Full cover / fine line spray coating method

Abstract

An air shim plate configured to direct air to the two or more adhesive filaments and / or having one or more air outlets having a width of at least 1 millimeter (mm). For example, the air outlets can each have a width of 1 mm to 75 mm (e.g., 1 mm or 2 mm wider overall than the corresponding one or more adhesive outlets). The air outlets can provide a reduction or elimination of a hammer head, thereby resulting in a more consistent application of adhesive. The nozzle can include an adhesive shim including two or more adhesive outlets for applying the two or more adhesive filaments.

Description

[Technical field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 63 / 325,351, filed March 30, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates generally to air-assisted nozzles and systems for extruding and moving filaments of viscous liquid in a desired pattern, and more particularly to air-assisted dispensing of hot melt adhesive filaments. [Background technology]

[0003] Various dispensing systems have been used in the past to deliver patterns of viscous liquid materials, such as hot melt adhesives, onto a moving substrate for a wide range of manufacturing purposes, including but not limited to packaging, assembly of various products, and the manufacture of disposable absorbent sanitary products. Thus, the described dispensing system can be used in the manufacture of disposable absorbent sanitary products, such as diapers. In the manufacture of disposable absorbent sanitary products, hot melt adhesive dispensing systems have been developed to deliver a lamination or bonding layer of hot melt thermoplastic adhesive between a nonwoven fiber layer and a thin polyethylene backsheet. Typically, the hot melt adhesive dispensing system is positioned above a moving polyethylene backsheet layer and delivers a uniform pattern of hot melt adhesive material across the top width of the backsheet substrate. Downstream of the dispensing system, a nonwoven layer is laminated to the polyethylene layer through a pressure nip, which is then further processed into a final usable product.

[0004] In various hot melt adhesive dispensing systems, continuous filaments of adhesive are emitted from multiple adhesive outlets by multiple process air jets oriented in various configurations adjacent the periphery of each adhesive outlet. The multiple air jets emit air in a converging, diverging, and / or parallel manner to the emitted adhesive filaments or fibers as the filaments emerge from the adhesive outlet. This process air generally can attenuate each adhesive filament and move the filaments in overlapping or non-overlapping patterns before being deposited on a moving substrate.

[0005] Manufacturers in many fields, including manufacturers of disposable absorbent hygiene products, are interested in miniature fiber technology for hot melt adhesive bond layers in nonwovens and polyethylene sheet laminates. To this end, hot melt adhesive dispensing systems incorporate slot nozzle dies with a pair of air passages formed on each side of the die's elongated extrusion slot. The air passages can be angled relative to the extrusion slot and symmetrically positioned so that a curtain of compressed air is discharged on the opposite side of the extrusion slot. Thus, as the hot melt adhesive exits the extrusion slot as a continuous sheet or curtain, the curtain of process air impinges on and attenuates the adhesive curtain, forming a uniform web of adhesive on the substrate.

[0006] Meltblowing technology has also been adapted for use in this field to produce hot melt adhesive bond layers with relatively small diameter fibers. Meltblown dies typically contain a series of closely spaced adhesive nozzles or orifices aligned on a common axis across the die head. A pair of angled air passages or individual air passages and orifices may be located on either side of the adhesive nozzle or orifice and aligned parallel to the common nozzle axis. As the hot melt adhesive is released from the aligned series of nozzles or orifices, pressurized air is released from the air passages or orifices and attenuated before the adhesive fiber or filament is delivered to the moving substrate. The air can also vibrate the fiber in a plane aligned with the movement of the substrate (i.e., the machine direction) or in a plane aligned with the cross-machine direction.

[0007] One of the challenges associated with the above-mentioned technology relates to the production of a fibrous adhesive layer during intermittent operation. More specifically, in some dispensing methods, it is desirable to produce a discrete pattern of a fibrous adhesive layer, rather than a continuous adhesive layer. Although some fibrous adhesive dispensers incorporate intermittent control of adhesive and air flow to produce such discrete patterns, it is difficult to provide a discrete pattern with well-defined edges.

[0008] For example, the velocity of the air directed at the adhesive must be sufficient to cleanly "break" the filament when the adhesive flow stops. Otherwise, the filament may continue to "string" along such that there are no clearly defined cut-off and cut-on edges between adjacent patterns deposited on the moving substrate. However, when high velocity air is used, it becomes more difficult to control the pattern of fibers between the cut-on and cut-off edges. This is especially true when the high velocity air flow is concentrated and impinges on the opposite side of the adhesive filament. The filament may end up breaking constantly during the dispensing cycle, rather than simply at the start and stop points of the adhesive flow.

[0009] A related problem resulting from high velocity air directed in this manner is "flies" which occur when the adhesive is blown away from the desired deposition pattern. "Flies" may deposit outside the desired edges of the pattern or even build up on the dispensing equipment, causing operational problems requiring significant maintenance. High velocity air, in combination with closely spaced nozzles, can also cause "shots" where adjacent adhesive filaments intertwine and form globules of adhesive on the substrate. "Shots" are undesirable as they can cause thermal deformation of the delicate polyethylene backsheet substrate.

