Variable flow automatic configuration fluid application device

Abstract

To provide a fluid dispensing apparatus, and a method of providing a controlled volume of a liquid to a substrate.SOLUTION: A fluid dispensing apparatus may be provided that includes a fluid reservoir configured to hold a liquid fluid. The fluid dispensing apparatus may include fluid output zones with at least one of the fluid output zones including multiple fluid pumps. Each of the fluid pumps may have a flow rate at which the liquid fluid is pumped by the fluid pump. A slot die may also be provided that has a slot for each of the fluid output zones. The fluid dispensing apparatus may also include a relief valve mechanically connected to each of the fluid pumps, and a control device. The control device may be functionally connected to each relief valve, and the control device may be adapted to selectively instruct each valve to open or close to produce differing volume rates of the fluid through each slot based on the relief valves selected.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 269,748 (filed March 22, 2022), the entire disclosure of which is incorporated herein by reference.

[0002] background Technical Field FIELD OF THE DISCLOSURE The present disclosure relates generally to systems and methods for coating strands, and more particularly to systems, subsystems, and methods for applying coatings (such as adhesives) to elongated strands and / or webs. [Background technology]

[0003] Technology Description Nonwovens include engineered fabrics that provide specific functions, such as absorbency, liquid repellency, resilience, stretch, softness, strength, flame resistance, ease of cleaning, cushioning, filtration, use as a bacterial barrier, sterility, etc. In combination with other materials, nonwoven materials can provide a wide range of products with diverse properties and can be used alone or as components of hygiene apparel, home furnishings, healthcare, engineering, industrial, and consumer goods. Such products can include baby diapers, feminine hygiene pads, adult diapers, other absorbent hygiene products, etc.

[0004] Typically, adhesive coatings are applied to elongated strands and / or webs. The elongated strands / webs are aligned with a nozzle through which adhesive filaments are dispensed. Additionally, multiple elastic strands / webs can be placed and adhered to nonwoven materials to allow flexibility, such as for fitting around an object or person, where the adhesive application device can apply glue to the strands / webs with either a contact or non-contact nozzle. Typically, the speed of application is difficult to vary, preventing designs other than linear patterns. Summary of the Invention

[0005] Additionally, manufacturing processes using hot melt adhesives are often inefficient and difficult to replicate. Current fluid delivery systems are fixed in the flow rate of fluid applied to a selected substrate. Typically, fluid delivery systems are used to provide different patterns of adhesive for different products. Therefore, when adapting a fluid delivery system to a new product, the system must be adjusted, equipment added, removed, or modified to achieve the flow rate required for the new product. This process not only requires significant time and resources, but can also require a large amount of space to accommodate such modifications.

[0006] Short description In one embodiment, a fluid supply device may be provided that includes a fluid reservoir that holds a liquid fluid. The fluid supply device may include fluid output zones, at least one of which includes a plurality of fluid pumps. Each of the fluid pumps may have a flow rate (same or different for each pump) at which the liquid fluid is pumped by the fluid pump. A slot die having a slot for each of the fluid output zones may also be provided. The fluid supply device may also include a relief valve mechanically connected to each of the fluid pumps and a controller. The controller may be operatively connected to each of the relief valves, and the controller may direct each valve to selectively open or close, thereby generating various volumetric flow rates (volume rates) of fluid through each of the slots based on the selected relief valve.

[0007] In another embodiment, a fluid supply adapted to provide a controlled fluid flow rate may be provided. The fluid supply may include a fluid reservoir containing a liquid fluid and at least two fluid output zones. At least one zone may include at least two fluid pumps, each pump having a predetermined flow rate. The fluid supply may also include a controllable relief valve mechanically connected to each pump, and a controller. The controller may be operatively connected to each valve, and the controller may selectively direct each valve to open or close, thereby adapting various volumetric flow rates of fluid to be generated based on the selected relief valve.

[0008] In another embodiment, a method for providing a controlled volume of liquid to a substrate may be provided. The method may include providing a liquid reservoir and providing a plurality of output zones. The method may also include providing a first pump and a second pump for at least one output zone of the plurality of output zones. The method may also include providing a first controllable relief valve for the first pump and a second controllable relief valve for the second pump, and providing a controller coupled to the first relief valve and the second relief valve. The method may also include selectively opening and closing the first relief valve and the second relief valve.

