Patent Description:
<CIT> discloses a gun for applying polyurethane foam or other elastomeric coatings.

The known fluid application devices are constructed differently depending on a particular application, for example, contact or non-contact strand coating, spray, or slot die coating applications. For example, the known fluid application devices require different nozzle types or configurations for certain applications. In addition, some applications require air to be discharged from the nozzle to act on the discharged hot melt adhesive, thereby controlling an application pattern of the adhesive, or that air be introduced within the nozzle for discharging the hot melt adhesive from the nozzle as a spray.

Some known fluid application devices are also configured to vary a coat weight of the fluid to be applied on the component. For example, in a fluid application device having a slot die assembly, separate inlet ports and associated passageways and discharge ports may be provided to allow for multiple flows of the hot melt adhesive to be individually controlled. Accordingly, a first coat weight of hot melt adhesive may be applied from one discharge port, and an add-on coat weight may be selectively applied to the first coat weight from a second discharge port.

In a known strand coating application, known fluid application devices include a metering device having a plurality of gear pumps mounted directly on a manifold of an applicator head. The metering device is configured to receive the hot melt adhesive from a remote supply source and meter the hot melt adhesive to individual nozzles, individual nozzle orifices, or individual valve modules to provide different volumes of the hot melt adhesive to the nozzle. However, such a fluid application device does not include preheated air, and thus, may be limited in the number of application patterns that can be produced.

Further, in some known fluid application devices, an application pattern of the hot melt adhesive, for example, a stitch-type pattern (e.g., an on-off-on-off pattern), may be limited by the on-off cycle time of the valve. For example, with an elasticated strand moving at a constant line speed, the minimum distance between hot melt applications on the strand is dependent upon the length of time required for a valve of the module to move from an open position to a closed position, and then return to the open position. In known fluid application devices, the on-off cycle time is around <NUM>. Thus, to reduce a length of hot melt adhesive application and/or gaps between the adhesive when applying the adhesive in a stitch pattern, the line speed of the strand must be reduced, thereby increasing manufacturing time and reducing output.

A manufacturer typically uses different applicator equipment for the various applications above, which may result in high equipment costs, significant amounts of time where equipment is not being utilized, and a reduction in available floor space in a manufacturing facility.

Accordingly, it is desirable to provide a fluid application device that may be configured to selectively provide heated air, allow different fluid coat weights, and interchangeably accept nozzles of different configurations, including slot die assemblies and laminated plate nozzles, for different applications. It is also desirable to reduce on-off cycle time, thereby increasing the number of possible application patterns and/or allowing for increased line speeds.

According to one aspect, a modular fluid application device includes a module base and first and second fluid passageways extending within the module base and intersecting to form a nozzle fluid supply passageway. The modular fluid application device also includes a fluid outlet formed on a nozzle mounting surface of the module base fluidically connected to the nozzle fluid supply passageway, a base air passageway extending in the module base and an air outlet formed on the nozzle mounting surface fluidically connected to the base air passageway. A first module bank is removably mounted on the module base and includes at least one first module having a first valve configured to control a flow of fluid in the first fluid passageway. A second module bank is removably mounted on the module base and includes at least one second module having a second valve configured to control a flow of fluid in the second fluid passageway. The first module and the second module are mounted at an angle relative to one another.

The modular fluid application device further includes a filter block removably secured and fluidically connected to the module base. The filter block includes first and second fluid supply inputs and first and second filters fluidically connected to the first and second fluid supply inputs, respectively, such that the first and second filters are configured to receive the fluid from respective first and second fluid supply inputs. The first module may be fluidically connected to the first filter to receive the fluid from the first filter, and the second module may be fluidically connected to the second filter to receive the fluid from the second filter.

The modular fluid application device may further include an air preheater removably secured and fluidically connected to the module base. The air preheater may include and air supply inlet, one or more heating elements configured to heat air received through the air supply inlet, an air passageway configured to receive the heated air and an air preheater outlet for discharging the air from the air preheater. The one or more heating elements may be spiral heaters. The base air passageway may be fluidically connected to the air preheater to receive air from air preheater.

The modular fluid application device may further include a nozzle removably mounted and fluidically connected to the module base on the nozzle mounting surface. The nozzle may include a front plate, a backing plate and a plurality of laminated nozzle plates secured therebetween. The nozzle may be configured to receive the air and the fluid from the module base.