[0010] Additionally, hammerheads can form due to variable pressure, resulting in inconsistent pattern distribution. Summary of the Invention

[0011] The present application provides an air shim plate having one or more air outlets configured to direct air to two or more adhesive filaments and / or having a width of at least 1 millimeter (mm). For example, the air outlets can each have a width of 1 mm to 75 mm (e.g., 1 mm or 2 mm wider overall than the corresponding one or more adhesive outlets). The air outlets can provide a reduction or elimination of the hammerhead, thereby resulting in a more consistent adhesive application. The nozzle can include an adhesive shim including two or more adhesive outlets for feeding two or more adhesive filaments. In some embodiments, the adhesive shim includes one or more adhesive outlets having a width greater than 1 mm. In aspects, the adhesive shim includes one or more adhesive outlets having a width greater than 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 10 mm, 20 mm, 30 mm, 50 mm, 75 mm, and / or 100 mm. In embodiments, the adhesive shim includes one or more adhesive outlets having a width of 2mm to 3mm, 3mm to 4mm, 4mm to 5mm, 5mm to 6mm, 6mm to 7mm, 7mm to 8mm, 8mm to 9mm, 9mm to 10mm, 10mm to 20mm, 20mm to 30mm, 30mm to 50mm, or 50mm to 100mm.

[0012] According to one embodiment of the present disclosure, a nozzle for dispensing a pattern of liquid adhesive filaments can include a first air shim plate and an adhesive shim plate. The first air shim plate has one or more air slots configured to receive and direct pressurized air. The adhesive shim plate has at least two liquid slots configured to receive pressurized liquid adhesive and discharge liquid adhesive filaments, and the pressurized air directed by the one or more air slots directs the filaments of pressurized liquid adhesive discharged from the at least two liquid slots in a pattern. The one or more air slots of the first air shim plate are configured to direct the pressurized air along a first angle relative to the adhesive shim plate, and when the at least two liquid slots discharge liquid adhesive filaments, one of the one or more air slots is configured to direct the pressurized air to the liquid adhesive filaments discharged by the at least two liquid slots.

[0013] According to another embodiment of the present disclosure, a nozzle for dispensing a pattern of liquid adhesive filaments can include a first air shim plate and an adhesive shim plate. The first air shim plate has one or more air slots configured to receive and direct pressurized air. The adhesive shim plate has at least one liquid slot configured to receive pressurized liquid adhesive and discharge at least one liquid adhesive filament, and the pressurized air directed by the one or more air slots directs the at least one liquid adhesive filament of the pressurized liquid adhesive discharged from the at least one liquid slot into the pattern. The one or more air slots of the first air shim plate are configured to direct the pressurized air along a first angle relative to the adhesive shim plate, and when the at least one liquid slot discharges the at least one liquid adhesive filament, one of the one or more air slots is configured to direct the pressurized air to the at least one liquid adhesive filament discharged by the at least one liquid slot. Each of the one or more air slots of the first air shim plate has a respective air outlet defining a width of at least 1 mm.

[0014] The foregoing summary, as well as the following detailed description, of exemplary embodiments of the nozzle of the present application will be better understood when read in conjunction with the accompanying drawings. For the purposes of illustrating the nozzle of the present application, exemplary embodiments are shown in the drawings. It will be understood, however, that the application is not limited to the precise arrangements and arrangements shown. [Brief description of the drawings]

[0015] [Figure 1] FIG. 2 is an assembled perspective view of one embodiment of a nozzle. [Diagram 2] FIG. 2 is an exploded / disassembled side perspective view of the nozzle shown in FIG. 1 including a first air shim plate, an adhesive shim plate, and a second air shim plate. [Diagram 3] FIG. 2 is a front elevational view of a first air shim plate of the nozzle of FIG. [Figure 4]FIG. 2 is a front elevational view of an isolated shim plate for the nozzle of FIG. 1; [Diagram 5] FIG. 2 is a front elevational view of an adhesive shim plate of the nozzle of FIG. 1. [Figure 6] FIG. 6 is a cross-sectional view taken along line 6-6 in FIG. [Figure 7] FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. [Figure 8] FIG. 2 is an enlarged view of the area surrounded by the dotted line in FIG. [Figure 9] FIG. 2 is an assembled bottom perspective view of the nozzle of FIG. [Figure 10] FIG. 10 is an enlarged view of the area surrounded by the dotted line in FIG. [Figure 11] FIG. 2 is a bottom view of the nozzle of FIG. 1. [Figure 12] FIG. 6 is a front elevational view of another embodiment of the adhesive shim plate of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] The present disclosure may be more readily understood by reference to the following detailed description taken in conjunction with the accompanying figures and examples, which form a part of this disclosure. It should be understood that the present disclosure is not limited to the specific devices, methods, applications, conditions or parameters described and / or illustrated herein, and the terminology used herein is intended to describe specific embodiments by way of example only, and is not intended to limit the scope of the present disclosure. Also, as used in the specification, including the appended claims, the singular forms "a," "an," and "the" include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise.

[0017] As used herein, the term "plurality" means more than one. When ranges of values ​​are expressed, other embodiments include from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it is understood that the particular value forms another embodiment. All ranges are inclusive and combinable.

[0018] 1 and 2 show one embodiment of a nozzle 10 for dispensing a pattern of liquid adhesive filaments (not shown), such as a uniform pattern of hot melt adhesive material and / or the like. As described in more detail below, the nozzle 10 may be configured such that pressurized air, such as pressurized process air, is asymmetrically directed at the liquid adhesive filaments. This general principle may be incorporated into a wide variety of adhesive dispensing systems. Thus, while the configuration of the nozzle 10 is described in detail, those skilled in the art will understand that the nozzle 10 is merely one example of a solid nozzle in which components may be arranged, drilled, or otherwise modified to achieve the configuration described below.

[0019] The nozzle 10 may include a nozzle body 12 with a first end plate 14 and a second end plate 16 secured to respective sides of the nozzle body 12. The nozzle body 12 may have a triangular or wedge-shaped cross-sectional configuration having a first surface 20 and a second surface 22 that converge toward one another and a top surface 18 that extends generally between the first surface 20 and the second surface 22. Nozzle 10 may include lateral protrusions 24, 26 on either side of top surface 18, which may secure nozzle 10 to a dispensing valve, dispensing module, and / or the like (not shown), as shown and described in U.S. Pat. No. 8,074,902, issued December 13, 2011, and entitled "Nozzle and Method for Dispensing Random Patterns of Adhesive Filaments," and U.S. Pat. No. 6,676,038, issued January 13, 2004, and entitled "Universal Dispensing System for Air-Assisted Extrusion of Liquid Filaments," the disclosures of both of which are incorporated herein by reference.