[0009] BRIEF DESCRIPTION OF THE DRAWINGS The subject matter of the present invention can be understood by reading the following description of non-limiting embodiments with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of an apparatus according to one embodiment.

[0011] [Figure 2] FIG. 1 is an exploded perspective view of an apparatus according to one embodiment.

[0012] [Figure 3]FIG. 1 is an exploded perspective view of an apparatus according to one embodiment.

[0013] [Figure 4] 1 is a schematic diagram of an apparatus according to one embodiment.

[0014] [Figure 5] 1 is a schematic diagram of an apparatus according to one embodiment.

[0015] [Figure 6] FIG. 1 is a schematic block diagram of a control system for an apparatus according to one embodiment.

[0016] [Figure 7] 1 is a schematic block diagram of a fluid delivery method according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] Detailed Description A fluid supply (dispensing) device, typically used for dispensing adhesives, is provided. A fluid reservoir is provided along with a plurality of fluid pumps to vary the fluid output zone. The flow rate to a plenum obtained from each fluid pump can be electronically controlled by a corresponding relief valve mechanically connected to the corresponding fluid pump to meter the flow from the fluid pumps to the plenum. Based on actuation of the relief valve, various volumetric flow rates of fluid are delivered to corresponding nozzles. Because each fluid pump has a corresponding relief valve that controls the fluid output through each fluid pump, individual control of each pump is achieved, allowing the fluid output of the fluid supply device to be varied as desired without the need for equipment modifications.

[0018] 1-5 illustrate an exemplary embodiment of a liquid dispensing apparatus 100. In one example, the liquid dispensing apparatus 100 can apply a fluid, including a liquid adhesive, to a strand or web of fibers or other substrate. The fluid can be an epoxy, glue, adhesive, paint, protective coating, lubricant, lotion, wax, surfactant, ink, etc. In an exemplary embodiment, the liquid can be applied in a pattern onto a substrate, including substrates forming baby diapers, feminine hygiene pads, adult diapers, other absorbent hygiene products, etc.

[0019] The liquid supply system 100 receives fluid from the fluid reservoir 102 at a manifold 104. In another example, a module can be used in place of the manifold, while in other examples, a combination of a module and a manifold is presented. The manifold includes a plurality of fluid inputs 106 and corresponding fluid outputs 108 with fluid passageways therebetween. A plurality of pumps 110 is also provided, where each fluid inlet 106 and corresponding fluid outlet 108 includes a corresponding fluid pump. Each of the plurality of pumps 110 controls the flow of fluid through a passageway of a corresponding fluid inlet 106 and fluid outlet 108 of the manifold 104. The number of fluid pumps 110 can vary based on the desired pattern of the product. Thus, in some embodiments, five fluid pumps can be provided, while in other exemplary embodiments, ten or more fluid pumps can be provided. Furthermore, each fluid pump 110 can be replaceable. For example, the manifold 104 can have ten fluid passageways disposed therethrough, but only seven pumps 110 corresponding to seven of the passageways. In this manner, three of the passageways do not include pumps, and fluid cannot pass through the passageways. In one embodiment, the fluid material is an adhesive that does not flow substantially by gravity. In other embodiments, the fluid inlet 106, fluid outlet 108, fluid passageway, etc. may be blocked to prevent fluid from flowing through passageways that do not include pumps 110. By having interchangeable pumps, different patterns can be quickly and efficiently provided by simply replacing, adding, etc. pumps 110.

[0020] In one example, multiple pumps 110 can be controlled by an actuator 111. In one embodiment, the actuator can be a servo motor that controls the operation of the pump. In one example, the servo motor can include an in-line configuration, a 90-degree configuration, etc.

[0021] Each of the fluid pumps 110 includes a relief valve 112 mechanically coupled to the fluid pump 110. In one example, the relief valves 112 can be mechanical valves, pneumatic relief valves, electrical relief valves, solenoid valves, etc. Each relief valve 112 can be actuated to control or meter fluid from a group corresponding to the fluid pump 110 to vary the rate at which the fluid flows to the fluid output zone 114. Alternatively, the spray pattern to the fluid output zone may be varied. The relief valves 112 can provide fluid flow control at rates as small as 0.05 cc (0.05 cm3) per revolution. In one example, if an operator desires a first pump to flow at 0.15 cc per revolution while a second pump flows at 0.4 cc per revolution, the relief valves can provide such precision. By providing relief valves 112 that can vary the flow rate to each fluid output zone 114, when a new product with a different pattern is offered, an operator need only adjust the flow rate to the fluid output zones 114 by actuating each individual relief valve 112 that supplies fluid to the fluid output zones 114, without having to reconfigure the entire fluid supply system. As a result, time, floor space, etc. can be saved while increasing manufacturing efficiency.