The first module and the second module may be operable to provide a first operating state in which the first valve is open and the second valve is closed to provide a first volume of fluid to the nozzle, a second operating state in which the fist valve is closed and the second valve is open to provide a second volume of fluid to the nozzle, a third operating state in which the first valve is open and the second valve is open to provide a sum of the first volume and the second volume of fluid to the nozzle, and a fourth operating state in which the first valve is closed and the second valve is closed to substantially prevent the fluid from flowing to the nozzle.

<FIG> is a front view of a modular fluid application device <NUM>, according to an embodiment, <FIG> is a side view of the modular fluid application device <NUM> of <FIG>, and <FIG> is a top view of the modular fluid application device <NUM> of <FIG>. The modular fluid application device <NUM> includes a module base <NUM> and a first module bank <NUM> removably mounted on the module base <NUM> having one or more first modules <NUM>. The modular fluid application device <NUM> also includes a second module bank <NUM> removably mounted on the module base <NUM> having one or more second modules <NUM>. One or more nozzles <NUM> may be releasably secured to a nozzle mounting surface <NUM> (see <FIG>) of the module base <NUM> with a suitable fastener (not shown). A suitable fastener includes, for example, a bolt configured to extend through the nozzle <NUM> for receipt in a corresponding opening of the module base <NUM>. The modular fluid application device <NUM> may also include one or more mounting brackets <NUM> for mounting to a support (not shown). In one embodiment, the modules <NUM>, <NUM> are fluidically connected to the module base <NUM>.

In one embodiment, the modular fluid application device <NUM> includes an air preheater <NUM> removably secured to the module base <NUM>. The air preheater <NUM> includes an air supply inlet <NUM> connected to an air supply (not shown). A preheater power connection <NUM> is configured for connection to a power source (not shown).

In addition, the modular fluid application device <NUM> includes a filter block <NUM> removably secured to the module base <NUM>. According to the invention, the filter block <NUM> includes a first fluid supply input <NUM> and a second fluid supply input <NUM>, each configured to receive a fluid, such as a hot melt adhesive, from one or more remotely positioned fluid supplies (not shown). In one embodiment, the first and second fluid inputs <NUM>, <NUM> may each be connected to the one or more fluid supplies by a flexible supply hose (not shown). In one embodiment, the same fluid is received by the first and second fluid supply inputs <NUM>, <NUM>. Thus, in one embodiment, the fluid may be provided to the modular fluid application <NUM> as two separate, discrete flows.

<FIG> is another front view of the modular fluid application device <NUM>, according to an embodiment, with the nozzle(s) <NUM> removed from the nozzle mounting surface <NUM>. As can be seen in <FIG>, the nozzle mounting surface <NUM> is formed with one or more fluid outlets <NUM> through which the fluid may be discharged from the module base <NUM> for receipt in corresponding nozzle inlets (not shown) of the one or more nozzles <NUM>. The nozzle mounting surface <NUM> may further be formed with one or more air outlets <NUM> though which air may be discharged from the module base <NUM> for receipt in corresponding nozzle air inlets (not shown) of the one or more nozzles <NUM>. In this manner, a nozzle <NUM> of the one or more nozzles may be fluidically connected to the module base <NUM> to receive the fluid, such as a hot melt adhesive, and air, such as the preheated air, from the module base <NUM>.

<FIG> is a cross-sectional view taken at F-F in <FIG>, showing a cross section of the air preheater <NUM>. In one embodiment, the air preheater <NUM> may include one or more heating elements <NUM> configured to preheat air received in the air preheater <NUM> via the air supply inlet <NUM>. The one or more heating elements <NUM> may be, for example spiral heating elements. The heating elements <NUM> may be powered by way of the power connection <NUM>.

<FIG> is a cross-sectional view of the modular fluid application device <NUM> taken at B-B in <FIG>, and <FIG> is an enlarged view showing a portion of the modular fluid application device <NUM>, taken at detail C in <FIG>. In one embodiment, a first module <NUM> of the first module bank <NUM> and a second module <NUM> of the second module bank <NUM> may be removably mounted on the module base <NUM> at an angle relative to one another with respect to a machine direction 'M' for example, to extend in a non-parallel relationship. Accordingly, the module base <NUM> may include first and second seats <NUM>, <NUM> to which the first and second modules <NUM>, <NUM> are mounted.