[0020] Nozzle body 12 may further include a liquid inlet 32 ​​disposed on top surface 18 for receiving pressurized liquid adhesive when nozzle 10 is secured to a dispense valve, dispense module, and / or the like. A seal member 34 may be disposed within and / or around liquid inlet 32 ​​to prevent leakage between these components. Top surface 18 may have multiple process air inlets 36a, 36b, 36c, 36d (e.g., pressurized process air inlets) for receiving pressurized air. FIGS. 1 and 2 further show process air inlets 36a, 36b, 36c, 36d formed in first arcuate channel 40 or second arcuate channel 42 on either side of liquid inlet 32. More specifically, the first process air inlet 36a and the second process air inlet 36b may be configured and disposed at a bottom surface 44 of the first arcuate channel 40, and the third process air inlet 36c and the fourth process air inlet 36d may be configured and disposed at a bottom surface 46 of the second arcuate channel 42. The first arcuate channel 40 and / or the second arcuate channel 42 may help to evenly distribute the pressurized air directed and / or supplied to the top surface 18 to the respective uses of the process air inlets 36a, 36b, 36c, 36d.

[0021] In one embodiment, the first end plate 14 may be secured to a first surface 20 of the nozzle body 12, and the second end plate 16 may be secured to a second surface 22 of the nozzle body 12. Additionally, the nozzle 10 may include a first air shim plate 50, a breakaway shim plate 52, an adhesive shim plate 54, or the like, which may be disposed between the first end plate 14 and the first surface 20. The first air shim plate 50 is described below as serving to direct pressurized air, although it will be understood that in alternative embodiments, the first end plate 14 may be provided with grooves (not shown) and / or the like for this purpose.

[0022] The first air shim plate 50, the isolation shim plate 52, and the adhesive shim plate 54 can be coupled to be disposed substantially parallel to the first surface 20. Threaded fasteners 60 can clamp the first air shim plate 50, the isolation shim plate 52, and the adhesive shim plate 54 between the first end plate 14 and the first surface 20. To this end, as illustrated in FIG. 2, one or more of the threaded fasteners 60 can include an enlarged head 62 that is held against the first end plate 14 and a threaded shaft 64 that extends through aligned holes 68, 70, 72, 74 in the first end plate 14, the first air shim plate 50, the isolation shim plate 52, and the adhesive shim plate 54, respectively, and engages a tapped hole (not shown) in the first surface 20. However, first end plate 14, first air shim plate 50, breakaway shim plate 52, and adhesive shim plate 54 may be attached to first surface 20 utilizing other components.

[0023] The second end plate 16 may be clamped or otherwise secured to the second surface 22 in substantially the same manner as the first end plate 14 and the first surface 20, but with the second air shim plate 80 disposed therebetween. However, the second end plate 16, the second air shim plate 80, etc. may be attached to the second surface 22 utilizing other components. Thus, the second air shim plate 80 may be coupled to be disposed substantially parallel to the second surface 22. The second air shim plate 80 is described below as serving to direct the pressurized air, but similar to the first end plate 14, the second end plate 16 may in alternative embodiments include grooves (not shown) and / or the like for this purpose. Thus, in some alternative embodiments, both the first end plate 14 and the second end plate 16 may direct the pressurized air in place of the first shim plate 50 and the second air shim plate 80.

[0024] 2, both the first end plate 14 and the second end plate 16 may further include protrusions or positioning members 84 that may facilitate proper positioning of the first end plate 14 and the second end plate 16, the first shim plate 50, the second air shim plate 80, the isolation shim plate 52, the adhesive shim plate 54, and / or the like relative to the nozzle body 12. To this end, the positioning member 84 of the second end plate 16 may extend through an upper slot or opening 86 of each of the second end plate 16 and the second air shim plate 80 before being received into a blind bore 88 of the second surface 22. Similarly, the positioning member 84 of the first end plate 14 may be configured to extend through an upper slot or opening 86 of each of the first end plate 14, the first air shim plate 50, the isolation shim plate 52, and the adhesive shim plate 54 before being received into a respective use of the blind bore 88 of the first surface 20.

[0025] FIG. 3 illustrates the first air shim plate 50 in further detail. The first air shim plate 50 and the second air shim plate 80 (FIG. 2) may have substantially the same structure so as to be interchangeable, such that the following description applies equally to the second air shim plate 80. As shown in FIG. 3, the first air shim plate 50 may include a bottom edge 98a and a plurality of air slots 100 extending from the bottom edge 98a. The first air shim plate 50 may include holes 102 configured and arranged to direct pressurized air from the nozzle body 12 to distribution channels 104 in the first end plate 14 (FIG. 2). As described in more detail below, the air slots 100 may be configured to receive and direct pressurized air from the first end plate 14.

[0026] In one embodiment, the air slots 100 can be disposed between opposing ends 106, 108 of the first air shim plate 50. Adjacent uses of the air slots 100 can converge toward one another as they extend toward the bottom edge 98a. For example, the first air shim plate 50 can include a tapered member 110 that can be defined between each adjacent use of the air slots 100. The air slots 100 can include air inlets 114a, 114b, 114c that can each be defined and / or disposed near a base 116 of the tapered member 110. The air slots 100 can include respective air outlets 118a, 118b, 118c that can each be defined between the bottom edge 98a and a terminal end 112 of the associated tapered member 110.

