With the second leg364bcontaining the first fluid F1at a higher pressure than the first fluid F1in the first leg364a, a portion of the first fluid F1may be discharged to the second leg feed hole368bof the oscillator conduit334and then into the second oscillator slot370b. The first fluid F1may then flow through the second oscillator slot370band be discharged through the second arm feed hole366bof the oscillator conduit334. This portion of first fluid F1may then be received in the second arm362bof the flow-splitting section342. Another portion of the higher pressure first fluid F1received in the second leg364bis discharged to the second branch374bof the application conduit336.

Meanwhile, the first fluid F1in the first leg364a, now at the lower pressure, may be discharged from the first leg364ato the first branch374aof the application conduit336.

Accordingly, the first fluid F1may be supplied to the first branch374aand the second branch374bat alternating higher and lower relative pressures. The varying pressures of the first fluid F1supplied to the first and second branches374a,374bcauses the first fluid F1to be discharged to the orifice228at different pressures, thereby causing the first fluid F1to be fluctuated back and forth across a width of the strand12. In one embodiment, this configuration causes a lateral fluctuation in first fluid F1as it is applied onto the strand12, such that the first fluid F1is applied in an irregular, non-predetermined, and/or non-repeatable pattern.

With further reference toFIGS. 6 and 7A-7C, the nozzle assembly222may include a depending guide section232having guide slots234similar to the guide slots34described in the embodiments above. For example, the nozzle assembly222may include three guide slots234, each configured to receive a strand of material12. Each guide slot234may include an open end236and a closed end238. The closed end238may act as a stop to position the strand12relative to the orifice28. The open end236of each guide slot234may include a portion shaped generally as an inverted “v” to assist in guiding the strand12into the guide slot234.

The nozzle assembly222may also include securing openings76and fastening holes80as described in the embodiments above and shown inFIGS. 1-5. In the examples shown inFIGS. 6 and 7A-7F, the nozzle assembly22may include two securing openings76and three fastening holes80. However, it is understood that these examples are non-limiting and different configurations are envisioned. The securing openings76are configured to receive securing elements74, and the fastening holes80are configured to receive fasteners82.

The nozzle assembly222may be formed from a plurality of laminated or stacked plates322a-fsecured together by the fasteners82, and in some embodiments, at least in part by the securing elements74as well. The securing openings76and fastening holes80may extend through each plate. Referring toFIGS. 6 and 7A-7F, the nozzle assembly222may be formed by six plates, including a first plate322a, a second plate322b, a third plate322c, a fourth plate322d, a fifth plate322eand a sixth plate322f. It is understood that a different number of plates may be implemented in the nozzle assembly222so long as the general concepts described above are preserved.

Referring toFIG. 7A, in one embodiment, the first plate322amay include the first portion346of the first conduit330, securing openings76and fastening holes80. Similar to the guide slots34described in the embodiments above, each guide slot234may be formed by, for example, a first guide slot segment234a, a second guide slot segment234b(FIG. 7B) and a third guide slot segment234c(FIG. 7C) formed in adjacent plates and aligned so as to receive the strand of material. The first guide slot segments234amay be formed in the first plate322a.

Referring toFIG. 7B, the second plate322bmay include body feed holes356, application conduits336, securing openings76and fastening holes80. The second plate322bmay also include second guide slot segments34band orifices28.

Referring toFIG. 7C, the third plate322cmay include flow-splitting sections342, third guide slot segments34c, securing openings76and fastening holes80. The orifices28may be defined in the second plate322bbetween the first plate322aand third plate322c. The depending guide section232may be formed on the first plate322a, second plate322band third plate322c. Referring toFIGS. 6 and 7A-7C, the aligned first, second and third guide slot segments234a-cmy form a single guide slot234, and three guide slots234may be formed across a width of the nozzle assembly222. Additionally, the third plate322cmay include three flow-splitting sections342. However, it is understood that the number of guide slots234and flow-splitting sections is not limited thereto.

Referring toFIG. 7D, the fourth plate322dmay include the first and second arm feed holes366a,366band the first and second leg feed holes368a,368bof the oscillator conduit334. The fourth plate322dmay also include securing openings76and fastening holes80. In one embodiment, the fourth plate322dmay include three pairs of first and second arm feed holes366a,366b, and three pairs of first and second leg feed holes368a,368b. However, the present disclosure is not limited thereto.

Referring toFIG. 7E, the fifth plate322emay include first and second oscillator slots370a,370bof the oscillator conduit334. In addition, the fifth plate322emay include securing openings76and fastening holes80. In one embodiment, the fifth plate322emay include three pairs of first and second oscillator slots370a,370b, but the present disclosure is not limited thereto.

With reference toFIG. 7F, the sixth plate322fmay include securing openings76and fastening holes80. The sixth plate322fmay seal the oscillator conduit334at the first and second oscillator slots370a,370b.

In the examples above, the first fluid F1may be directly, i.e., contactingly, applied on a strand or strands12in a non-linear pattern. Accordingly, the fluid application device10may be operated at increased line speeds when compared to non-contact nozzle configurations, while still providing a benefits of a non-linear application pattern detailed above.

It should also be understood that various changes and modifications to the presently disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.