US20200378062A1 - Apparatus and method for applying materials to substrates and related products - Google Patents
Apparatus and method for applying materials to substrates and related products Download PDFInfo
- Publication number
- US20200378062A1 US20200378062A1 US16/994,550 US202016994550A US2020378062A1 US 20200378062 A1 US20200378062 A1 US 20200378062A1 US 202016994550 A US202016994550 A US 202016994550A US 2020378062 A1 US2020378062 A1 US 2020378062A1
- Authority
- US
- United States
- Prior art keywords
- materials
- fabric
- yarn
- substrate
- applicators
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000463 material Substances 0.000 title claims abstract description 250
- 239000000758 substrate Substances 0.000 title claims abstract description 83
- 238000000034 method Methods 0.000 title claims abstract description 45
- 239000000654 additive Substances 0.000 claims abstract description 132
- 239000004744 fabric Substances 0.000 claims abstract description 109
- 239000000835 fiber Substances 0.000 claims abstract description 44
- 239000006185 dispersion Substances 0.000 claims abstract description 26
- 239000000203 mixture Substances 0.000 claims abstract description 24
- 230000003068 static effect Effects 0.000 claims abstract 3
- 239000002105 nanoparticle Substances 0.000 claims description 19
- 239000007788 liquid Substances 0.000 claims description 11
- 238000002156 mixing Methods 0.000 claims description 8
- 230000000717 retained effect Effects 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- 229910003460 diamond Inorganic materials 0.000 claims description 4
- 239000010432 diamond Substances 0.000 claims description 4
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052737 gold Inorganic materials 0.000 claims description 4
- 239000010931 gold Substances 0.000 claims description 4
- 239000010977 jade Substances 0.000 claims description 4
- 239000002245 particle Substances 0.000 claims description 4
- 229910052709 silver Inorganic materials 0.000 claims description 4
- 239000004332 silver Substances 0.000 claims description 4
- 229910052725 zinc Inorganic materials 0.000 claims description 4
- 239000011701 zinc Substances 0.000 claims description 4
- 239000004677 Nylon Substances 0.000 claims description 3
- 239000004809 Teflon Substances 0.000 claims description 3
- 229920006362 Teflon® Polymers 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- 230000000737 periodic effect Effects 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 239000007789 gas Substances 0.000 claims 1
- 230000001105 regulatory effect Effects 0.000 claims 1
- 230000000996 additive effect Effects 0.000 abstract description 103
- 239000012530 fluid Substances 0.000 description 12
- 230000008569 process Effects 0.000 description 8
- 238000001035 drying Methods 0.000 description 5
- 230000010354 integration Effects 0.000 description 5
- 230000007246 mechanism Effects 0.000 description 5
- 238000011084 recovery Methods 0.000 description 5
- 238000010792 warming Methods 0.000 description 5
- 238000009472 formulation Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 238000000889 atomisation Methods 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000007654 immersion Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000010985 leather Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 230000000845 anti-microbial effect Effects 0.000 description 1
- 239000004599 antimicrobial Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 210000003746 feather Anatomy 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 239000012510 hollow fiber Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000006225 natural substrate Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
- D06M23/06—Processes in which the treating agent is dispersed in a gas, e.g. aerosols
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B1/00—Applying liquids, gases or vapours onto textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing or impregnating
- D06B1/02—Applying liquids, gases or vapours onto textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing or impregnating by spraying or projecting
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
- D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
- D06M11/38—Oxides or hydroxides of elements of Groups 1 or 11 of the Periodic System
- D06M11/42—Oxides or hydroxides of copper, silver or gold
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
- D06M11/74—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon or graphite; with carbides; with graphitic acids or their salts
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/83—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
- D06M23/08—Processes in which the treating agent is applied in powder or granular form
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B5/00—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating
- D06B5/02—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating through moving materials of indefinite length
- D06B5/06—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating through moving materials of indefinite length through yarns, threads or filaments
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B5/00—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating
- D06B5/02—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating through moving materials of indefinite length
- D06B5/08—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating through moving materials of indefinite length through fabrics
Definitions
- the present invention relates to improving the characteristics of fabrics and other substrates that may or may not be related to fabrics. More particularly, the present invention relates to effective and cost-efficient application of materials such as additives to substrates including but not limited to fabrics, down feathers, fill, leather, synthetics, and yarn, which are generally referred to herein as materials.
- the present invention is an apparatus and a method for applying materials to substrates by spraying or otherwise directing the materials on to the substrate to infuse them on and/or into the substrate.
- Fabrics and applicable substrates mentioned are widely used throughout the world to make finished products such as clothing, bedding, and towels, to name just three.
- product manufacturers seek to establish in their products. These characteristics vary widely and can include, but not be limited to feel, temperature control, moisture control and microbe control. Manufacturers also seek to maintain the product integrity and the desired characteristics through many cycles of cleaning and usage. It is therefore important to treat materials effectively to enable desired characteristics. It is also important to be able to do so in a cost-effective manner.
- components, or materials such as additives are applied to fabric items in a wet condition, such as in a bath, by conventional spraying, coating, or foam.
- Application of material in a liquid state as currently accomplished is costly in terms of the amount of additive material used, the amount of liquid used to deliver the additive material and the energy required to dry the material after liquid immersion.
- the additive material delivery vehicle in the form of solvents and adherence-enhancing chemicals are increasingly undesirable components of the treatment that may remain in the substrate material and/or be exposed in the effluent downstream. Nevertheless, the desired material characteristics achieved by liquid additive application currently outweigh the negative consequences.
