The present invention relates generally to liquid dispensing systems, and more specifically, to nozzle assemblies for a liquid dispensing apparatus configured to dispense a liquid filament on a strand of material.
Many reasons exist for dispensing liquid adhesives, such as hot melt adhesives, in the form of a thin filament with a controlled pattern. One technology capable of dispensing controlled patterns of thin filaments is known as controlled fiberization (for example, CF® technology from Nordson Corporation). CF® technology is especially useful for accurately covering a wider region of a substrate with adhesive dispensed as single filaments or as multiple side-by-side filaments from nozzle passages having small diameters, such as on the order of 0.010 inch to 0.060 inch.
CF® technology is often used to improve control over adhesive placement. This may be especially useful along the edges of a substrate and on very narrow substrates, for example, such as on strands of material (e.g., LYCRA® by INVISTA) used in the leg bands of diapers.
Conventional swirl nozzles or die tips typically have a central adhesive discharge passage surrounded by a plurality of air passages. The adhesive discharge passage is centrally located on a protrusion that is symmetrical in a full circle or radially about the adhesive discharge passage. A common configuration for the protrusion is conical or frustoconical with the adhesive discharge passage exiting at the apex. The air passages are arranged in a radially symmetric pattern about the central adhesive discharge passage. The air passages are directed in a generally tangential manner relative to the adhesive discharge passage and are all angled in a clockwise or counterclockwise direction around the central adhesive discharge passage.
Conventional meltblown adhesive dispensing apparatus typically comprise a nozzle body having multiple adhesive or liquid discharge passages disposed along an apex of a wedge-shaped member and air passages of any shape disposed along the base of the wedge-shaped member. The wedge-shaped member is not a radially symmetric element. Rather, it is typically elongated in length relative to width. The air is directed from the air discharge passages generally along the side surfaces of the wedge-shaped member toward the apex, and the air impacts the adhesive or other liquid material as it discharges from the liquid discharge passages to draw down and attenuate the filaments. The filaments are discharged in a generally random manner.
Various types of nozzle bodies, such as those of the type described above, have been used to dispense adhesive filaments onto one or more elastic strands. Each strand is typically aligned and directed by a strand passage proximate the corresponding adhesive discharge passage. The strands tend to acquire airborne particulates present in the environment surrounding the liquid adhesive dispensing apparatus. These airborne particulates consist of dust and other contaminants that primarily originate from the processing operations performed by the production line. In addition, the strands, particularly those available from Fulflex, Inc. may be intentionally coated with particulates, such as talc, to facilitate release when extracted from their packaging. In addition, other strand manufactures may add pigments to the strand material to color the strand. Typically, the coloration pigments are abrasive to the nozzle body and, consequently, wear rate on the nozzle may be appreciably higher with colorized strand materials.
Furthermore, as each strand interacts with the corresponding strand passage, the particulates, regardless of origin, may be wiped off and accumulate or agglomerate into larger masses. The agglomerated masses of particulates may dislodge from the strand passage and incorporate into the dispensed adhesive filament. For example, the agglomerated mass may be dislodged by a knot that is formed between the trailing end of a first length of strand material and the leading edge of a second length of strand material joined to provide a continuous strand. Alternatively, the agglomerated mass may remain resident in the guide and increase in dimensions to such an extent that the strand itself is displaced or removed from the guide. In multi-strand dispensing operations, an adjacent guide may capture the displaced strand, which disrupts the application of adhesive to the strands and ultimately produces defective product because the strands are adhesively bonded to a substrate with improper positioning. The reduction in product quality may be significant and may increase the manufacturing cost.
Yet another difficulty associated with dispensing adhesive onto a guided, moving strand arises from contact between the strand and the strand passage. Specifically, the strand wears the metal surfaces of the nozzle body and the metal surfaces of the strand passages due to frictional wear. Eventually, the wear may necessitate replacement of the nozzle body.
What is needed, therefore, is a nozzle body for dispensing a liquid filament onto a substrate in which the difficulties associated with strand guiding are reduced or eliminated.
In one embodiment, a protective member is provided for use with a nozzle. The nozzle has a strand guide passageway and a liquid discharge port. The strand guide passageway is adapted for receiving a strand of material that is in motion relative to the nozzle. The liquid discharge port is adapted for dispensing a filament of liquid on the strand after the strand passes through the strand guide passageway. The protective member comprises a body configured to be received in the strand guide passageway of the nozzle. The body has a passageway for receiving the strand and for preventing the strand from contacting the strand guide passageway. The body is constructed, at least in part, from a material having a wear resistance sufficient to resist wear caused by the strand being guided thereby.
In another embodiment, the body is composed of a metal selected from a stainless steel, a tool steel, a high speed steel, or combinations thereof. In yet another embodiment, the body is composed of a ceramic material. In still another embodiment, the body is composed of a first material, the body includes a tubular sidewall extending about the passageway and has an inner surface confronting the strand, and further comprises a coating of a second material on the inner surface. The second material has a greater wear resistance to contact by the strand than the first material of the body.
In another embodiment, a nozzle assembly is provided for dispensing a filament of liquid onto a strand of material that is in motion relative to the nozzle assembly. The nozzle assembly comprises a nozzle and a protective member. The nozzle has a strand guide passageway for receiving the strand of material that is in motion relative to the nozzle. The nozzle has a liquid discharge port for dispensing the liquid filament onto the strand of material after the strand passes through the strand guide passageway. The protective member has a body that is configured to be received in said strand guide passageway. The body has a passageway for receiving the strand and for preventing the strand from contacting the strand guide passageway. The nozzle is composed of a first material and said protective member is composed, at least in part, of a second material having a greater wear resistance than the first material.