[0027] The air slots 100 may be tapered such that their respective widths are greater at each air inlet 114a, 114b, 114c than at each air outlet 118a, 118b, 118c. In some embodiments, the air slots 100 are not tapered, thereby defining a constant width from each air outlet to each air inlet. Additionally, although FIG. 3 shows a particular number of air slots 100, holes 102, tapered members 110, and / or terminations 112, the nozzle 10 may use any number of air slots 100, holes 102, tapered members 110, and / or terminations 112.

[0028] The width WOA of each air outlet 118a may be 5.0 mm. In some embodiments, the width WOA is greater than 1 mm. For example, the width WOA may range from 1 mm to 20 mm. In embodiments, the width WOA may be from 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, or 6 mm to 7 mm. In one embodiment, the width WOA may be in the range of 1 mm to 10 mm, 1 mm to 5 mm, or 1 mm to 2.5 mm.

[0029] The width W of each air inlet 114a may be 4.8 mm. In some embodiments, the width W is greater than 1 mm. For example, the width W may range from 1 mm to 20 mm. In some embodiments, the width W may be from 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, or 6 mm to 7 mm. In one embodiment, the width W may be in the range of 1 mm to 10 mm, 1 mm to 5 mm, or 1 mm to 2.5 mm.

[0030] The width WOB of each air outlet 118b may be 3.9 mm. In some embodiments, the width WOB is greater than 1 mm. For example, the width WOB may range from 1 mm to 20 mm. The width WOB may be different from the width WOA such that adjacent tapered members 110 are configured to overlap a portion of the adhesive shim plate 54, as described below. In an embodiment, the width WOB may be 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, or 6 mm to 7 mm. In an embodiment, the width WOA may be in the range of 1 mm to 10 mm, 1 mm to 5 mm, or 1 mm to 2.5 mm.

[0031] The width WIB of each air inlet 114b may be 3.5 mm. In some embodiments, the width WIB is greater than 1 mm. For example, the width WIB may range from 1 mm to 20 mm. The width WIB may be different from the width WIA such that adjacent tapered members 110 are configured to overlap a portion of the adhesive shim plate 54, as described below. In an embodiment, the width WIB may be 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, or 6 mm to 7 mm. In one embodiment, the width WIA may be in the range of 1 mm to 10 mm, 1 mm to 5 mm, or 1 mm to 2.5 mm.

[0032] The width Woe of each air outlet 118a may be 5.0 mm. In some embodiments, the width Woe is greater than 1 mm. In some embodiments, the width Woe may be 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, or 6 mm to 7 mm. For example, the width Woe may range from 1 mm to 20 mm. In one embodiment, the width Woe may range from 1 mm to 10 mm, 1 mm to 5 mm, or 1 mm to 2.5 mm.

[0033] The width W of each air inlet 114a may be 5.0 mm. In some embodiments, the width W is greater than 1 mm. For example, the width W may range from 1 mm to 20 mm. In some embodiments, the width W may be from 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, or 6 mm to 7 mm. For example, the width W may range from 1 mm to 20 mm. In one embodiment, the width W may be from 1 mm to 10 mm, 1 mm to 5 mm, or 1 mm to 2.5 mm.

[0034] The tapered members 110 can be configured to support the isolated shim plate 52 from bending when dispensing the high pressure material (e.g., hot melt adhesive material). For example, each of the tapered members 110 can be configured to abut both the isolated shim plate 52 and the first end plate 14. Each of the tapered members 110 can be configured to overlap a portion of the adhesive shim plate 54 that defines the distance Ds between adjacent liquid slots 136, thereby supporting the adhesive shim plate 54 (e.g., via the isolated shim plate 52) from bending when dispensing. In another embodiment, some of the tapered members can be configured to not overlap a portion of the adhesive shim plate.

[0035] The terminus 112 of the tapered member 110 can extend slightly beyond the plane defined by the bottom edge 98a. For example, the terminus 112 can extend beyond the plane by any range between 0.01 mm and 1 mm, or between 0.025 mm and 0.05 mm. In some embodiments, the terminus 112 can terminate at the plane defined by the bottom edge of the corresponding air shim. In one embodiment, the terminus 112 can be recessed from the plane defined by the bottom edge.

[0036] 4, the separated shim plate 52 may include holes 130 configured to align with the holes 102 (FIG. 3) of the first air shim plate 50. The separated shim plate 52 may be rectangular and may function as a spacer between the first air shim plate 50 and the adhesive shim plate 54. In some embodiments, multiple uses of the separated shim plate 50 may be disposed between the first air shim plate 50 and the adhesive shim plate 54.

[0037] 5 illustrates an adhesive shim plate 54. Similar to the separation shim plate 52, the adhesive shim plate 54 may include holes 134 configured to align with the holes 102 (FIG. 3) in the first air shim plate 50. The adhesive shim plate 54 may include a number of liquid slots 136 extending from a bottom edge 138 between opposing ends 142, 144 of the adhesive shim plate 54.

[0038] The liquid slots 136 may be parallel to one another. For example, the liquid slots 136 may be spaced apart an equal distance Ds (e.g., 0.26 mm) from one another. In embodiments, the distance Ds may be between 0.1 mm and 0.2 mm, between 0.2 mm and 0.3 mm, between 0.3 mm and 0.4 mm, between 0.4 mm and 0.5 mm, or between 0.m and 0.6 mm. In some embodiments, the distance Ds may range from any of 0.1 mm to 0.2 mm, or between 0.1 mm and 1 mm.

