Intermittent Barrier Nozzle for Precise High-Speed Adhesive Gaps
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Solution Overview
Problem
Conventional adhesive application systems struggle with precise control of adhesive application, leading to overspray, glue contamination, and reduced production efficiency due to overspray and glue strike through, especially during startup and at high line speeds.
Innovation Solution
A nozzle assembly with a convex edge region and multiple discharge orifices, including a first fluid conduit for adhesive discharge, a second fluid conduit for air discharge to cut off adhesive, and a third conduit for oscillation, allowing for precise control of adhesive application and reducing overspray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive supply is interrupted to create gaps, then adhesive application control is improved, but residual adhesive continues to discharge causing overspray
Solution Approach 1:
The air outlet orifices are positioned to discharge air directly into the adhesive flow path before the adhesive reaches the substrate. This preliminary air discharge action cuts off and clears residual adhesive from the nozzle orifices before the next adhesive application cycle begins, preventing overspray while maintaining precise gap positioning.
Solution Approach 2:
Air flow acts as an intermediary substance that interacts with the adhesive flow. The air discharged from the air outlet orifices creates a counter-flow that opposes and clears residual adhesive, enabling precise control of adhesive application start and stop positions without material loss.
2Manufacturing precision
If line speed is reduced to improve gap positioning, then adhesive application precision is improved, but production time increases
Solution Approach 1:
The air outlet orifices are positioned upstream relative to the adhesive orifices, allowing air to be discharged before adhesive reaches the substrate. This creates a self-cleaning effect that enables precise gap positioning even at high line speeds without requiring reduced speed for positioning accuracy.
3Device complexity
If air outlet orifices are spaced laterally from adhesive outlets, then device complexity is reduced, but adhesive is pushed beyond lateral edges causing overspray
Solution Approach 1:
The air outlet orifices are integrated into the same nozzle body as the adhesive orifices, with the air outlets positioned immediately adjacent to and facing the adhesive outlets. This merged configuration allows precise control of adhesive flow and lateral edge definition while maintaining a simple, unified nozzle structure.
4Device complexity
If conventional nozzle structure is used, then device complexity is low, but adhesive discharge is not fiberized causing glue strike through
Solution Approach 1:
Air is discharged through the air outlet orifices before and during adhesive discharge to create a counter-flow that fiberizes the adhesive. This preliminary air action ensures proper adhesive fiberization is achieved immediately upon startup, preventing glue strike through while maintaining a relatively simple nozzle structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The nozzle assembly enables accurate adhesive application with reduced overspray, improved lateral edge definition, and increased production efficiency by allowing higher line speeds and minimizing adhesive contamination.
Implementation Method 1
a second discharge orifice disposed downstream from and in fluid communication with the second fluid conduit, the second discharge orifice configured to discharge the second fluid generally in a second direction intersecting the first direction
Implementation Method 2
a third discharge orifice disposed downstream from and in fluid communication with the second fluid conduit, the third discharge orifice configured to discharge the second fluid to oscillate or vacillate the first fluid during discharge of the first fluid
Implementation Method 3
a convex edge region on one or more plates of the plurality of plates, and wherein the first, second and third discharge orifices are positioned along the convex edge region
Data Source
Figure 1A~3
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AI summary
A nozzle assembly for applying a fluid on a substrate includes a plurality of plates, a first fluid conduit having a first inlet configured and a first discharge orifice configured to discharge a first fluid generally in a first direction, and a second fluid conduit having a second inlet, a second discharge orifice configured to discharge a second fluid generally in a second direction intersecting the first direction and a third discharge orifice. The second fluid acts on the first fluid at the first discharge orifice. A method of applying the fluid on the substrate includes continuously feeding the substrate by the nozzle assembly, discharging, in the first direction, the first fluid from the first discharge orifice onto the substrate, discharging, in the second direction, the second fluid from the second discharge orifice, and discharging, generally in the first direction, the second fluid from the third orifice.