The first and second modules <NUM>, <NUM> may be formed as respective valve modules each including a valve <NUM>, <NUM> having a valve plug <NUM>, <NUM> movable between a closed position where fluid flow is restricted or prohibited through the respective first and second fluid passageways <NUM>, <NUM> and an open position where fluid flow is permitted through the respective first and second fluid passageways <NUM>, <NUM>. In addition, each of the first and second modules <NUM>, <NUM> either include or form in combination with a portion of the module base <NUM>, first and second inlet chambers <NUM>, <NUM> in fluid communication with the filter block <NUM>. The first and second inlet chambers <NUM>, <NUM> are configured to receive the fluid from the first and second filters <NUM>, <NUM>, respectively. In one embodiment, the first inlet chamber <NUM> is fluidically connected to the first filter <NUM> by a first module supply passageway <NUM> and the second inlet chamber <NUM> is fluidically connected to the second filter <NUM> by a second module supply passageway <NUM>.

In one embodiment, the first and second modules <NUM>, <NUM> may include respective first and second solenoids <NUM>, <NUM> for actuating the valves <NUM>, <NUM>. For example, in one embodiment, the first and second solenoids <NUM>, <NUM> may be operated to allow for control air to pressurize the modules <NUM>, <NUM> and move the valves <NUM>, <NUM>, for example, the valve plugs <NUM>, <NUM> from the closed position to the open position and, in some embodiments, maintain the valves <NUM>, <NUM> in the open position. Conversely, the solenoids <NUM>, <NUM> may be operated to allow for control air to pressurize the modules <NUM>, <NUM> to move the valve <NUM>, <NUM> and plugs <NUM>, <NUM> from the open position to the closed position. In one embodiment, the valves <NUM>, <NUM> may be moved against a biasing force from respective biasing members, such as coil springs, which may hold the valve <NUM>, <NUM> and plugs <NUM>, <NUM> in a normally closed or open position as desired. Power may be supplied to the solenoids <NUM>, <NUM> by a module power connection <NUM> (<FIG>).

The first and second fluid passageways <NUM>, <NUM> may extend in one or both a respective module <NUM>, <NUM> and the module base <NUM>. In one embodiment, the first and second fluid passageways <NUM>, <NUM> intersect downstream from the first and second valve modules <NUM>, <NUM> to form one or more nozzle fluid supply passageways <NUM>. The nozzle fluid supply passageway(s) <NUM> fluidically connected to a corresponding fluid outlet <NUM> on the nozzle mounting surface <NUM>. In one embodiment, each valve module <NUM>, <NUM> may control fluid flow to two nozzle fluid supply passageways <NUM>.

<FIG> is another side view of the modular fluid application device <NUM> according to an embodiment, and <FIG> is a cross-sectional view of the modular fluid application device <NUM> taken at E-E in <FIG>, according to an embodiment. In one embodiment, the air preheater <NUM> is fluidically connected to the module base <NUM> such that the preheated air may be received in the module base <NUM> from the air preheater <NUM>. For example, in one embodiment, the air preheater <NUM> includes an air passageway <NUM> extending between the one or more heating elements <NUM> and an air preheater outlet <NUM> on a surface of the air preheater <NUM>. The module base <NUM> may include a base air inlet <NUM> positioned relative to the air preheater outlet <NUM> to receive the air from the air preheater <NUM>. A base air passageway <NUM> extends in the module base <NUM> from the base air inlet <NUM> to one or more air outlets <NUM> on the nozzle mounting surface <NUM> (<FIG>). The one or more air outlets <NUM> are fluidically connected to the base air passageway <NUM> so that the air may be discharged from the one or more air outlets <NUM> for receipt in the nozzle <NUM>.

According to the embodiments herein, the first module <NUM> and the second module <NUM> may be operated by moving the valves <NUM>, <NUM> between open and closed positions to provide respective volumes (i.e. volume flow rates) of the fluid to the one or more nozzles <NUM>. In one embodiment, the volume of the fluid provided to the nozzle <NUM> by each module <NUM>, <NUM> is dependent upon a volume flow rate of the fluid provided to the module from first and/or second metering devices (not shown), which may be positioned remotely and upstream from the filter block <NUM>. In one embodiment, the first metering device may provide the fluid to the first module <NUM>, via the filter block <NUM> and first filter <NUM>, at a first volume, and the second metering device may provide the fluid to the second module <NUM>, via the filter block <NUM> and second filter <NUM>, at a second volume. The first volume and the second volume may be controlled by the metering devices, and may be equal to, or different from one another. Accordingly, the first module <NUM> and the second module <NUM> may provide equal or different volumes of the fluid to the nozzle <NUM> depending on a desired application.

