Patent Document

TECHNICAL FIELD 
       [0001]    The present invention relates generally to an apparatus and method for forming one or more liquid streams having relatively small, well defined cross sectional areas which are normally directed to a target substrate, and for selectively interrupting and redirecting the flow of such liquid streams by application of gaseous fluid impingement jets transverse to the normal flow direction of the liquid streams. More specifically, the invention relates to an apparatus and method providing precise and substantially instantaneous switching between (i) a normal application mode in which a liquid stream is applied to a substrate and (ii) a diversion mode in which the liquid stream is redirected away from the substrate. Such switching is carried out in response to commands to develop desired fine scale treatment patterns across the substrate. 
       BACKGROUND OF THE INVENTION 
       [0002]    Systems that provide relatively fine scale treatment patterns of liquid across a target substrate by interruption of the applied liquid streams are generally known. In prior systems, multiple liquid streams are expelled under pressure from orifice openings arranged in close, side-by-side relation. The orifice openings are surrounded circumferentially by walls defining the openings. The pressure liquid streams normally project towards a target substrate but are intermittently interrupted by application of a transverse gas jet which redirects the liquid stream away from the target substrate and into a collection reservoir to be reused. When application of the gas jet is discontinued, the liquid streams resume along the initial path. Such systems are used typically to apply intricate patterns of dye or other liquids to textile substrates, although other substrates may likewise be treated if desired. 
         [0003]    While the prior systems work very well, it is a continuing challenge to provide improved definition in the applied pattern across the substrate while nonetheless delivering a sufficient quantity of dye or other liquid to the substrate to provide complete treatment. It is also a continuing challenge to provide reduced complexity in the system set-up as well as enhanced functionality in the collection of unused liquid. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides advantages and alternatives over prior constructions and practices by providing an improved system for application of liquid streams to a substrate. The system of the present invention incorporates open face flow channels prior to discharge along an unconstrained flow path. 
         [0005]    The present invention further provides an improved self-aligning modular assembly for delivery of impingement stream to the liquid streams. The present invention further provides an improved arrangement for collection of the liquid stream in a diverted flow path in response to application of the impingement stream, without excess residue build-up. 
         [0006]    In accordance with one exemplary aspect, the present invention provides an apparatus for intermittently applying one or more liquid streams to a target substrate. The apparatus includes a liquid supply in the form of a manifold for holding a liquid and a plurality of liquid conveyance channels in fluid communication with the liquid supply. The liquid conveyance channels are adapted to carry liquid away from the manifold and towards the target substrate. At least one of the liquid conveyance channels includes a first segment defining a substantially fully enclosed liquid passageway and a second segment downstream from the first segment. The second segment has an open-face flume configuration. The end of the second segment defines an open sided liquid outlet projecting towards the target substrate such that a liquid stream exiting the second segment is expelled towards the target substrate along a normal flow path substantially aligned with the liquid conveyance channel. A plurality of impingement jet directional passages are positioned at an elevation between the liquid conveyance channels and the target substrate. At least one of the impingement jet directional passages has a central axis oriented in an intersecting relation to the undisrupted flow path of a corresponding liquid stream expelled from the corresponding liquid conveyance channel. The impingement jet directional passages are adapted to selectively deliver an impingement stream to divert the corresponding liquid stream away from the undisrupted flow path into a diverted flow path. A liquid collection assembly captures the liquid stream in the diverted normal flow path. 
         [0007]    In accordance with another exemplary aspect, the present invention provides an apparatus for intermittently applying one or more liquid streams to a target substrate. The apparatus includes a liquid supply in the form of a manifold for holding a liquid and a channel module with a plurality of liquid conveyance channels in fluid communication with the manifold. The liquid conveyance channels are adapted to carry liquid away from the manifold and towards the target substrate. The end of the liquid conveyance channel defines a liquid outlet projecting towards the target substrate such that a liquid stream exiting the liquid conveyance channel is expelled towards the target substrate along a normal flow path substantially aligned with the liquid conveyance channel. Below the liquid outlet, the channel module has a landing. The landing has impingement jet positioning apertures with central axis that align with the central axis of a corresponding liquid conveyance channel. The apparatus also includes an impingement jet module having a plurality of individually activatable impingement jet tubes mounted in an impingement jet body. The impingement jet tubes include distal ends extending from the impingement jet body, which are arranged in a pattern adapted for coaxial, plug-in into corresponding impingement jet positioning apertures in the landing of the channel module. The impingement jet tubes are adapted to selectively deliver the impingement stream to divert the corresponding liquid stream away from the undisrupted flow path into a diverted flow path. A liquid collection module captures the liquid diverted from the normal flow path. 