- additive material introduction to substrates also limit the number, form and type of desired additives that can be applied to fabrics particularly to improve their characteristics. Some additives may not be suitable for dispersion in a liquid and/or uniform introduction to the material. It may not be possible to combine a plurality of additives in a single liquid mixture and so multiple applications may be required. These and other limitations reduce the manufacturer's options for improving materials in a desired but cost-effective way. Therefore, what is needed is an apparatus and method for the effective application of one or more materials such as additives to a substrate by adhering and/or embedding the one or more materials on and/or into the substrate material. Further, what is needed is such an apparatus and method that provides additive application in a cost-effective process. In addition, what is needed is an apparatus and method to apply one or more sprayable materials to other types of substrates as well as components of materials, particularly nanoparticle additives but not limited thereto. Relatedly, the present invention forms new products including such additive materials.
- the applied materials may be sprayable or otherwise transferable onto and into the substrate. It is also an objective of the present invention to provide such an apparatus and method that improves additive material application in a cost-effective process.
- the present invention is a material application device that may be a stand-alone apparatus or that may form part of a more comprehensive system, such as a fabric or fill production and treatment apparatus.
- the material may be an additive, for example.
- the application device includes a plurality of applicators arranged in an array to provide a substantially uniform dispersion of the atomized material, which may be a plurality of materials, such as additives, onto a substrate so that at least a portion of the one or more applied materials is retained within, or at least attached to the surface of, the substrate.
- the focus of the description of the present invention is directed to application of one or more additives to fabrics and/or the components of fabrics; however, it is not limited to that substrate alone.
- the present invention may be used to adhere and/or embed one or more additive materials on and/or into fibers, yarns, down, fills, leather, and other synthetic or natural substrates, that may include porous and nonporous substrates.
- the substrate items may be stationary, or they may be moving during the application process.
- the number and arrangement of applicators in the array is selectable.
- the applicators include nozzles that are selectably positioned with respect to the substrate item or items to ensure substantial uniformity of additive material dispersion and substantially complete contact of applied material with the substrate.
- the device includes one or more manifolds to which the applicators are connected.
- the manifold supplies an additive material delivery vehicle, which may be air, to the applicators.
- the additive material or additive materials are also supplied to the applicators with the delivery vehicle and transmitted through applicator nozzles.
- the nozzles are configured to generate a dispersive pattern of the mixture, such as in a conical arrangement, for example, but not limited thereto.
- the delivery vehicle is configured to disperse the one or more additive materials onto the substrate with minimal liquid inclusion. As a result, the substrate is treated with the additive material(s) with minimal liquid and decreased drying requirements.
- the device optionally includes a heater used to warm the additive material enough to manipulate the physical properties thereof.
- the material substrate particularly synthetic fibers but not limited thereto, may have thermoplastic characteristics that allow the physical properties of such substrates to be modified when manipulated with and exposed to heat.
- the process of warming a substrate material to enhance additive adhesion is not limited to use of the additive application device described herein. That is, the mechanism of warming may be employed separate from the additive apparatus as described, with the one or more additives directed to the substrate material in an alternative way provided that the one or more additive materials or at least a portion thereof are embedded into or adhered onto the substrate.
- the warming of the substrate may also be accomplished by other means not limited to a heater placed adjacent to the substrate.
- the substrate may be warmed due to a process of making it, such as when synthetic materials are thermally set but not limited thereto.
- the material application device of the present invention may be used to improve characteristics of substrate items and any resultant product made using such substrate items.
- Prior systems for adding materials to substrates often involved immersing the substrate material in water or another solvent that included such additives or simply coating the surface of the substrate material with a treatment.
- the present invention enables introduction of the materials, such as additives, in a form that is close to dry relative to the immersion method while enabling integration of at least a portion of the additive into or onto the substrate. There is less energy required to complete drying, less water (with its corresponding waste removal obligations) used and the substrate is of a better quality with less residual dampness therein.
- the method of the present invention involves generating an additive material formulation, an additive material delivery vehicle and directing a dispersion of that mixture to the substrate material to be treated.
- the dispersed additive material formulation uses an efficient amount of moisture to allow the additive material to adhere to the substrate material or embed into the surface of the substrate material.
- the additive formulation is directed to the substrate material in a pattern and at a rate selected to provide substantially uniform dispersion on the substrate with enough speed, power, and pressure to ensure integration and while maximizing the efficiency of the additive material usage.
- the use of a relatively dry delivery vehicle reduces the time and energy required to dry the substrate to completion after additive material application.
- the apparatus of the present invention may also be used to apply one or more additives to a surface, such as a wall, a carpet, a chair, a computer keyboard, and any other substrate where it is of interest to treat at least the surface thereof with nanoparticle additives.
- the apparatus used to deliver a formulation of additives and the material delivery vehicle includes components that come in contact with the additive that are made of, or treated with, low surface tension substrate materials.
- the nanoparticles tend to adhere to interior surfaces of components such as pump walls, tubes, valves, and applicator nozzles when those interior surfaces are relatively rough.
- the surfaces of the components of the apparatus of the present invention that are designed to contact nanoparticle additives are either coated with low-surface-tension materials or are made of low-surface-tension materials. That includes nonmetallic materials such as Nylon and Teflon, for example.
- FIG. 1 is a front perspective view of an example of a fabric treatment apparatus including the material application device of the present invention.
- FIG. 2 is a rear perspective view of the apparatus of FIG. 1 .
- FIG. 3 is a front view of the apparatus of FIG. 1 .
- FIG. 4 is a side view of the apparatus of FIG. 1 .
- FIG. 5 is a side view of the material application device of the present invention showing a section of a fabric substrate arranged for treatment therein and including an optional fabric heating component.