[0039] Each use of the liquid slot 136 may not vary in width along its length. For example, each use of the liquid slot 136 may include a respective use of a respective liquid inlet 156 and liquid outlet 158. The liquid slot 136 may extend at a constant width between an associated use of each liquid inlet 156 and a respective use of the liquid outlet 158. Additionally, although FIG. 5 illustrates a particular number of liquid slots 136, liquid outlets 158, and / or liquid inlets 156, the nozzle 10 may employ any number of liquid slots 136, liquid outlets 158, and / or liquid inlets 156.

[0040] For example, each liquid inlet 156 may define a respective inlet width WLI and each liquid outlet 158 ​​may define a respective outlet width WLO that may be the same as the inlet width WLI. The width WLI of each liquid inlet 156 may be 0.25 mm and the width WLO of each use mode of the liquid outlet 158 ​​may be 0.25 mm. In embodiments, the width WLI may be 0.1 mm to 0.2 mm, 0.2 mm to 0.3 mm, 0.3 mm to 0.4 mm, 0.4 mm to 0.5 mm, or 0.5 mm to 0.6 mm. In embodiments, the width WLI may be 0.1 mm to 0.2 mm, 0.2 mm to 0.3 mm, 0.3 mm to 0.4 mm, 0.4 mm to 0.5 mm, or 0.5 mm to 0.6 mm. In some embodiments, the width WLI may range from 0.1 mm to 0.2 mm, or 0.1 mm to 1 mm. In some embodiments, the width WLO may range from 0.1 mm to 0.2 mm, or from 0.1 mm to 1 mm.

[0041] The width of each slot taken together may be 5 mm. In some embodiments, the width of each slot of the adhesive shim plate taken together is less than 5 mm, for example 1 mm. In some embodiments, the width of each slot of the adhesive shim plate taken together is greater than 5 mm, for example 10 mm or 100 mm. In aspects, the width of each slot taken together may be 1 mm to 2 mm, 2 mm to 3 mm, 3 mm to 4 mm, 4 mm to 5 mm, 5 mm to 6 mm, 6 mm to 7 mm, 7 mm to 8 mm, 8 mm to 9 mm, 9 mm to 10 mm, 10 mm to 20 mm, 20 mm to 30 mm, 30 mm to 50 mm, or 50 mm to 100 mm.

[0042] 5 and 6, the adhesive shim plate 54 may be configured to receive pressurized liquid adhesive from the nozzle body 12 when the nozzle 10 is assembled. More specifically, the nozzle body 12 includes a liquid supply passage 150 (FIG. 5) that conveys pressurized liquid adhesive from the liquid inlet 32 ​​to a distribution channel 154 (shown diagrammatically in dotted lines in FIG. 4) defined in the first surface 20.

[0043] 4, a portion of the distribution channel 154 may extend across the first surface 20 proximate to a respective liquid inlet 156 of the liquid slot 136. Thus, pressurized liquid adhesive communicated to the distribution channel 154 enters the liquid slot 136 through the respective liquid inlet 156 and is directed towards the bottom edge 138. The pressurized liquid adhesive ultimately exits each use aspect of the liquid slot 136 through an associated liquid outlet 158 ​​as a filament of adhesive material.

[0044] 7, the nozzle body 12 may include an air supply passage 160 for directing pressurized air from each of the process air inlets 36a, 36b, 36c, 36d to the first surface 20 and the second surface 22. The nozzle body 12 may include a separate air supply passage 160 for each of the process air inlets 36a, 36b, 36c, 36d. The air supply passage 160 may be configured to direct the pressurized air through the holes 134 (FIGS. 2 and 5) in the adhesive shim plate 54. As a result, the pressurized air conveyed by the air supply passage 160 may flow through the holes 134 in the adhesive shim plate 54, the holes 130 in the isolation shim plate 52, and the holes 102 in the first air shim plate 50 before reaching the first end plate 14.

[0045] The first end plate 14 may include channels 104 (shown diagrammatically in FIGS. 2 and 3) formed in an inner surface 168 facing the first air shim plate 50. The distribution channels 104 are configured to direct pressurized air to respective air inlets 114a, 114b, 114c (FIG. 3) of the air slots 100. The distribution channels 104 may include vertical recesses 174 aligned with the holes 102 and non-horizontal recesses 178 intersecting the vertical recesses 174 and extending across the air inlets 114 of the air slots 100.

[0046] Pressurized air may be directed to and distributed by the second end plate 16 in a similar manner. For example, air supply passage 160 may be fluidly connected to process air inlets 36b, 36d and may be directed to holes 102 in second air shim plate 80 to allow the pressurized air to flow to distribution channels 182 formed in an inner surface 184 of second end plate 16. Distribution channels 182 may have a configuration similar to distribution channels 104, or at least operate on the same principles.

[0047] 7 and 8, in an assembled state, the first surface 20 of the nozzle body 12 defines a plane 190 and the second surface 22 defines a plane 192 positioned at an angle θ1 relative to the plane 190. Because the adhesive shim plate 54 is parallel to the first surface 20 (e.g., angle 0 degrees) and the second air shim plate 80 is parallel to the second surface 22, the second air shim plate 80 may be positioned at an angle θ1 relative to the adhesive shim plate 54. The angle θ1 may be 70 degrees. In some embodiments, the angle θ1 ranges anywhere from 40 degrees to 90 degrees.

[0048] 7 and 8 also show one example of the relative positions of the adhesive shim plate 54, the first air shim plate 50, the second air shim plate 80, the first end plate 14, the second end plate 16, and / or similar configurations when the nozzle 10 is assembled. The first air shim plate 50 may extend flush with the first end plate 14 such that an associated bottom edge 98a is not spaced apart from a bottom edge 200 of the first end plate 14.