         [0008]    In accordance with still another exemplary aspect, the present invention provides an apparatus for intermittently applying one or more liquid streams to a target substrate. The apparatus includes a liquid supply in the form of a manifold for holding a liquid and a channel module with a plurality of liquid conveyance channels in fluid communication with the manifold. The liquid conveyance channels are adapted to carry liquid away from the manifold and towards the target substrate. The end of the liquid conveyance channel defines a liquid outlet projecting towards the target substrate such that a liquid stream exiting the liquid conveyance channel is expelled towards the target substrate along a normal flow path substantially aligned with the liquid conveyance channel. A plurality of impingement jet directional passages are positioned at an elevation between the liquid conveyance channels and the target substrate. At least one of the impingement jet directional passages has a central axis oriented in an intersecting relation to the undisrupted flow path of a corresponding liquid stream expelled from the corresponding liquid conveyance channel. The impingement jet directional passages are adapted to selectively deliver an impingement stream to divert the corresponding liquid stream away from the undisrupted flow path into a diverted flow path. A liquid collection module captures the liquid diverted from the normal flow path. The liquid collection module having an entrance, funnel section, and an exit. The entrance is position for receiving the liquid stream in the diverted flow path, the funnel section is in fluid communication with the entrance and reduces in cross section as it progresses away from the entrance, and an the exit allows the fluid progressing through the liquid collection module to exit the collection module. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The accompanying drawings, which are incorporated in and which constitute a part of this specification, illustrate a potentially preferred embodiment of the present invention, and together with the general description above and the detailed description below, serve to explain the principles of the invention wherein: 
           [0010]      FIG. 1  is a schematic cut-away view illustrating an exemplary apparatus in accordance with the present invention showing a liquid jet assembly projecting a single pressure liquid stream towards a carpet substrate; 
           [0011]      FIG. 2  is a view similar to  FIG. 1  showing application of an impinging gaseous deflection jet from an impingement jet assembly redirecting the liquid stream away from the substrate and into a collection tray assembly; 
           [0012]      FIG. 3  is the schematic cut-away view of the liquid jet module showing the manifold component, the channel component, and the liquid streams projecting onto the carpet substrate; 
           [0013]      FIG. 4  is a schematic view taken generally along the line  4 - 4  in  FIG. 3  illustrating the channel liquid channels in the channel body, and the flow of liquid streams from the manifold chamber to the carpet substrate; 
           [0014]      FIG. 5  is a schematic view taken generally along line  5 - 5  in  FIG. 4  with an abutting channel body cover shown in phantom; 
           [0015]      FIG. 6  is a schematic view taken generally along line  6 - 6  in  FIG. 5  showing the grooves in the channel body of the liquid jet module; 
           [0016]      FIG. 7  is a schematic view illustrating a impingement jet module in place with the channel body of the liquid jet module; 
           [0017]      FIG. 8  is a view similar to  FIG. 7  showing the impingement jet delivery module separated from the channel body; 
           [0018]      FIG. 9  is a schematic cut-away view illustrating the collection module from  FIGS. 1 and 2  for capture of a liquid stream in a diverted flow path; and 
           [0019]      FIG. 10  is a view taken generally along line  10 - 10  in  FIG. 9 . 