- FIG. 6 is a perspective view of an embodiment of the applicator array of the material application device.
- FIG. 7 is a side view of the applicator manifold of the material application device without applicator nozzles.
- FIG. 8 is an end view of the applicator manifold and its two end caps.
- FIG. 9 is an example representation of the material delivery controller of the material application device for transfer of additive material to the applicator manifold.
- FIG. 10 is a photograph of fibers of a fabric or yarn substrate subjected to the application of an additive material using the apparatus and method of the present invention wherein the additives are embedded into or adhered onto the fabric or yarn.
- FIG. 11 is a simplified representation of a mobile version of the material application device of the present invention.
- the present invention provides an apparatus and method to facilitate the introduction and adhesion of one or more materials to a substrate with minimal after drying and processing required.
- the present invention improves the opportunity to enhance the characteristics of treated substrate through a more effective integration of the material or materials into the interstices of the substrate.
- the present invention provides a method for substrate material enhancement using the apparatus described. The steps of the method as described may be done in different orders without deviating from the scope of the invention.
- the method of the present invention involving the application of one or more additive materials to a substrate of interest results in the fabrication of products having improved characteristics due to the integration of one or more materials into and on the substrate so that it is effectively joined thereto.
- FIGS. 1-4 illustrate a fabric treatment apparatus 10 including a material application device 12 forming part thereof.
- the material application device 12 is shown as part of the fabric treatment apparatus 10 that includes other components, the device 12 may be a stand-alone device as well.
- the fabric treatment apparatus 10 may form part of a larger fabric manufacturing system.
- the apparatus 10 includes a fabric introduction section 14 , a fabric roller section 16 , an optional fabric treatment section 18 , a fabric recovery section 20 , and the material application device 12 . While this description describes the treatment of a fabric substrate, it is to be understood that it may also be used to treat other substrates in a similar way.
- the fabric introduction section 14 includes a plurality of preparation rollers 22 and an optional pretreater 24 that can be used to prepare a fabric for subsequent processing in the apparatus 10 .
- the fabric roller section 16 is used to configure the fabric in a desired alignment and for controlling the rate of fabric passage through the apparatus 10 .
- the fabric recovery section 20 is used to spool treated fabric for subsequent delivery and later processing into finished product. It is to be understood that the fabric introduction section 14 , the fabric roller section 16 , the optional fabric treatment section 18 , and the fabric recovery section 20 are all elements of a fabric processing system known to those of skill in the art.
- the apparatus 10 shown in FIGS. 1-4 represents examples of such known components and that representation is not intended to be limiting.
- the material application device 12 renders the apparatus 10 novel.
- the material application device 12 includes one or more additive material manifolds 26 and a plurality of additive material applicators 28 .
- Each manifold 26 is constructed to supply a dispersion vehicle to the applicators 28 .
- Each applicator 28 is constructed to deliver one or more materials, such as additives, to fabric 30 wherein the one or more additive materials are combined with the dispersion vehicle in a way that disperses the one or more additive materials in a selectable spray pattern on and into the fabric 30 .
- the dispersion vehicle may be air or another gaseous material.
- the one or more additive materials may be in solid, liquid, or gaseous form prior to the combination with the dispersion vehicle.
- the material application device 12 shown in the figures includes structural support members 32 to position the one or more manifolds 26 in a desired proximity to the fabric 30 as the fabric 30 is conveyed from the fabric introduction section 14 to the fabric recovery section 20 .
- the mechanism of conveyance of the fabric is of any form known to those skilled in the art and can include, but not be limited to, a belt-and-pulley system powered by a motor.
- the material application device 12 may optionally include a substrate heater such as fabric heater 100 that may be positioned on either or both sides of the fabric 30 .
- the fabric heater 100 may optionally be used to warm the fabric 30 to a selectable temperature prior to introducing the one or more additives to the fabric via the applicators 28 .
- the fabric heater 100 may be any sort of heating apparatus suitable for applying heat at a selectable temperature over a desired area.
- the fabric heater 100 may be a radiant heater or a convection heater with a directed blowing mechanism but not limited thereto.
- the material application device 12 may be configured so that there is a plurality of manifolds 26 wherein the manifolds are in opposing positions with the applicators 28 facing one another so that when the fabric 30 passes into space 34 between the opposing manifolds 26 , the one or more additive materials are sprayed onto both sides of the fabric 30 . It is to be understood that the one or more materials may be applied to just one side of the fabric 30 if that is desired. As shown in FIGS. 6-8 , the applicators 28 are removably coupled to ports 36 of the manifold 26 .
- Each of the applicators 28 includes a dispersion vehicle inlet 38 , a material additive inlet 40 , a mixing chamber 42 and a nozzle 44 .
- the inlets 38 and 40 may be of any sort suitable to direct fluids into the mixing chamber 42 .
- the mixing chamber 42 is configured to receive the additive material dispersion vehicle from the manifold 26 and enable turbulent fluid flow therein with the one or more additive materials introduced through the inlet 40 so that the one or more additive materials are well interspersed with the additive dispersion vehicle.
- the nozzles 44 are selected to maintain integrity and minimize clogging based on the materials selected to pass therethrough.
- the nozzles 44 include conical inserts 45 selected and arranged to generate a conical pattern on the fabric 30 passing by. It is to be understood that the nozzles 44 may be configured to generate any desired spray pattern not limited to a conical pattern.