[0022] In one example, the fluid output zones 114 include plenums. The plenums can provide a pattern for delivering fluid onto the substrate. Each fluid output zone 114 includes at least one corresponding fluid pump 110 having a distinct volumetric fluid output flow rate. The fluid output zones 114 can also include two or more pumps 110 associated with the fluid output zones 114. The number of different fluid output zones 114 and the number of pumps 110 associated with each fluid output zone 114 are determined based on the desired pattern on the substrate. Each fluid output zone 114 includes a corresponding fluid outlet 108. In one example, each fluid outlet can be a slot die. Alternatively, the fluid outlet can include a spray nozzle, a strand or web output, a bead output, a port, or the like. Selecting the number of fluid pumps 110, the location of the pumps 110, and the flow rate through each relief valve 112 results in adhesive 116 having different consistencies being deposited on the substrate or fabric in the different fluid output zones 114.

[0023] In one example, each fluid output zone may have a single fluid pump 110 and associated corresponding relief valve 112 (e.g., FIG. 4 ) such that the consistency of the adhesive 116 in each fluid output zone 114 may be different. As a result, at each fluid output zone 114 (e.g., FIG. 5 ), various volumetric flow rates of fluid may be applied based on actuation of the relief valve 112. In one example, the pumps and / or relief valves may be spaced from one another at the same or various distances. In one example, the width may vary from fifty millimeters (50 mm) to three hundred millimeters (300 mm). In other embodiments, the spacing may be less than 50 mm or greater than 300 mm.

[0024] In one example, to change the consistency of the adhesive in a particular fluid output zone 114, the relief valves 112 are actuated to meter the fluid that forms the adhesive in the fluid output zone at different flow rates. Alternatively, multiple fluid pumps 110 and corresponding relief valves 112 can be provided in a single fluid output zone 114, and the consistency of the adhesive 116 in the fluid output zone may be changed simply by turning on and off different relief valves 112 associated with the fluid output zone 114. For example, a single fluid output zone 114 may include a first pump 110A and a first relief valve 112A that, when actuated, deposit adhesive into the fluid output zone 114 at 1 cc / rev, and a second pump 110B and a second relief valve 112B that, when actuated, deposit adhesive into the fluid output zone 114 at 0.15 cc / rev (e.g., FIG. 5). In this manner, the controller can operate the first relief valve 112A and the second relief valve 112B as follows: i.) only the first relief valve 112A deposits adhesive 116 into the fluid output zone 114 to produce a respective volumetric flow rate of 1 cc / rev, ii.) only the second relief valve 112B deposits adhesive 116 into the fluid output zone 114 to produce a respective volumetric flow rate of 0.15 cc / rev, iii.) both the first relief valve 112A and the second relief valve 112B deposit adhesive 116 into the fluid output zone 114 to produce a respective volumetric flow rate of 1.15 cc / rev, or iv.) neither the first relief valve 112A nor the second relief valve 112B deposits adhesive. In this manner, by selecting the activation of relief valves (e.g., 112A and / or 112B) that produce different flow rates, different volumetric flow rates of fluid can be produced in the fluid output zone 114 based on the selected relief valves 112A, 112B. In this manner, the consistency of the adhesive in the fluid output zone 114 can be changed without changing the equipment or changing the individual flow rates of the individual relief valves.Although this example describes only two pumps with respective first and second relief valves 112A and 112B, in other examples there may be three pumps with three relief valves, four pumps with four relief valves, or more, thereby achieving multiple combinations and flow rates to the individual fluid output zones 114. For example, with four different pumps, each with a different flow rate, and four corresponding relief valves, by controlling the individual relief valves, up to 12 different flow rate combinations can be provided to a single fluid output zone 114 without requiring pump or equipment replacement.

[0025] 6 illustrates a control system 600 that may be electronically coupled to and / or may be part of a fluid supply device. In one example, the fluid supply device is a fluid supply device such as those shown in FIGS. 1-5.