       
    
    
       [0020]    Before the embodiments of the invention are explained in detail, it is to be understood that the invention is in no way limited in its application to the details of construction and/or the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use herein of “including”, “comprising”, and variations thereof is meant to encompass the items listed thereafter and equivalents, as well as additional items and equivalents thereof. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0021]    Reference will now be made to the drawings, wherein to the extent possible, like reference numerals designate like characters throughout the various views. Referring now to  FIGS. 1 and 2 , there is shown a cross-sectional view of an exemplary liquid-jet application system  10 . As illustrated, the liquid-jet application system  10  generally includes a liquid jet module  100 , an impingement jet module  200  and a collection module  300 . A pressurized liquid supply  90 , holding a liquid, such as an ink, dye, or the like, under pressure, provides the liquid to the liquid jet module  100 . The pressurized liquid passes through the liquid jet module  100  and is emitted as pressurized, coherent liquid streams  11 . As shown in  FIG. 1 , the liquid stream  11  may be applied as an undisrupted flow path  15  against the surface of a target substrate  20 . In the illustrated arrangement, the substrate  20  is a textile such as a carpet, pile fabric, or the like. However, it is likewise contemplated that the substrate may be virtually any material to which a liquid pattern may be applied. When it is desired that the liquid stream  11  does not reach the substrate  20 , the impingement jet module  200  provides an impingement stream  19  that engages the liquid stream  11  and creates a diverted flow path  16  for the liquid stream  11  into the collection module  300 , as shown in  FIG. 2 . 
         [0022]    As illustrated by the directional arrows in  FIGS. 1 and 2 , the substrate  20  may move relative to the liquid jet application system  10  such that the undisrupted flow path  15  of the liquid stream  11  will apply a treatment pattern of the liquid as a line or line segment that is oriented generally parallel to the direction of travel for the substrate  20 . During periods when the impingement jet module  200  emits an impingement stream  19  creating the diverted flow path  16 , the liquid stream  11  is diverted from the substrate  20  and the portion of the substrate  20  passing under the liquid jet module  100  goes untreated by the liquid stream  11 . By way of example only, and not limitation, in the event that the substrate  20  is a carpet fabric and the liquid stream  11  is a dye, the undisrupted flow path  15  of the liquid stream  11  will dye the carpet substrate  20  with a line or line segment generally parallel to the direction of travel of the carpet substrate  20 . When the impingement jet module  200  emits the impingement stream  19 , the liquid stream  11  will have the diverted flow path  16  causing liquid stream  11  to divert into the collection module  300  and the portion of the carpet substrate  20  passing below the liquid stream  11  will remain undyed. By having a series of liquid jet application systems  10  perpendicular to the direction of travel of the carpet substrate  20 , the dye can be applied across the width of the carpet substrate  20 . By having a plurality of liquid jet application systems  10  in series in the direction of travel for the substrate  20 , each liquid jet application system  10  can apply liquid streams  11  of different liquids, such as different dye colors, across the surface of the substrate  20  to obtain different patterns of the different liquids (such as different colors) on the substrate  20 . 
         [0023]    Referring now to  FIG. 3 , the liquid jet module  100  generally includes a manifold component  120  and a liquid channel component  130 . In the embodiment illustrated, the liquid channel component  130  includes liquid channels  112  that are in fluid communication with a manifold chamber  111  in the manifold component  120 . Opposite to the manifold component  120 , the liquid channels  112  each have a liquid discharge end  116  that the liquid streams exit the channel component  130 . The liquid channels  112  are formed by groves  141  in a channel body  140  and a channel block cover  150 . The liquid channels  112  in the liquid channel component  130  are. In the embodiment illustrated, the manifold chamber  111  is primarily formed by a manifold body  120 , which is enclosed by the channel body  140  and the channel body cover  150 . The pressurized liquid supply  90  is in fluid communication with the manifold chamber  111 , and the manifold chamber  111  provides a supply source feeding the liquid through the liquid discharge ends  116  in the array of liquid channels  112  to create the liquid streams  11  that are emitted towards the substrate  20 . 
         [0024]    It is contemplated that each liquid stream  11  will have a relatively small cross-sectional area to provide a finer pattern control on the application of liquid streams  11  across the substrate  20 . As will be appreciated and illustrated in  FIG. 4 , such fine diameter streams may be arranged in a side-by-side arrangement to one another so as to define a substantially continuous curtain of liquid oriented transverse to the travel direction of the substrate  20 . Such an arrangement permits detailed liquid application patterns across the target substrate  20  by selectively discontinuing individual liquid streams  11  and/or groups of liquid streams  11 . By way of example only, and not limitation, the liquid streams  11  may have a diameter of less than about 150 mils, and more preferably less than about 100 mils, and most preferably about 3 to about 30 mils, although greater or lesser effective diameters may likewise be utilized. In order to provide fine-scale patterning across the substrate  20 , it is desirable to maintain the cross sectional integrity of the liquid stream  11  along the travel path between the liquid jet module  100  and the substrate  20 . The present invention provides a multi-stage liquid travel path for delivery of the liquid stream  11  from the manifold chamber  111  to the substrate  20 , which is believed to improve the cross sectional integrity of the liquid stream  11  from the liquid jet module  100  to the substrate  20 . 