- the nozzles 44 are arranged on the manifold 26 and the force of the applied pattern is selected to ensure substantially that the dispersions of additive material from adjacent nozzles 44 overlap. That configuration, the dispersion force selected, and the additive materials chosen are designed in combination to enhance the likelihood that the material application to the fabric 30 is complete and uniform over the entire surface of the fabric 30 .
- Each manifold 26 includes a first end cap 46 and a second end cap 48 .
- the first end cap 46 seals interior cavity 50 of the manifold 26 so that any dispersion vehicle introduced into the cavity 50 can only exit through the ports that are coupled to the dispersion vehicle inlets 38 of the applicators 28 .
- the second end cap 48 includes a supply port 52 that may be coupled to a dispersion vehicle supply.
- the dispersion vehicle supply may be an air compressor having a supply tube removably coupled to the supply port 52 of the manifold 26 .
- the dispersion vehicle is maintained at a force sufficient to cause turbulent mixing with the one or more additive materials in the mixing chamber 42 of the applicator 28 and sufficient to force the material-dispersion vehicle mixture to pass through the nozzle 44 with enough force to reach the fabric 30 passing by or retained in position adjacent to the manifolds 26 .
- the inlet 40 of each applicator 28 is removably coupled to an additive material supply tube 54 .
- the supply tubes 54 are coupled to one or more material sources represented by material source 56 .
- the amount, type, and rate of the one or more materials contained in the material source 56 is determined by programming of delivery controller 58 .
- the delivery controller 58 controls flow rate and flow volume through the supply tubes 54 by managing operation of pump apparatus 60 , which may be formed of a plurality of pumps, one for each of the supply tubes 54 . It is to be noted that the number and size of the supply tubes 54 is selectable and that the number of supply tubes 54 in operation for any material delivery event may also be selectable through the programming of the controller 58 .
- controller 58 may be programmed to deliver the one or more materials on a continuous, periodic, or sporadic basis. That control of material delivery rate and timing may be accomplished throughout the entire array of applicators 28 and it may be accomplished on a per applicator basis.
- the material application device 12 of the present invention may be used to improve characteristics of a substrate such as a fabric, and any resultant product made using such substrate.
- a substrate such as a fabric
- the present invention enables introduction of the material or materials in a form that is close to dry relative to the immersion method. There is less energy required to complete drying, less solvent (with its corresponding waste removal obligations) used and the fabric is of a better quality with less residual dampness therein.
- the method of the present invention involves generating a mixture of additive material and additive material delivery vehicle and directing a dispersion of that mixture to fabric to be treated.
- the dispersed mixture is sufficiently damp to cause the material to adhere to the fabric while the delivery vehicle is selected to be relatively dry, such as a gas like air, for example.
- the mixture is directed onto the fabric in a pattern and at a rate selected to provide substantially uniform dispersion on the fabric and embed into or adhere onto the fabric while maximizing the efficiency of additive material usage.
- the use of a relatively dry delivery vehicle reduces the time and energy required to dry the fabric to completion after additive material application.
- the material application device 12 or at least those components used to combine the one or more additive materials with the delivery vehicle and the applicator 28 may be employed to treat a surface with desired materials.
- the material application device 12 so configured can be used to apply one or more additive materials to a wall, a floor, a chair, a keyboard, and any other surface of interest.
- the type of additive material that may be used and the number of additive materials used in a single dispersion process is selectable.
- the additive material is preferably in a fluid form, such as a gas, a liquid, solid particles, or any combination thereof but not limited thereto.
- materials that may be deployed on and into a substrate such as a fabric using the present invention include, but are not limited to, anti-microbials, dyes, moisture suppressors, insulative materials and fluid transport regulators.
- Nanoparticles of materials may be applied to fabric with the present invention. Examples of suitable nanoparticles include, but are not limited to, Diamond, Gold, Silver, Jade, Copper, Zinc, and combinations thereof. Other types of particles may also be added or substituted.
- nanoparticles are suitable additive materials in the present invention
- additive materials sized in a manner so that they may not qualify as nanoparticles as conventionally understood are also contemplated as suitable additives in the present invention.
- FIG. 10 shows a fabric having nanoparticles bonded to fibers thereof. Such nanoparticles may also be used to treat other types of surfaces, such as walls, floors, chairs, keyboards, or any other substrate of interest using the mixing and delivery components of the material application device 12 .
- the material application device 12 is shown in the drawings as part of the more comprehensive and stationary fabric treatment apparatus 10 . It is to be understood that alternative configurations exist for the material application device 12 .
- the material application device 12 may be operated as a mobile device that is not specifically coupled to a stationary structure or to a broader treatment apparatus.
- FIG. 11 illustrates an example mobile apparatus that is a mobile container within which the components of the material application device 12 described herein may be contained.
- the mobile device with the material application device 12 includes the one or more additive material manifolds and the plurality of additive material applicators.
- the mobile device also includes the supply tubes that are coupled to or that may be coupled to one or more material sources that are retained in the mobile device or that are separate from the mobile device.
- the mobile device also includes the programmable material delivery controller. It may include one or more pumps for transferring the additive material or materials to the one or more manifolds.
- the mobile device may also or alternatively include couplings to connect to power and/or fluid transfer devices such as pumps.
- the mobile device may be wheeled as shown in FIG. 11 for ease of transfer such as when a substrate having a large area is to be treated with the applied material.
- the components of the material application device 12 that contact those types of materials are preferably treated with, or made of, materials that minimize additive material buildup thereon.
- the supply tubes 54 , the inlet 40 , the mixing chamber 42 , and the nozzles 44 are fabricated of a low-surface-tension material such as Nylon or Teflon, for example.
- at least the additive material contact surfaces of those components are treated with low-surface-tension material.