[0026] The control system 600 may include one or more processors 602 capable of executing instructions, including program instructions, application instructions, etc. The control system may also include at least one storage device 604 that may be in communication with the one or more processors 602. The at least one storage device 604 may be memory and store instructions, etc., executed by the one or more processors. The control system may also include a transceiver 606 that receives and transmits signals, data, information, etc. The control system 600 may also include inputs 608, such as a keyboard, mouse, touchscreen, microphone, etc. The control system 600 may also include outputs 610, such as a display, speaker, etc. In some examples, the inputs 608 and the output 610 may be the same device, such as a screen.

[0027] The control system 600 may also include a fluid delivery application 612. The fluid delivery application 612 may provide instructions to enable one or more processors to determine the pattern or amount of adhesive desired to be deposited on a substrate at a particular location. In an exemplary embodiment, the substrate may be a cloth, diaper, feminine hygiene product, etc. The fluid delivery application 612 may include or be able to access multiple product templates containing adhesive consistencies to be deposited on the substrate. The templates may be obtained, uploaded, downloaded, created, saved, etc. via the transceiver 606. In each example, the amount of adhesive for each individual fluid output zone may be predetermined prior to applying the adhesive on the substrate. The fluid delivery application 612 may then vary the flow or amount of adhesive provided to each fluid output zone according to the predetermined amount.

[0028] In one example, two or more pumps are used to provide adhesive to a particular fluid output zone, and a relief valve corresponding to each pump can be activated to add, subtract, or otherwise vary the amount of adhesive flowing to the fluid output zone. In this manner, the fluid delivery application can make a determination regarding the amount of adhesive needed for each fluid output zone for a given product and activate various relief valves accordingly to apply the desired amount of adhesive to each fluid output zone.

[0029] 7 shows a block flow diagram of a method 700 of dispensing a fluid onto a substrate. The fluid in one example can be an adhesive. In one example, this method can be accomplished or performed using any of the systems, assemblies, devices, etc. previously described herein.

[0030] At 702, multiple fluid output zones may be provided. In one example, the fluid output zones may include fluid outlets through which discrete amounts of fluid may flow. In one example, amounts of fluid for a spray pattern may be provided. In another example, the fluid output zones may include portions of a plenum.

[0031] At least two pumps are provided for at least one fluid output zone at 704. In one example, a first pump is provided to control the fluid flow of a first volume of fluid, while a second pump is provided to control the fluid flow of a second volume of fluid different from the first volume of fluid. In this manner, the one or more processors can control the amount of fluid flowing through the outlet to include the first volume of fluid, the second volume of fluid, or a combination of the first volume of fluid and a third volume of fluid. In this manner, the amount of fluid provided can be changed simply by operating the pumps instead of modifying parts of the system. In another example, the first pump and the second pump can provide fluid flow at the same flow rate or volume, providing two different pumps that can provide the same flow rate, or alternatively, providing a combination of pumps that can provide twice the flow rate of a single pump. Furthermore, using two pumps for a single fluid output zone can add, subtract, or otherwise vary the flow rate.

[0032] At 706, a control valve is provided for each pump. In one example, a pneumatic control valve may be provided, while in other examples, a solenoid control valve, an electrically controlled valve, a hydraulic control valve, or the like may be used. The control valves may be actuated to provide the desired individual amounts of fluid to the fluid output zones.

[0033] At 708, a controller coupled to each pneumatic control valve can selectively open and close each control valve. The controller can control the control valves based on operator input, timing devices within the program, and as a result of the program, as well as sensor information including sensors detecting the position of the substrate, fabric, etc. As a result, a liquid such as an adhesive can be pumped through the selectively opened valves and onto the substrate, fabric, etc. In one example, a slot die having a slot can be used to provide a pattern on the substrate with fluid being pumped through the slot die.

[0034] In one or more exemplary embodiments, a fluid supply apparatus may be provided that includes a fluid reservoir configured to hold a liquid fluid. The fluid supply apparatus may include fluid output zones, at least one of which may include a plurality of fluid pumps. Each of the fluid pumps may have a flow rate at which the liquid fluid is pumped by the fluid pump. A slot die may also be provided having a slot corresponding to each of the fluid output zones. The fluid supply apparatus may also include a relief valve mechanically connected to each of the fluid pumps and a controller. The controller may be operatively connected to each relief valve, and may be adapted to command each valve to open or close, thereby generating various volumetric flow rates of fluid through each slot based on the selected relief valve.