[0049] The bottom edge 138 of the adhesive shim plate 54 may protrude beyond the bottom edge 98. For example, the bottom edge 138 may protrude beyond the bottom edge 98 anywhere from 0.1 mm to 2 mm, or 0.1 mm to 1 mm. The bottom edge 138 protruding beyond the bottom edge 98 may provide a reduction in air velocity by allowing air from the air outlets 118a, 118b, 118c to expand. The reduction in air velocity may provide the air to catch the adhesive fibers more effectively.

[0050] Similarly, the second air shim plate 80 may extend flush with the second end plate 16 such that the associated bottom edge 98 b is not spaced apart from the bottom edge 202 of the second end plate 16 .

[0051] The bottom edges 200, 202 may extend across a portion of the air slot 100 (FIG. 3) in related uses of the first air shim plate 50 and the second air shim plate 80.

[0052] The location of the bottom edges 200 , 202 may correspond approximately to the terminal end 112 of the tapered member 110 .

[0053] 9 and 10, the second air shim plate 80 may be disposed between the second surface 22 and the second end plate 16 such that the terminus 112 extends slightly beyond the bottom edge 202. The first air shim plate 50 and the first end plate 14 may be disposed in a similar manner.

[0054] For example, the terminus 112 may protrude slightly beyond the bottom edge 200. For example, the terminus 112 may protrude anywhere in the range of 0.1 mm to 2 mm or 0.1 mm to 1 mm beyond the bottom edge 200. In one embodiment, the terminus 112 is flush with or recessed from the bottom edge of the corresponding air shim plate. For example, the terminus may be slightly recessed from the bottom edge 200 (e.g., anywhere in the range of 0.1 mm to 1 mm or 0.1 mm to 2 mm).

[0055] Each use of the air slot 100 can define an air passage extending from a respective air inlet 114a, 114b, 114c (FIG. 3) to a respective air outlet 118a, 118b, 118c to direct pressurized air to one or more liquid outlets 158 and / or filaments distributed by the liquid outlets 158.

[0056] In one embodiment, one or both of the first and second air shim plates 50 and 80 can be positioned such that their associated bottom edges are substantially flush with the bottom edge of the first end plate 14 or the bottom edge of the second end plate 16. In one aspect, the first and second air shim plates 50 and 80 can also be configured such that the terminus of the tapered members 110 are substantially aligned with the associated bottom edges in a plane defined by the corresponding bottom edges (FIG. 3).

[0057] 10 , the adhesive shim plate 54 can be positioned such that the plurality of liquid slots 136 are disposed between a single use of the air slots 100 of the first air shim plate 50 and a single use of the air slots 100 of the second air shim plate 80. As a result, only the single use of the air slots 100 of the first air shim plate 50 is configured to provide pressurized air to the plurality of liquid slots 136 and / or the filaments distributed by the liquid slots 136. Also, only the single use of the air slots 100 of the second air shim plate 80 is configured to provide pressurized air to the plurality of liquid slots 136 and / or the filaments distributed by the liquid slots 136.

[0058] A pair of opposing usage of the air slots 100 (e.g., one usage of the air slots 100 of the first air shim plate 50 and one usage of the air slots 100 of the second air shim plate 80) may be configured to supply pressurized air to the same usage of the liquid slots 136 and / or to the filaments dispensed by such usage of the liquid slots 136.

[0059] FIG. 11 shows the bottom of the nozzle 10, with the first end plate 14 and the second end plate 16 facing each other relative to the nozzle body 12. Respective air outlets 118a, 118b, 118c are shown on either side of the corresponding use of the liquid slot 136. During a dispensing operation, pressurized liquid adhesive is provided to the respective liquid inlets 156 of the liquid slots 136 in the adhesive shim plate 54, as described above. The liquid slots 136 may be configured to eject the pressurized liquid adhesive as adhesive filaments via the liquid outlets 158 (FIG. 10). The adhesive filaments may be ejected at a slight angle to the machine direction 210 (FIG. 6) of a substrate (not shown) passing the nozzle 10, due to the positioning of the nozzle 10 relative to the machine direction 210. At the same time, pressurized air is provided to the air inlets 114 (FIG. 3) of the air slots 100 in the first air shim plate 50 and the second air shim plate 80. The air passages defined by the air slots 100 can direct pressurized air towards the adhesive filaments exiting the liquid slots 136 .

[0060] The opposing use of each pair of air slots 100 may provide uniform pressure zones that can direct the filaments in a consistent and / or uniform manner. For example, the adhesive filaments may be directed by the pressure zones toward the substrate without moving back and forth in the "web direction" (i.e., substantially parallel to the machine direction 210) and without moving back and forth in the "cross-web direction" (i.e., substantially perpendicular to the machine direction 210). In this manner, the adhesive filaments may be deposited on the substrate in a consistent and / or uniform pattern generally along the machine direction 210. For example, to the naked eye, the pattern appears consistent and / or uniform, but when examined under a microscope, the pattern may appear as a random fiber pattern having multiple small fibers. In this regard, the disclosed configuration of the nozzle 10 provided these unexpected results.

[0061] The above implementation of the air slot 100, nozzle 10, and / or similar configurations to direct pressurized air at the adhesive filaments can result in improved intermittent performance and reduced hammerhead (e.g., about 30%), which can be inversely correlated with the air flow through the air slot 100. For example, an air slot 100 having a width greater than 1 mm can provide for the pressurized air to guide the adhesive filaments, thereby reducing deviations from the desired adhesive pattern applied. The air flow can be reduced, which can result in more random fibers. If the air flow is maintained at a high level, the air can cut the adhesive fibers into small pieces for dotted application. For example, the air curtain generated by the air slot 100 can encourage the adhesive fibers to break into more small pieces. In this regard, the disclosed configuration of the nozzle 10 provides these unexpected results.