- the optional step of warming the substrate material to the point that its components are in a state of viscosity increases the adhesion of the additive material or materials on and into the fabric, yarn, or a surface to be treated.
- the apparatus and method of the present invention improve the uniformity and certainty of additive material inclusion in and on a fabric, yarn or surface while reducing drying time and overall expense of such an effort.
- the invention includes the process of applying the additive material described to any substrate wherein either or both the substrate and the additive material are warmed to a temperature suitable to enhance the adhesion of the additive material to the substrate.
- the substrate may be a solid or a fluid material.
- the substrate may also be a component of a product.
- the additive material is shown in FIG. 10 adhere to fiber of a fabric wherein the additive has been applied to the fabric.
- the additive may be applied to a component of the fabric before it is manufactured into a fabric. That component may be for example, a yarn or yarns used to make the fabric. That component may be fibers of the yarn or yarns used to make the fabric.
- the material application device 12 or another type of device can be used to direct fluid material onto fibers.
- the fluid material may be warmed to facilitate adhesion of the additive material to the fibers.
- the fibers may be warmed to facilitate that adhesion.
- Both the fluid additive material(s) and the fibers may be warmed to enhance the adhesion.
- the fibers may be warmed by applying heat to them prior to or while they are twisted into a yarn.
- the additive material may be applied to the fibers either before or after the fibers exit the spinneret while in a semi-solid state prior to twisting into a yarn through various methods of introduction into the screw extrusion or application after yarn stabilization.
- Fibers to be treated with the additive material may be of any shape, including those of uniform cross section, those of non-uniform cross section and those that are at least partially voided, such as fibers referred to as hollow fibers.
- the fibers of non-uniform cross-section such as those with a plurality of lobes including, but not limited to X-shaped, Y-shaped and W-shaped fibers, for example are suited for additive adhesion, whether warmed or not warmed, as they have perimeters that are greater than fibers of uniform cross-section, such as round fibers.
- fibers with non-uniform cross section effectively are formed with valleys, pockets and other entrapment configurations that are more likely to retain desired additive material or materials joined on and/or into the fiber structure than fibers having smooth perimeters.
- the additive material may be applied to fibers of any shape.
- Application of one or more desired additive materials at the fiber level enhances the effectiveness of the one or more additive materials when the fibers form part of a product because the additive material is integrated throughout the product rather than at the surface of the perimeter of the product.
- the material application device 12 or the mobile example described herein may be used to apply one or more additive materials to selectable fibers
- the one or more additive materials may be applied to fibers by using other types of application devices, as well as by contacting them with the additive material such as by placing them on, or immersing them into, a bath of fluid containing the one or more additive materials, whether or not warmed.
- the one or more additive materials may also be incorporated into the polymeric fluid prior to extruding the fibers through the spinneret.
- the application of one or more additive materials having desirable characteristics to individual fibers results in the formation of new fiber products having such characteristics. Further, products such as yarns and fabrics made with such fibers are also new products having such characteristics. More generally, the present invention produces enhanced products of all types because of the effective integration of the one or more additive materials on and into those products, wherein at least a portion of those one or more additive materials are nanoparticles.
Abstract
Description
- The present invention relates to improving the characteristics of fabrics and other substrates that may or may not be related to fabrics. More particularly, the present invention relates to effective and cost-efficient application of materials such as additives to substrates including but not limited to fabrics, down feathers, fill, leather, synthetics, and yarn, which are generally referred to herein as materials. The present invention is an apparatus and a method for applying materials to substrates by spraying or otherwise directing the materials on to the substrate to infuse them on and/or into the substrate.
- Fabrics and applicable substrates mentioned are widely used throughout the world to make finished products such as clothing, bedding, and towels, to name just three. There are many desirable characteristics that product manufacturers seek to establish in their products. These characteristics vary widely and can include, but not be limited to feel, temperature control, moisture control and microbe control. Manufacturers also seek to maintain the product integrity and the desired characteristics through many cycles of cleaning and usage. It is therefore important to treat materials effectively to enable desired characteristics. It is also important to be able to do so in a cost-effective manner.
- Presently, for the most part, components, or materials such as additives are applied to fabric items in a wet condition, such as in a bath, by conventional spraying, coating, or foam. Application of material in a liquid state as currently accomplished is costly in terms of the amount of additive material used, the amount of liquid used to deliver the additive material and the energy required to dry the material after liquid immersion. Moreover, the additive material delivery vehicle in the form of solvents and adherence-enhancing chemicals are increasingly undesirable components of the treatment that may remain in the substrate material and/or be exposed in the effluent downstream. Nevertheless, the desired material characteristics achieved by liquid additive application currently outweigh the negative consequences. In addition, existing methods for treating materials by applying additives thereto involve simply coating the substrate material rather than applying the additives in a way that integrates or embeds them into the material and so, while enhancing material characteristics, additive materials applied by current processes do not improve those characteristics as much as is possible.
- The described limitations of additive material introduction to substrates also limit the number, form and type of desired additives that can be applied to fabrics particularly to improve their characteristics. Some additives may not be suitable for dispersion in a liquid and/or uniform introduction to the material. It may not be possible to combine a plurality of additives in a single liquid mixture and so multiple applications may be required. These and other limitations reduce the manufacturer's options for improving materials in a desired but cost-effective way. Therefore, what is needed is an apparatus and method for the effective application of one or more materials such as additives to a substrate by adhering and/or embedding the one or more materials on and/or into the substrate material. Further, what is needed is such an apparatus and method that provides additive application in a cost-effective process. In addition, what is needed is an apparatus and method to apply one or more sprayable materials to other types of substrates as well as components of materials, particularly nanoparticle additives but not limited thereto. Relatedly, the present invention forms new products including such additive materials.