In the manner above, different operating states in which different volumes (i.e., volume flow rates) of the fluid are discharged from the nozzle <NUM> may be realized. For example, in a first operating state, the first module <NUM> may be open and the second module <NUM> may be closed to provide the first volume of the fluid to the nozzle <NUM>. In a second operating state, the first module <NUM> maybe closed and the second module <NUM> may be open to provide the second volume of fluid to the nozzle <NUM>. In a third operating state, the first module <NUM> and the second module <NUM> may both be open to provide the sum of the first volume and the second volume of fluid to the nozzle <NUM>. In a fourth operating state, the first module <NUM> and the second module <NUM> may both be closed to substantially prevent the fluid from being delivered to the nozzle <NUM>. In one embodiment, the modular fluid application device <NUM> may switch between operating states in a predetermined manner to discharge the fluid at a desired coat weight and/or stitch pattern. Fluid provided to the nozzle may be discharged for application onto a substrate, such as a strand or layer of material, substantially according to the volume at which the fluid was provided to the nozzle.

Referring again to <FIG>, in one embodiment, the nozzle <NUM> may be a laminated plate (LP) nozzle comprising a plurality of nozzle plates <NUM> secured between a face plate <NUM> and a backing plate <NUM>. The nozzle <NUM> is configured to receive the fluid and the air from the module base <NUM> through the backing plate and direct the fluid and air through nozzle <NUM> for discharge and application on a strand of material. In one embodiment, the air is discharged in a manner which causes the fluid to oscillate or vacillate, and in turn, to be applied on the strand in a non-linear pattern.

However, the present disclosure is not limited to the nozzle <NUM> described above and shown in <FIG>. For example, in one embodiment, the nozzle may be a spray nozzle in which the air and fluid are supplied to a common channel thereby causing the fluid to be sprayed in an atomized or droplet form. In some embodiments, the nozzle <NUM> and/or the plurality nozzle plates <NUM> may be formed as a unitary structure, instead of a laminated structure, for example, using known machining processes or additive manufacturing.

In one embodiment, the nozzle may be a LP nozzle configured for use in contact strand coating applications which may be performed without supplying air to the nozzle. Thus, in one embodiment, the modular fluid application device <NUM> may be assembled without the air preheater <NUM>, or operated without supplying preheated air to the nozzle <NUM>, for applications in which preheated air is not used.

In another embodiment, the nozzle may be a slot die assembly configured for substrate coating applications. The slot die assembly may include an adapter, a front plate, and a shim package secured therebetween in a manner which will be appreciated by those having skill in the art. The shim package may include a plurality of shims, one or more of which may include a discharge slot for discharging the fluid. Such a slot die assembly does not require preheated air. Accordingly, the modular fluid application device <NUM> may be assembled without the air preheater <NUM>, or operated without supplying preheated air to the nozzle <NUM>, for this application as well.

In the embodiments above, different fluid coat weights may be provided in the first, second, third and fourth operation states. However, in a disclosed but not claimed embodiment where different fluid coat weights are not desired, the filter block <NUM> may be replaced with a conventional single inlet filter block (not shown) configured to receive a single supply or flow of fluid at a predetermined flow rate and provide the single supply of fluid to a module for controlling flow of the fluid to the nozzle <NUM>. Alternatively, the filter block <NUM> described herein may be used while receiving a fluid flow into only one of the fluid inputs <NUM>, <NUM>, and/or maintaining one valve <NUM>, <NUM> in the closed condition while operating the other valve <NUM>, <NUM> to control the single flow of fluid to the nozzle <NUM>.