[0062] During the intermittent outages, the air slot 100 can receive pressurized air at increased pressure and / or velocity to effectively "break" the adhesive filaments during the dispensing cycle, providing well-defined cut-off and cut-on edges in the deposition pattern. In this regard, the disclosed configuration of the nozzle 10 provides these unexpected results.

[0063] During the dispensing cycle, the pressurized air may be at a lower pressure and / or velocity compared to the intermittent outages.

[0064] The placement of the second air shim plate 80 relative to the adhesive shim plate 54 can provide well-defined cut-off and cut-on edges. For example, the second air shim plate 80 may be configured to direct the pressurized air in use immediately adjacent the liquid outlet 158 ​​(FIG. 5) due to the angle θ1 (FIG. 8) and the proximity of the bottom edge 98b to the bottom edge 138. This placement may allow the pressurized air to impinge on the adhesive filament as soon as it is ejected from the liquid outlet 158. In this regard, the disclosed configuration of the nozzle 10 provided these unexpected results.

[0065] 12, a second embodiment of an adhesive shim plate 54' is shown. It should be understood that the second embodiment may be similar to the first embodiment of the adhesive shim plate 54 shown in, for example, FIG. 5. Accordingly, the same reference numbers used above with respect to the first embodiment may also be used with the "primary" designation with respect to the second embodiment. It should also be understood that, unless otherwise noted below, the components (and features thereof) of the second embodiment adhesive shim plate 54' may be similar to the components of the first embodiment adhesive shim plate 54.

[0066] The adhesive shim plate 54' can define a single liquid slot 136' that defines a single liquid inlet 156' and a single liquid outlet 158'. The liquid inlet 156' can define an inlet width WLI and the liquid outlet 158' can define an outlet width WLO that can be the same as the inlet width WLI. The width WLI of the liquid inlet 156' can be 10 mm and the width WLO of the liquid outlet 158' can be 10 mm. In embodiments, the outlet width WLO can be 6 mm to 7 mm, 7 mm to 8 mm, 8 mm to 9 mm, 9 mm to 10 mm, 10 mm to 12 mm, or 12 mm to 14 mm. In embodiments, the inlet width WLI can be 6 mm to 7 mm, 7 mm to 8 mm, 8 mm to 9 mm, 9 mm to 10 mm, 10 mm to 12 mm, or 12 mm to 14 mm. In some embodiments, the width WLI can be in the range of 10 mm to 20 mm, 20 to 30 mm, 30 mm to 50 mm, or 50 mm to 100 mm. In some embodiments, the width WLO can be in the range of 10 mm to 20 mm, 20 to 30 mm, 30 mm to 50 mm, or 50 mm to 100 mm.

[0067] The liquid outlet 158' may be configured to provide a single adhesive filament having a width the same as (or within 1%, 2%, 3%, 4%, or 5%) the width WLO when dispensed on the substrate. When the nozzle 10 is assembled with the adhesive shim plate 54' instead of the adhesive shim plate 54 (e.g., FIG. 6), each pair of opposing aspects of the air slots 100 (e.g., as shown in FIG. 10) may provide a uniform pressure zone that may guide the single adhesive filament in a consistent and / or uniform manner. For example, the adhesive filament may be guided by the pressure zone toward the substrate without moving back and forth in the "web direction" and without moving back and forth in the "cross-web direction." In this manner, the single adhesive filament may be deposited on the substrate in a consistent and / or uniform pattern generally along the machine direction 210. In this regard, the disclosed configuration of the nozzle 10 provides these unexpected results.

[0068] By directing pressurized air at a single adhesive filament through the air slot 100 described above, the nozzle 10 can provide improved intermittent performance and reduced hammerhead. For example, an air slot 100 having a width greater than 1 mm can be provided for the pressurized air to guide the adhesive filament, thereby reducing deviations from the desired adhesive pattern being applied. In this regard, the disclosed configuration of the nozzle 10 provides these unexpected results.

[0069] In the following description, certain terminology is used for convenience only and not as a limitation. The terms "right", "left", "bottom" and "top" refer to directions in the drawings to which reference is made. The terms "inside", "inner" and "inside" refer to directions toward the geometric center of the nozzle 10, and the terms "outside", "external" and "outside" refer to directions away from the geometric center of the nozzle. Terminology includes the terms listed above, derivatives thereof and terms of similar import.

[0070] Although the disclosure has been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, any of the embodiments disclosed herein can incorporate features disclosed with respect to any of the other embodiments disclosed herein. Furthermore, it is not intended to limit the scope of the disclosure to the specific embodiments described herein. As will be readily understood by those skilled in the art, any process, machine, manufacture, composition of matter, means, methods, or steps, whether currently existing or later developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized in accordance with the present disclosure.

[0071] For example, while FIG. 6 shows one arrangement of the nozzle 10 relative to the machine direction 210, the nozzle 10 can alternatively be arranged such that the machine direction 210 is in the opposite direction (e.g., from right to left in FIG. 6). In such an embodiment, the adhesive shim plate 54 emits adhesive filaments at a slight angle relative to the machine direction. The various aspects and features described herein can be used alone or in any combination, depending on the needs of the user. Thus, the disclosure in its broader aspects is 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.

Claims

1. A nozzle for dispensing patterns of liquid adhesive filament, The device comprises a first air shim plate having one or more air slots configured to receive and guide pressurized air, and an adhesive shim plate having at least two liquid slots configured to receive pressurized liquid adhesive and discharge liquid adhesive filaments, The pressurized air guided by the one or more air slots guides the pressurized liquid adhesive filaments discharged from the at least two liquid slots in a patterned manner. A nozzle wherein one or more air slots of the first air shim plate are configured to guide pressurized air along a first angle relative to the adhesive shim plate, and when the at least two liquid slots discharge the liquid adhesive filament, one of the one or more air slots guides pressurized air to the liquid adhesive filament discharged by the at least two liquid slots.