- It is an objective of the present invention to provide an apparatus and method for the effective application of one or more materials, such as additive materials, to a substrate such as a fabric but not limited thereto. The applied materials may be sprayable or otherwise transferable onto and into the substrate. It is also an objective of the present invention to provide such an apparatus and method that improves additive material application in a cost-effective process.
- These and other objectives are achieved with the present invention, which is a material application device that may be a stand-alone apparatus or that may form part of a more comprehensive system, such as a fabric or fill production and treatment apparatus. The material may be an additive, for example. The application device includes a plurality of applicators arranged in an array to provide a substantially uniform dispersion of the atomized material, which may be a plurality of materials, such as additives, onto a substrate so that at least a portion of the one or more applied materials is retained within, or at least attached to the surface of, the substrate. The focus of the description of the present invention is directed to application of one or more additives to fabrics and/or the components of fabrics; however, it is not limited to that substrate alone. For example, but not limited thereto, it is to be understood that the present invention may be used to adhere and/or embed one or more additive materials on and/or into fibers, yarns, down, fills, leather, and other synthetic or natural substrates, that may include porous and nonporous substrates. The substrate items may be stationary, or they may be moving during the application process. The number and arrangement of applicators in the array is selectable. The applicators include nozzles that are selectably positioned with respect to the substrate item or items to ensure substantial uniformity of additive material dispersion and substantially complete contact of applied material with the substrate. The device includes one or more manifolds to which the applicators are connected. The manifold supplies an additive material delivery vehicle, which may be air, to the applicators. The additive material or additive materials are also supplied to the applicators with the delivery vehicle and transmitted through applicator nozzles. The nozzles are configured to generate a dispersive pattern of the mixture, such as in a conical arrangement, for example, but not limited thereto. The delivery vehicle is configured to disperse the one or more additive materials onto the substrate with minimal liquid inclusion. As a result, the substrate is treated with the additive material(s) with minimal liquid and decreased drying requirements.
- The device optionally includes a heater used to warm the additive material enough to manipulate the physical properties thereof. The material substrate, particularly synthetic fibers but not limited thereto, may have thermoplastic characteristics that allow the physical properties of such substrates to be modified when manipulated with and exposed to heat. The process of warming a substrate material to enhance additive adhesion is not limited to use of the additive application device described herein. That is, the mechanism of warming may be employed separate from the additive apparatus as described, with the one or more additives directed to the substrate material in an alternative way provided that the one or more additive materials or at least a portion thereof are embedded into or adhered onto the substrate. The warming of the substrate may also be accomplished by other means not limited to a heater placed adjacent to the substrate. For example, the substrate may be warmed due to a process of making it, such as when synthetic materials are thermally set but not limited thereto.
- The material application device of the present invention may be used to improve characteristics of substrate items and any resultant product made using such substrate items. Prior systems for adding materials to substrates often involved immersing the substrate material in water or another solvent that included such additives or simply coating the surface of the substrate material with a treatment. On the other hand, the present invention enables introduction of the materials, such as additives, in a form that is close to dry relative to the immersion method while enabling integration of at least a portion of the additive into or onto the substrate. There is less energy required to complete drying, less water (with its corresponding waste removal obligations) used and the substrate is of a better quality with less residual dampness therein. The method of the present invention involves generating an additive material formulation, an additive material delivery vehicle and directing a dispersion of that mixture to the substrate material to be treated. The dispersed additive material formulation uses an efficient amount of moisture to allow the additive material to adhere to the substrate material or embed into the surface of the substrate material. The additive formulation is directed to the substrate material in a pattern and at a rate selected to provide substantially uniform dispersion on the substrate with enough speed, power, and pressure to ensure integration and while maximizing the efficiency of the additive material usage. The use of a relatively dry delivery vehicle reduces the time and energy required to dry the substrate to completion after additive material application.
- As noted, the apparatus of the present invention may also be used to apply one or more additives to a surface, such as a wall, a carpet, a chair, a computer keyboard, and any other substrate where it is of interest to treat at least the surface thereof with nanoparticle additives. For such types of additives, the apparatus used to deliver a formulation of additives and the material delivery vehicle includes components that come in contact with the additive that are made of, or treated with, low surface tension substrate materials. The nanoparticles tend to adhere to interior surfaces of components such as pump walls, tubes, valves, and applicator nozzles when those interior surfaces are relatively rough. The surfaces of the components of the apparatus of the present invention that are designed to contact nanoparticle additives are either coated with low-surface-tension materials or are made of low-surface-tension materials. That includes nonmetallic materials such as Nylon and Teflon, for example.
- These and other advantages of the invention will become more apparent upon review of the following detailed description, the accompanying drawings, and the appended claims.