According to an embodiment described herein, the fluid may be received in the filter block <NUM> as at least two separate and discrete flows through the first and second supply inputs <NUM>, <NUM>. The fluid may be maintained as separate and discrete flows through the filter block <NUM>, the first and second modules <NUM>, <NUM> and into the module <NUM>. In one embodiment, the separate flows of the fluid may be combined in the nozzle fluid supply passageway <NUM> or controlled to flow alternately in the nozzle fluid supply passageway <NUM> based on operation of the valves <NUM>, <NUM> in the first and second modules <NUM>, <NUM>. In another embodiment, the single fluid flow may be provided to the modular fluid application device <NUM> and be split into two or more fluid flows by way of a manifold (not shown).

Moreover, in the embodiments above, the first and second modules <NUM>, <NUM> may be operated to reduce an on-off cycle time compared to a conventional fluid application device in which a single module controls fluid flow to a nozzle. For example, in the embodiments above, the first and second modules <NUM>, <NUM> may be operated simultaneously such that one of the modules <NUM>, <NUM> may be moving to the open position while the other of the modules <NUM>, <NUM> is moving to the closed position, thereby reducing the length of a time period in which fluid is not provided to the nozzle <NUM>. Accordingly, in one embodiment, a line speed of a substrate, such as an elasticated strand, may be increased compared a line speed of the same in a conventional single module fluid application device, while maintaining or reducing a length of a stitch application pattern (e.g., an on-off-on-off. application pattern). Moreover, the modular fluid application device <NUM> described herein may be operated to apply the fluid on a substrate, such as a strand or layer of material, at a variety of different coat weights without modifying the construction modular fluid application device <NUM>. Rather, the coat weights may be modified by operating the first and second modules <NUM>, <NUM>, while maintaining the ability to operate at the reduced on-off cycle times.

In one embodiment, the first and second modules <NUM>, <NUM> may be operably connected to a controller configured to control operation of the valves <NUM>, <NUM>, for example, by operating the solenoids <NUM>, <NUM>. The controller may include a processor, such as a microprocessor, and a memory configured to store program instructions relating to the operation of the modules <NUM>, <NUM>. The processor may execute the program instructions and control operation of the valves <NUM>, <NUM> and the solenoids <NUM>, <NUM> according to the program instructions. The controller may also include an input/output unit configured to allow for information, signals, instructions, communications and the like to be received by and/or transmitted from the controller.

The modular fluid application device <NUM> described in the embodiments above may be used to apply a fluid, such as a hot melt adhesive, onto a strand of material (including elasticated strands) or a layer of material, such as a barrier or shell layer. Such an application may be useful in the manufacture of nonwoven products including disposable hygiene products. However, the present disclosure is not limited thereto. It is understood that the fluid application device described herein may be used in other applications as well, for example, packaging.

In the embodiments above, various features from one embodiment may be implemented in, used together with, or replace other features in different embodiments as suitable.

All patents referred to herein, are hereby incorporated herein in their entirety, by reference, whether or not specifically indicated as such within the text of this disclosure.

Claim 1:
A modular fluid application device (<NUM>) comprising:
a module base (<NUM>);
a first fluid passageway (<NUM>) extending within the module base (<NUM>);
a second fluid passageway (<NUM>) extending within the module base (<NUM>) and intersecting the first fluid passageway to form a nozzle fluid supply passageway (<NUM>) downstream from the first and second fluid passageways;
a fluid outlet (<NUM>) formed on a nozzle mounting surface (<NUM>) of the module base and fluidically connected to the nozzle fluid supply passageway (<NUM>);
a base air passageway (<NUM>) extending in the module base (<NUM>);
an air outlet (<NUM>) formed on the nozzle mounting surface (<NUM>) and fluidically connected to the base air passageway;
a first module bank (<NUM>) removably mounted on the module base (<NUM>), the first module bank comprising at least one first module (<NUM>) having a first valve configured to control a flow of fluid in the first fluid passageway; and
a second module bank (<NUM>) removably mounted on the module base, the second module bank comprising at least one second module (<NUM>) having a second valve configured to control a flow of fluid in the second fluid passageway,
wherein the first module (<NUM>) and the second module (<NUM>) are mounted at an angle relative to one another and;
characterized by
further comprising a filter block (<NUM>) removably secured and fluidically connected to the module base (<NUM>);
wherein the filter block (<NUM>) comprises first and second fluid supply inputs (<NUM>, <NUM>) and first and second filters (<NUM>, <NUM>) fluidically connected to the first and second fluid supply inputs, respectively, such that the first and second filters are configured to receive the fluid from respective first and second fluid supply inputs.