         [0025]    As illustrated in  FIGS. 3 and 4 , the liquid streams  11  progress from the manifold chamber  111  into liquid channels  112  with an enclosed first stage  12  and then through a open directed second stage  13 , then exits the liquid channels  112  through liquid discharge ends  116  associated with individual liquid channels  112  along an unconstrained third stage  14  to the substrate  20 . In the enclosed first stage  12 , the liquid forming the liquid streams  11  passes through an enclosed first segment  114  of the of the liquid channel  112  created by the grooves  141  in the channel body  140  which are enclosed by the channel body cover  150 . As illustrated in  FIG. 6 , the grooves  141  in the channel body  140  have a substantially rectangular shaped cross section, although other geometries may be used if desired, such as substantially circular or “U” shaped cross sections. Also the face the channel body cover  150  enclosing the grooves  141  in the embodiment illustrated is substantially flat, although it may include complementary grooves for alignment with the grooves  141  in the face of the channel body  140 . In the open directed second stage  13 , the liquid forming the liquid streams  11  passes through open flume second segment  113  created by the grooves  141  in the channel block  140 , which are not enclosed by the channel body cover  150 . That is, the liquid stream  11  is not bounded on all sides, such as being bounded by only two or three sides. In this area of the channel body  140 , the channel body cover  150  does not extend to cover the groves  141 , thereby creating the open flume-like configuration. Thus, the liquid streams  11  within the second segment  115  have an outer face which is free from an opposing constraining boundary surface and liquid traveling along the liquid channels  112  transitions from the enclosed first segment  114  in the first stage  12  to the open-faced second segment  115  second stage  13 . Following the second stage  13  created by the open faced second segment  113 , the liquid streams  11  exit the liquid channels  112  through associated liquid discharge ends  116  along an unconstrained third stage  14  of the liquid conveyance path in which the liquid streams  11  are normally substantially aligned with the liquid channels  112 , but no longer are bounded or guided by the liquid channels  112 . In this third stage  14  the liquid streams  11  are unconstrained and unguided by external boundary surfaces. 
         [0026]    It is believed that transitioning from the enclosed first stage  12  to the open faced second stage  13  prior to discharge into the unbounded space of unconstrained third stage  14  is beneficial in promoting the coherency and overall stability of the liquid streams  11 . While not meaning to be constrained to a particular theory, it is believed that the open face of the second stage  13  allows the liquid stream  11  to dissipate static pressure before being released into an unconstrained or unguided stream. It is believed that a sudden abrupt change from a fully enclosed stream to a completely unenclosed stream may result in the expansion of the static pressure in the liquid stream to create cross sectional disruptions that will unpredictably expand the cross sectional size of the stream, or create uneven cross sections in the stream prior to being received by the substrate  20 . In practice, the length of the second stage  13  is preferably at least four (4) times the largest cross-sectional dimension of the liquid channels  112  provides an improved transition and guidance of the liquid stream that minimizes these disruptions. By way of example only, and not limitation, according to one practice the width dimension of the liquid channels  112  in the second segment  115  is about 14 mils. Accordingly, in that exemplary arrangement, the length of the second stage  13  is preferably about 56 mils or greater. Of course, larger and smaller effective diameters may likewise be utilized, if desired. As shown in  FIG. 5 , the terminal ends of the second segment  115  define open sided outlets projecting towards the target substrate  20 . 