-
FIG. 1 is a front perspective view of an example of a fabric treatment apparatus including the material application device of the present invention. -
FIG. 2 is a rear perspective view of the apparatus ofFIG. 1 . -
FIG. 3 is a front view of the apparatus ofFIG. 1 . -
FIG. 4 is a side view of the apparatus ofFIG. 1 . -
FIG. 5 is a side view of the material application device of the present invention showing a section of a fabric substrate arranged for treatment therein and including an optional fabric heating component. -
FIG. 6 is a perspective view of an embodiment of the applicator array of the material application device. -
FIG. 7 is a side view of the applicator manifold of the material application device without applicator nozzles. -
FIG. 8 is an end view of the applicator manifold and its two end caps. -
FIG. 9 is an example representation of the material delivery controller of the material application device for transfer of additive material to the applicator manifold. -
FIG. 10 is a photograph of fibers of a fabric or yarn substrate subjected to the application of an additive material using the apparatus and method of the present invention wherein the additives are embedded into or adhered onto the fabric or yarn. -
FIG. 11 is a simplified representation of a mobile version of the material application device of the present invention. - While the following description is directed for the embodiment of the invention wherein one or more materials such as additives are delivered to a substrate such as a fabric, it is to be understood that the invention is not limited thereto. Instead, the present invention provides an apparatus and method to facilitate the introduction and adhesion of one or more materials to a substrate with minimal after drying and processing required. In addition, the present invention improves the opportunity to enhance the characteristics of treated substrate through a more effective integration of the material or materials into the interstices of the substrate. Additionally, the present invention provides a method for substrate material enhancement using the apparatus described. The steps of the method as described may be done in different orders without deviating from the scope of the invention. The method of the present invention involving the application of one or more additive materials to a substrate of interest results in the fabrication of products having improved characteristics due to the integration of one or more materials into and on the substrate so that it is effectively joined thereto.
-
FIGS. 1-4 illustrate afabric treatment apparatus 10 including amaterial application device 12 forming part thereof. It is to be understood that while thematerial application device 12 is shown as part of thefabric treatment apparatus 10 that includes other components, thedevice 12 may be a stand-alone device as well. In addition, thefabric treatment apparatus 10 may form part of a larger fabric manufacturing system. For the example of the present invention represented in the drawings, theapparatus 10 includes afabric introduction section 14, afabric roller section 16, an optionalfabric treatment section 18, afabric recovery section 20, and thematerial application device 12. While this description describes the treatment of a fabric substrate, it is to be understood that it may also be used to treat other substrates in a similar way. - The
fabric introduction section 14 includes a plurality ofpreparation rollers 22 and anoptional pretreater 24 that can be used to prepare a fabric for subsequent processing in theapparatus 10. Thefabric roller section 16 is used to configure the fabric in a desired alignment and for controlling the rate of fabric passage through theapparatus 10. Thefabric recovery section 20 is used to spool treated fabric for subsequent delivery and later processing into finished product. It is to be understood that thefabric introduction section 14, thefabric roller section 16, the optionalfabric treatment section 18, and thefabric recovery section 20 are all elements of a fabric processing system known to those of skill in the art. Theapparatus 10 shown inFIGS. 1-4 represents examples of such known components and that representation is not intended to be limiting. Thematerial application device 12 renders theapparatus 10 novel. - With reference to
FIGS. 1-2 and 4-5 , thematerial application device 12 includes one or moreadditive material manifolds 26 and a plurality ofadditive material applicators 28. Each manifold 26 is constructed to supply a dispersion vehicle to theapplicators 28. Eachapplicator 28 is constructed to deliver one or more materials, such as additives, tofabric 30 wherein the one or more additive materials are combined with the dispersion vehicle in a way that disperses the one or more additive materials in a selectable spray pattern on and into thefabric 30. The dispersion vehicle may be air or another gaseous material. The one or more additive materials may be in solid, liquid, or gaseous form prior to the combination with the dispersion vehicle. Thematerial application device 12 shown in the figures includesstructural support members 32 to position the one ormore manifolds 26 in a desired proximity to thefabric 30 as thefabric 30 is conveyed from thefabric introduction section 14 to thefabric recovery section 20. The mechanism of conveyance of the fabric is of any form known to those skilled in the art and can include, but not be limited to, a belt-and-pulley system powered by a motor. - As illustrated in
FIG. 5 , thematerial application device 12 may optionally include a substrate heater such asfabric heater 100 that may be positioned on either or both sides of thefabric 30. Thefabric heater 100 may optionally be used to warm thefabric 30 to a selectable temperature prior to introducing the one or more additives to the fabric via theapplicators 28. Thefabric heater 100 may be any sort of heating apparatus suitable for applying heat at a selectable temperature over a desired area. For example, thefabric heater 100 may be a radiant heater or a convection heater with a directed blowing mechanism but not limited thereto. - It has been observed that at least some additive materials bind better to the fibers of the
fabric 30 when those fibers have been warmed to a point of increased viscosity, more particularly, at or greater than glass transition temperature. When the one or more additives contact thefabric 30 with viscous fibers, the additive material is retained in and on the fibers, particularly as those fibers cool while passing from theadditive application device 12 through to thefabric recovery section 20. That is, the additive material applied using theapplicators 28 adhere well to the fabric fibers. The resultant improved fabric has a better chance of retaining the desired characteristics imparted by the one or more additives for a longer period than when the one or more additives are applied to fabric that is cooler. This additive adhesion improvement resulting from additive material application when the fabric fibers are in a viscous state is not limited to additive introduction with a device such as thematerial application device 12 described herein. - With respect to