For the purposes of this description, words of direction such as “upward”, “vertical”, “horizontal”, “right”, “left”, “front”, “rear”, “side”, “top”, “bottom”, and the like are applied in conjunction with the drawings for purposes of clarity and providing a reference frame in the present description only. As is well known, liquid dispensing devices may be oriented in substantially any orientation, so these directional words should not be used to imply any particular absolute directions for an apparatus consistent with the invention.
Referring to
The protective members 14 function as sleeves or liners that are received in the strand guide passageways 18. As a result of this arrangement, the strands 16 fed in a machine direction 25 contact the protective members 14 rather than the nozzle 12 during dispensing. Thus, the material selected for the nozzle 12 may be optimized without having to take wear caused by contact with the strands 16 within the strand guide passageway 18 into consideration, as will be described in more detail below.
The dispensing module 10 generally has a central body portion (not shown), a lower body portion 22, and a quick disconnect mechanism 24 for facilitating the installation and removal of various nozzles or dies from the dispensing module 10, as more fully described in U.S. Pat. No. 6,619,566, filed on Mar. 22, 2001, and assigned to the assignee of the present application. The nozzle assembly 11 is coupled to the dispensing module 10 and secured with the quick disconnect mechanism 24. Nozzle assembly 11 receives liquid and pressurized air from the dispensing module 10 and dispenses a filament 15 of liquid material in a controlled pattern onto a strand 16 of substrate material moving relative to the nozzle assembly 11, generally in the direction of arrow 25, while directing pressured air toward the filament 15.
The nozzle 12 of the nozzle assembly 11 includes protrusions 26, 27 and angled cam surfaces 28, 29, as more fully described in U.S. Pat. No. 6,619,566, to facilitate coupling the nozzle assembly 11 with the dispensing module 10. The nozzle 12 includes a first side 30 configured to mount to the lower body portion 22 of the dispensing module 10 (
A liquid discharge port 42 is in fluid communication with a liquid discharge passage 44, which in turn is in communication with the liquid supply port 32 by way of a liquid passage 46, whereby liquid material from the module 10 may be dispensed from the liquid discharge port 42 to the strand 16 of substrate material depicted in
The second side 36 of the nozzle 12 further includes a plurality of air discharge outlets 48 proximate the liquid discharge port 42. The air discharge outlets 48 are in fluid communication with air discharge passages 52 (
Multiple strand guide passageways 18 are formed in the frustoconically-shaped protrusion 40, extending from the second side 36 to the third side 38. As best shown in
As apparent from
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While embodiments of the invention are generally illustrated and described herein with the nozzle 12 as an integral one-piece structural component configured with a liquid discharge port 42, one or more air discharge outlets 48, strand guide passageways 18, and protective members 14 provided in the strand guide passageways 18, the invention is not limited to these representative embodiments. For example, other embodiments may include nozzles configured with one or more strand guide passageways in one component and another component configured with a liquid discharge port and/or air discharge outlets. In other words, one or more strand guide passageways may not be an integral part of the same component that contains the liquid discharge ports and/or air discharge outlets, but may instead be contained in a non-integral component that is attached to another component containing the liquid discharge outlet and/or air discharge outlets. Thus, in these embodiments, the component with the strand guide passageway may be removed from the nozzle without removing other components configured with liquid discharge ports and/or air discharge outlets.
In one specific embodiment, the nozzle 12 may be constructed from brass and the protective members 14 may be constructed from stainless steel. In other specific embodiments, the protective members 14 may be constructed, at least in part, from metals that exhibit high wear resistance, including but not limited to CPM metals (e.g., 9V, 10V, and 12V) available from Crucible Specialty Metals, Syracuse, N.Y., as well as those high speed or tool steels that exhibit extreme wear resistance. In one embodiment, the protective members 14 may be constructed, at least in part, from a material exhibiting a hardness of 9 or greater on the Mohs scale. The Mohs scale is one generally excepted scale for rating the relative hardness of various materials. In particular, the Mohs scale provides information on the capability of one material to scratch another. The Mohs scale rates materials from 1, being the softest, to 10, being the hardest. By way of example, talc is rated 1 on the Mohs scale, while alumina is generally rated as a 9 on the Mohs scale. In other embodiments, the protective members 14 may exhibit a hardness of less than 9 on the Mohs scale while extending the life of the nozzle 12 in proportion to, for example, the life of a protective member made of a material rated as a 9 on the Mohs scale. In yet additional embodiments, a wide variety of other materials may be used for the protective members 14, including, but not limited to, wear resistant oxide ceramic materials, like alumina and zirconia, or nitride ceramic materials.
In an alternative embodiment and with reference to
With reference now to
Another embodiment of the protective member 14 is illustrated in
With reference to
Referring now to
As best shown in
The protective member 14 may be machined or molded to have the shape shown in the figures, depending on the type of material used to make the protective member 14. By way of example only, and not limitation, the protective member 14 may be machined if constructed from a metal, such as stainless steel or another metal, previously mentioned. Alternatively, the protective member 14 may be formed by molding a ceramic powder as known in the art if constructed from a ceramic material, such as alumina. The protective members 14 may be inserted into the bores 55 defined in the nozzle 12 and within the strand guide passageways 18 or, alternatively, the nozzle 12 and protective members 14 may be assembled in a different manner to form the nozzle assembly 11.
While the invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of the general inventive concept.
This application claims the benefit of U.S. Provisional Application No. 60/909,817, filed Apr. 3, 2007 (pending), which is hereby incorporated by reference herein in its entirety.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US08/59261 | 4/3/2008 | WO | 00 | 9/2/2009 |
Number | Date | Country | |
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60909817 | Apr 2007 | US |