         [0027]    The liquid streams  11  will travel from the liquid channels  112  to the substrate  20  as substantially cohesive and stable units. However, it is also desirable to have the capability to substantially instantaneously prevent the liquid stream  11  from being applied to the substrate  20 , followed by substantially instantaneous reapplication of the liquid stream  11  to the substrate  20  on demand so as to control the pattern application of the liquid onto the substrate  20  with a degree of definition and precision. To this end, the liquid streams  11  may be manipulated by the application of the gaseous impingement stream  19  from the impingement jet module  200  to provide manipulated patterning of the liquid stream  11  on the substrate  20 , as previously described and illustrated in  FIG. 2 . The impingement jet module  200  includes an impingement stream directional passage  211  that emits and directs the impingement stream  19 . Each impingement stream directional passage  211  has a central directional axis that intersects a central directional axis of an associated the liquid channel  112  in the liquid jet module  100 , down stream from the liquid jet module  100  in the unconstrained third stage  14  of the liquid streams  11 . In the embodiment illustrated, the impingement stream directional passage  211  emits the impingement stream  19  towards a location on the liquid stream  11  at is opposite of the location on the liquid stream  11  that was unconstrained in the open directed second stage  13  of the liquid stream  11 . 
         [0028]    Referring now to  FIGS. 2 ,  3 ,  4 ,  5 ,  7  and  8 , the channel body  140  of the channel component  130  includes a recessed landing  142  at the end of the grooves  141 , which is spaced a short distance away from the liquid streams  11  exiting the liquid channel  112 . A series of impingement jet positioning apertures  143  are located in the recessed landing  142 , and the central axis of each impingement jet positioning aperture  143  intersects with the central axis of a corresponding liquid channel  112  below the liquid discharge end  116  of that liquid channel  112 . As illustrated, the impingement jet positioning apertures  143  may be arranged in side-by-side relation such that the impingement streams  19  are arranged to project along a substantially common plane. However, other arrangements may be used if desired. On the opposite side of the recess landing  142  from the exit of liquid stream  11  from the grooves  141  is an impingement jet mounting surface  144 . 
         [0029]    Referring now to  FIGS. 2 ,  7  and  8 , the impingement jet system  200  includes an impingement jet module body  220  housing an array of side-by-side gas tubes  230 . Each of the gas tubes  230  are spaced and positioned in the module body  220  at the same spacing and layout as the impingement jet positioning apertures  143  in the channel body  140 . The module body  220  has a mounting surface  221 , and each of the gas tubes  230  includes a distal end  231  extending from the mounting surface  221 . When the impingement jet module  200  is installed, the impingement jet module mounting surface  221  of the impingement jet delivery system  200  engages the impingement jet mounting surface  144  of the channel body  140  and the distal ends  231  of the gas tubes  230  project into the impingement jet positioning apertures  143  of the channel body  140 . The outer diameter of the gas tubes  230  will preferably correspond substantially with the inner diameter of the impingement jet positioning apertures  143  of the channel body  140  such that a secure plug-in relation is achieved upon insertion of the distal ends  231 . In order to accommodate the distal ends  231  of the gas tubes  230 , the impingement jet positioning apertures  133  in the channel body  140  are tapered with the wider end near the impingement jet mounting surface  143  and the narrower end near the landing  142 . Alternatively, or in addition, the distal ends  231  of the gas tubes  230  can be tapered with the larger end near the impingement jet body  220  and the narrower end near the proximal end  233 . It has also been found that, in a preferred arrangement, the distal ends  231  of the gas tubes  230  terminate flush with the surface of the landing  142  closest to the liquid streams  11 , thereby avoiding crevasses and corners that overspray liquid from the liquid streams  11  might accumulate and create errant drops. 
         [0030]    The interior of the gas tubes  230  create the impingement stream directional passages  211 . As will be appreciated, since the gas tubes  230  plug into the corresponding impingement jet positioning apertures  143 , there is no need or ability to adjust the position of the gas tubes  230 . Rather, that position is pre-established and maintained by the position of the jet positioning apertures  143 . The position of the impingement stream directional passage  211  will have a central axis that intersects a central axis of the corresponding liquid channel  112  below the liquid discharge end  116  of that liquid channel  112 , and preferably in a perpendicular relationship. 
         [0031]    According to the potentially preferred practice, the gas directional passages  211  in the impingement jet system  200  have a diameter which is greater than the width dimension of the corresponding liquid channel  112  in the liquid jet module  100 , and resultant liquid streams  11 . Most preferably, the cross sectional diameter of the gas directional passages  211  will be as large a possible while maintaining the substantially centered relation relative to the corresponding liquid streams  11 , and not allowing the impingement stream  19  therefrom to interfere with the adjacent liquid streams  11  or the adjacent impingement streams  19 . In this regard, it is desirable that the diameter of the gas directional passages  211  are at least as large as the diameter of the lines feeding into the gas tubes  230  such that the gas directional passages  211  do not create a flow restriction in the system. By way of example only, a diameter of about 43 mils for the gas directional passages  211  has been found to provide good performance when used with liquid channels  112  having a cross-section of about 14 mils, although larger or smaller diameters may be used if desired. 