[0035] Optionally, the liquid fluid can be an adhesive. In one embodiment, the fluid output zones can include a plenum. In another embodiment, the relief valve can be a pneumatic relief valve. In one example, at least one of the fluid output zones includes a first fluid pump having a first flow rate and a second fluid pump having a second flow rate. Optionally, the first flow rate is different from the second flow rate. Alternatively, the first fluid pump can operate while the second fluid pump is operating. In another example, the fluid supply device can also include a manifold that supplies fluid from a fluid reservoir to each of the output zones.

[0036] In one or more exemplary embodiments, a fluid supply adapted to provide a controlled fluid flow rate may be provided. The fluid supply may include a fluid reservoir containing a liquid fluid and at least two fluid output zones. At least one zone includes at least two fluid pumps, each pump having a flow rate. The fluid supply may also include a controllable relief valve mechanically connected to each pump, and a controller. The controller may be operatively connected to each valve, and the controller may direct each valve to open or close, thereby adapting to generate various volumetric flow rates of fluid based on a selected relief valve.

[0037] Optionally, the fluid supply device includes a slot die having a slot for each output zone. In one embodiment, the controller is configured to generate different volumetric flow rates for each slot for each output zone. In another embodiment, the liquid fluid is an adhesive. In yet another embodiment, the relief valve is at least one of a pneumatic relief valve or an electrical relief valve.

[0038] Optionally, at least one of the fluid output zones includes a first fluid pump having a first flow rate and a second fluid pump having a second flow rate. In one embodiment, the first flow rate is different from the second flow rate. In another embodiment, the first fluid pump is configured to operate while the second fluid pump is operating. In one example, the fluid supply apparatus also includes a manifold that supplies fluid from a fluid reservoir to each of the output zones.

[0039] In one or more exemplary embodiments, a method for providing a controlled volume of liquid to a substrate may be provided. The method may include providing a liquid reservoir and providing a plurality of output zones. The method may also include providing a first pump and a second pump for at least one output zone of the plurality of output zones. The method may also include providing a first controllable relief valve for the first pump and a second controllable relief valve for the second pump, and providing a controller coupled to the first relief valve and the second relief valve. The method may also include selectively opening and closing the first relief valve and the second relief valve.

[0040] Optionally, the method also includes pumping the liquid through the slot of the slot die and onto the substrate through the selectively opened first and second relief valves. In one embodiment, the method may also include varying the amount of liquid flowing to the output zone by selectively opening and closing the first and second relief valves.

[0041] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances in which the event occurs and instances in which it does not occur. As used herein throughout the specification and claims, simplification terms may be applied to modify any quantitative expression that allows for variation without causing a change in the basic function to which the term may relate. Thus, values ​​modified by singular or plural terms, such as "about," "substantially," and "approximately," may not be limited to the exact value specified. In at least some instances, simplification terms may correspond to the precision of an instrument for measuring the value. Herein, and throughout the specification and claims, range limitations may be combined and / or interchangeable, and such ranges may be identified and include all subranges contained therein, unless the context or term indicates otherwise.

[0042] Examples are used herein to disclose embodiments, including the best mode, and to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems, and performing any incorporated methods. The claims define the patentable scope of this disclosure, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the claim language, or if they have equivalent structural elements that differ only insignificantly from the claim language.

Claims

1. A fluid supply device, comprising: a plurality of fluid pumps, each configured to have a flow rate, such that a fluid is pumped by the fluid pump at the flow rate; a relief valve mechanically connected to each of the fluid pumps; a controller operatively connected to each relief valve; Equipped with the controller is adapted to selectively command each relief valve to open or close so that different volumetric flow rates of fluid through a fluid output for each of the fluid pumps are produced based on the relief valve selected. Fluid supply device.

2. 1. A fluid supply device adapted to provide a controlled fluid flow rate, comprising: a fluid reservoir configured to contain a fluid; at least two fluid output zones receiving said fluid from at least two fluid pumps at respective flow rates of said fluid pumps; a controllable relief valve mechanically connected to each of said fluid pumps; a controller operatively connected to each controllable relief valve; Equipped with the controller is adapted to selectively command each controllable relief valve to open or close so that different volumetric flow rates of fluid are produced based on the controllable relief valve selected; Fluid supply device.

3. 1. A method for providing a controlled volume of liquid to a substrate, comprising: selectively opening and closing a first relief valve of the first pump and a second relief valve of the second pump to produce various volumetric flow rates of fluid to one of a plurality of output zones; The method includes:

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