2. The nozzle according to claim 1, wherein one or more air slots of the first air shim plate are configured to guide pressurized air so as to guide the pressurized liquid adhesive filaments discharged from the liquid slots in the patterned manner.

3. The nozzle according to any one of claims 1 to 2, wherein the pattern is predetermined.

4. The nozzle according to any one of claims 1 to 3, wherein each of the one or more air slots of the first air shim plate has an air outlet defining a width in the range of 1 mm to 10 mm.

5. The nozzle according to claim 4, wherein the width of each of the aforementioned air outlets is in the range of 1 mm to 2.5 mm.

6. The nozzle according to any one of claims 1 to 5, wherein each of the at least two liquid slots has a liquid outlet defining a width in the range of 0.1 mm to 2 mm.

7. The nozzle according to claim 6, wherein the width of each of the liquid outlets is in the range of 0.1 mm to 1 mm.

8. The nozzle according to any one of claims 1 to 7, further comprising a separation shim plate disposed between the first air shim plate and the adhesive shim plate.

9. The nozzle according to any one of claims 1 to 8, wherein the at least two liquid slots are configured to extrude the liquid adhesive filament parallel to each other.

10. The nozzle according to any one of claims 1 to 9, wherein the at least two liquid slots are at least five liquid slots configured to receive pressurized liquid adhesive and extrude the liquid adhesive filament, and one of the one or more air slots is configured to direct pressurized air onto the liquid adhesive filament extruded by the at least five liquid slots.

11. The nozzle according to any one of claims 1 to 10, further comprising a second air shim plate, the second air shim plate having one or more air slots configured to receive and guide pressurized air, the one or more air slots of the second air shim plate being configured to guide pressurized air along a second angle relative to the adhesive shim plate, the first angle being different from the second angle, the first and second air shim plates being configured to asymmetrically direct the pressurized air toward the liquid adhesive filament, and the adhesive shim plate being positioned between the first and second air shim plates.

12. The nozzle according to claim 11, wherein the first angle is 0 degrees and the second angle is an angle in the range of 40 degrees to 90 degrees.

13. The nozzle according to any one of claims 11 to 12, further comprising: a nozzle body to which the first and second air shim plates and the adhesive shim plate are connected; a first end plate fixed to the first surface of the nozzle body, wherein the first air shim plate and the adhesive shim plate are positioned between the first end plate and the nozzle body; and a second end plate fixed to the second surface of the nozzle body, wherein the second air shim plate is positioned between the second end plate and the nozzle body.

14. The nozzle according to any one of claims 11 to 13, wherein the at least two liquid slots are at least five liquid slots configured to receive the pressurized liquid adhesive and discharge the liquid adhesive filament, and one or more air slots of the first air shim plate and the second air shim plate are configured to direct the pressurized air towards the liquid adhesive filament being discharged by the at least five liquid slots.

15. The nozzle according to any one of claims 11 to 14, wherein each of the liquid slots is positioned between one or more air slots of the first air shim plate and the second air shim plate, respectively.

16. A nozzle for dispensing patterns of liquid adhesive filament, The device comprises a first air shim plate having one or more air slots configured to receive and guide pressurized air, and an adhesive shim plate having at least one liquid slot configured to receive pressurized liquid adhesive and discharge at least one liquid adhesive filament, The pressurized air guided by the one or more air slots guides the pressurized filaments of the at least one liquid adhesive discharged from the at least one liquid slot in a patterned manner. The one or more air slots of the first air shim plate are configured to guide pressurized air along a first angle relative to the adhesive shim plate, and when the at least one liquid slot discharges the at least one liquid adhesive filament, one of the one or more air slots guides pressurized air to the at least one liquid adhesive filament discharged by the at least one liquid slot, and one of the one or more air slots of the first air shim plate has a nozzle, each having an air outlet that opens to a width of at least 1 mm.

17. The nozzle according to claim 16, wherein the width of each of the aforementioned air outlets is in the range of 1 mm to 10 mm.

18. The nozzle according to claim 17, wherein the width of each of the aforementioned air outlets is in the range of 1 mm to 2.5 mm.

19. The nozzle according to any one of claims 16 to 18, wherein each of the at least one liquid slots has a liquid outlet defining a width in the range of 0.1 mm to 2 mm.

20. The nozzle according to claim 19, wherein the width of each of the aforementioned liquid outlets is in the range of 0.1 mm to 1 mm.

21. The nozzle according to any one of claims 16 to 20, wherein the at least one liquid slot is a single liquid slot, and the at least one liquid adhesive filament is a single adhesive filament.

22. The nozzle according to any one of claims 16 to 21, wherein the one or more air slots are three or more air slots.

23. The nozzle according to any one of claims 16 to 22, further comprising a second air shim plate, the second air shim plate having one or more air slots configured to receive and guide pressurized air, the one or more air slots of the second air shim plate configured to guide pressurized air along a second angle with respect to the adhesive shim plate, the first angle being different from the second angle, the first and second air shim plates being configured to asymmetrically direct the pressurized air toward the liquid adhesive filament, and the adhesive shim plate being positioned between the first and second air shim plates.

24. The nozzle according to claim 23, wherein the first angle is 0 degrees and the second angle is an angle in the range of 40 degrees to 90 degrees.

25. The nozzle according to any one of claims 23 to 24, further comprising: a nozzle body to which the first and second air shim plates and the adhesive shim plate are connected; a first end plate fixed to the first surface of the nozzle body, wherein the first air shim plate and the adhesive shim plate are positioned between the first end plate and the nozzle body; and a second end plate fixed to the second surface of the nozzle body, wherein the second air shim plate is positioned between the second end plate and the nozzle body.

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