         [0032]    The impingement jet system  200  may be installed into, and removed from, the liquid jet module  100  as a single module. Of course, in actual practice, the impingement jet module  100  may be number of such modules disposed across the row of liquid streams  11 , each of which may incorporate a separate plurality of gas tubes  230 . In the event that one or more gas tubes  230  becomes damaged, the individual module containing that gas tube may simply be removed and replaced with minimal disruption. 
         [0033]    The gas tubes  230  each may be operatively connected in fluid communication to a discreet supply line (not shown) which selectively delivers pressurized air or other gaseous fluid to the gas tube  230 . This selective delivery of pressurized gaseous fluid to individual gas tubes  230  is activated by valves which open and close based on instructions from a computer or other command device. As will be appreciated, during periods when a no pressurized gas is supplied to a gas tube  230 , the liquid stream  11  associated with that gas tube  230  passes in an undisrupted flow path  15  to the substrate  20 . Conversely, during periods when pressurized gas is supplied to a gas tube  230 , the resulting impingement stream  19  engages the liquid stream  11  which is then diverted away from the substrate  20  in a diverted flow path  16  and the portion of the substrate  20  in passing under the normal position of that liquid stream  11  goes untreated. As shown in  FIG. 2 , the application of this diverting force is carried out within the unconstrained third stage  14  of the liquid stream  11  downstream from the open directed second stage  13 . 
         [0034]    As shown in  FIGS. 1 and 2 , the application system  10  includes a collection module designated generally as  300 . The collection module  300  from  FIGS. 1 and 3  is illustrated in further detail in  FIGS. 9 and 10 . The collection system  300  includes an angle body  320  and an opposing deflection blade  330 . The angle body  320  is mounted to the channel cover block  140  of the liquid jet module  100  and has a deflection surface  321  which is positioned near the liquid stream  11  exiting the liquid jet module  100 . The deflection surface  321  of the angle body  320  is oriented at an acute angle from the liquid stream  11  when measured from the downstream position of the liquid stream  11 . The position and angle of the deflection surface  321  is selected in a manner to hinder any mist or overspray of the liquid stream  11  from circling around in an eddy like current back out of the collection module  300 . The deflection blade  330  is mounted to the angled body  320  by standoffs  323  in a manner that creates a discharge passage  310  for the liquid stream  11  to pass through. The standoffs  323  are spaced intermittently along the cross machine length of the collection assembly  300 . 
         [0035]    This arrangement allows the deflected liquid stream  11  through the discharge passage  310  and into a recovery sump (not shown) for reuse. By way of example only, and not limitation, the slot openings between the standoffs  323  may have a height dimension of about 90 mils, although larger or smaller heights may be used, if desired. 
         [0036]    As illustrated, the discharge passage  310  has a collection section  311 , a funnel section  314 , and an exit section  315 . The collection section  311  is positioned adjacent to the liquid stream  11  as the liquid stream  11  exits the liquid jet module  100 , and such that the diverted flow path  16  of the liquid stream  11  will enter the collection section  311  upon application of the impingement stream  19 . 
         [0037]    The collection section  311  is illustrated as having a short length before reaching the funnel section  314 , but could also be only the opening for the funnel section  314 . Inversely, the exit section  315  is illustrated as exit the opening for the funnel section  314 , but could have a short length extending away from the funnel section  314 . As illustrated, the liquid jet application system  10  is positioned with the liquid streams  11  progressing vertically to the substrate  20 . In this position, it is preferable that a vacuum be applied to the exit  315  of the discharge passage  310  to insure proper removal of the liquid stream  11  in the diverted flow path  16 . However, the liquid jet application system  10  can be positioned at an angle from the vertical in a manner that gravity will assist the progression of the liquid stream  11  in the diverted flow path  16  from the discharge passage  310  without a vacuum. 
         [0038]    As illustrated, the deflection blade  330  includes leading edge  331 , a guidance surface  332 , and a contraction surface  333 . The deflection blade  330  is relatively thin. By way of example only, in one potentially preferred embodiment the deflection blade  330  may have a thickness of about 20 mils, although thicker or thinner blades may be used if desired. The leading edge  331  is position on the lower side of the entrance  311  adjacent to the undisrupted flow path  15  of the liquid stream  11 , and the surface of the leading edge  331  is flat and substantially parallel to the undisrupted flow path  15  of the liquid stream  11 . The guidance surface  332  progresses away from the leading edge  331  and angle between the leading edge  331  and the guidance surface  332  creates a knife edge adjacent to the undisrupted flow path  15  of the liquid stream  11 . Because of the closeness of the leading edge  331  to the liquid stream  11 , the knife edge will “cut off” any hook shape in the liquid stream  11  created when the liquid stream  11  transitions from the undisrupted flow path  15  to the diverted flow path  16 , or back. According to one potentially preferred practice, the spacing between the liquid stream  18  and the leading edge  331  is set at about 5 to about 15 mils although larger or smaller spacing levels may be used, if desired. 
         [0039]    The guidance surface  332  leads away from the leading edge  314  and is preferably substantially parallel to a deflection surface  321  on the angled body  320 . This portion of the guide surface  332  that is substantially parallel to the deflection surface  321  creates the collection section  311  of the collection discharge passage  310 . At the rear of the guidance surface  331  of the deflection blade  330 , the deflection blade  330  away from the guidance surface  331  and angles towards the deflection surface  321  of the angled body  320 . The section of the deflection blade  330  that angles towards the deflection surface  321  of the angled body  320  is the contraction surface  333 . The space between the deflection surface  321  and the contraction surface  333  create the funnel section  314  of the discharge passage  310 . By way of example only, and not limitation, it has been found that an angle of about 150°-155° between the guidance surface  332  and the contraction surface  333  may be particularly desirable for the deflection blade  330 . This angle creates a constriction in the funnel section of about 25°-30° relative to the deflection surface  321  of the angle body  320 . 
         [0040]    Upon the application of an impinging stream  19  from the gas directional passage  211  of the impingement jet module  200 , a diverted flow path  16  of the liquid stream  11  is created that passes through the discharge passage  310 . The disturbed flow of the liquid stream  11  enters the discharge passage  310  through the collection section  311  and is routed towards the funnel section  314 . Upon entering the collection section  311 , the knife edge of the deflection blade  330  cuts off any of the liquid stream  11  that might not follow the same path as the fully diverted stream  16  into the discharge passage  310 . The deflection surface  321  of the angled body  320  maintains a distance to the guidance surface  332  of the deflection blade  330  that helps prevent spray from the liquid stream  11  drifting back out of the discharge passage  310  due to circling currents onto parts of the equipment that might allow accumulated liquid to condensate and drop onto the substrate  20  below. The reducing cross sectional area of the funnel section  314  causes the disrupted flow path  16  of the liquid stream  11  and the impingement stream  19  to accelerate towards, and out of the exit section  315  of the discharge passage  310  where it can be collected by a liquid recovery system (not shown). When the impingement stream  19  is terminated, the liquid stream  11  resumes its normal undisrupted flow path  15  to the substrate  20  ( FIG. 1 ). 
         [0041]    As will be appreciated, the present invention provides an application system which is highly functional and which can be set up and serviced relatively simply. In particular, due to the plug-in relation of the impingement jet delivery system  200  there is no need to engage in complex alignment of impingement jets with corresponding liquid streams  11 . Moreover, the incorporation of the open face transitional flow stage along the flow path is believed to substantially promote a cohesive and stable liquid stream which provides fine scale patterning across the substrate  20 . Further, the incorporation of the substantially parallel spaced-apart baffle and deflection blade arrangement promotes efficient and effective recovery of deflected liquid stream material. Such features, individually and in combination, promote substantially enhanced functionality and precision in the application of a spray pattern to the substrate  20 . 
         [0042]    Of course, variations and modifications of the foregoing are within the scope of the present invention. Thus, it is to be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. the claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art. The term “about” means ±10% when used in reference to distances. 
         [0043]    Various features of the invention are set forth in the following claims.

Technology Category: b