FIG. 6 and the other drawings, thematerial application device 12 may be configured so that there is a plurality ofmanifolds 26 wherein the manifolds are in opposing positions with theapplicators 28 facing one another so that when thefabric 30 passes intospace 34 between the opposingmanifolds 26, the one or more additive materials are sprayed onto both sides of thefabric 30. It is to be understood that the one or more materials may be applied to just one side of thefabric 30 if that is desired. As shown inFIGS. 6-8 , theapplicators 28 are removably coupled toports 36 of the manifold 26. Each of theapplicators 28 includes adispersion vehicle inlet 38, a materialadditive inlet 40, a mixingchamber 42 and anozzle 44. Theinlets chamber 42. The mixingchamber 42 is configured to receive the additive material dispersion vehicle from the manifold 26 and enable turbulent fluid flow therein with the one or more additive materials introduced through theinlet 40 so that the one or more additive materials are well interspersed with the additive dispersion vehicle. While theapplication device 12 is described herein as using a pump or other form of mechanical mechanism for moving the mixture through thenozzles 44, it is to be understood that alternative delivery mechanisms may be employed including, but not limited to, ultrasonic atomization, electrostatic atomization, and air atomization. - The
nozzles 44 are selected to maintain integrity and minimize clogging based on the materials selected to pass therethrough. In an embodiment of the invention, thenozzles 44 includeconical inserts 45 selected and arranged to generate a conical pattern on thefabric 30 passing by. It is to be understood that thenozzles 44 may be configured to generate any desired spray pattern not limited to a conical pattern. Thenozzles 44 are arranged on the manifold 26 and the force of the applied pattern is selected to ensure substantially that the dispersions of additive material fromadjacent nozzles 44 overlap. That configuration, the dispersion force selected, and the additive materials chosen are designed in combination to enhance the likelihood that the material application to thefabric 30 is complete and uniform over the entire surface of thefabric 30. - Each manifold 26 includes a
first end cap 46 and asecond end cap 48. Thefirst end cap 46 sealsinterior cavity 50 of the manifold 26 so that any dispersion vehicle introduced into thecavity 50 can only exit through the ports that are coupled to thedispersion vehicle inlets 38 of theapplicators 28. Thesecond end cap 48 includes asupply port 52 that may be coupled to a dispersion vehicle supply. For example, when air is used as the dispersion vehicle, the dispersion vehicle supply may be an air compressor having a supply tube removably coupled to thesupply port 52 of the manifold 26. The dispersion vehicle is maintained at a force sufficient to cause turbulent mixing with the one or more additive materials in the mixingchamber 42 of theapplicator 28 and sufficient to force the material-dispersion vehicle mixture to pass through thenozzle 44 with enough force to reach thefabric 30 passing by or retained in position adjacent to themanifolds 26. - Referring to
FIGS. 6 and 9 , theinlet 40 of eachapplicator 28 is removably coupled to an additivematerial supply tube 54. Thesupply tubes 54 are coupled to one or more material sources represented bymaterial source 56. The amount, type, and rate of the one or more materials contained in thematerial source 56 is determined by programming ofdelivery controller 58. Thedelivery controller 58 controls flow rate and flow volume through thesupply tubes 54 by managing operation ofpump apparatus 60, which may be formed of a plurality of pumps, one for each of thesupply tubes 54. It is to be noted that the number and size of thesupply tubes 54 is selectable and that the number ofsupply tubes 54 in operation for any material delivery event may also be selectable through the programming of thecontroller 58. In addition, thecontroller 58 may be programmed to deliver the one or more materials on a continuous, periodic, or sporadic basis. That control of material delivery rate and timing may be accomplished throughout the entire array ofapplicators 28 and it may be accomplished on a per applicator basis. - The
material application device 12 of the present invention may be used to improve characteristics of a substrate such as a fabric, and any resultant product made using such substrate. Whereas prior systems for adding materials to fabrics often involved submerging the fabric in water or another solvent that included such materials, the present invention enables introduction of the material or materials in a form that is close to dry relative to the immersion method. There is less energy required to complete drying, less solvent (with its corresponding waste removal obligations) used and the fabric is of a better quality with less residual dampness therein. The method of the present invention involves generating a mixture of additive material and additive material delivery vehicle and directing a dispersion of that mixture to fabric to be treated. The dispersed mixture is sufficiently damp to cause the material to adhere to the fabric while the delivery vehicle is selected to be relatively dry, such as a gas like air, for example. The mixture is directed onto the fabric in a pattern and at a rate selected to provide substantially uniform dispersion on the fabric and embed into or adhere onto the fabric while maximizing the efficiency of additive material usage. The use of a relatively dry delivery vehicle reduces the time and energy required to dry the fabric to completion after additive material application. It is to be understood that thematerial application device 12, or at least those components used to combine the one or more additive materials with the delivery vehicle and theapplicator 28 may be employed to treat a surface with desired materials. For example, thematerial application device 12 so configured can be used to apply one or more additive materials to a wall, a floor, a chair, a keyboard, and any other surface of interest. - The type of additive material that may be used and the number of additive materials used in a single dispersion process is selectable. The additive material is preferably in a fluid form, such as a gas, a liquid, solid particles, or any combination thereof but not limited thereto. Examples of materials that may be deployed on and into a substrate such as a fabric using the present invention include, but are not limited to, anti-microbials, dyes, moisture suppressors, insulative materials and fluid transport regulators. Nanoparticles of materials may be applied to fabric with the present invention. Examples of suitable nanoparticles include, but are not limited to, Diamond, Gold, Silver, Jade, Copper, Zinc, and combinations thereof. Other types of particles may also be added or substituted. In addition, while nanoparticles are suitable additive materials in the present invention, additive materials sized in a manner so that they may not qualify as nanoparticles as conventionally understood are also contemplated as suitable additives in the present invention.
FIG. 10 shows a fabric having nanoparticles bonded to fibers thereof. Such nanoparticles may also be used to treat other types of surfaces, such as walls, floors, chairs, keyboards, or any other substrate of interest using the mixing and delivery components of thematerial application device 12. - The
material application device 12 is shown in the drawings as part of the more comprehensive and stationaryfabric treatment apparatus 10. It is to be understood that alternative configurations exist for thematerial application device 12. For example, and not limited thereto, thematerial application device 12 may be operated as a mobile device that is not specifically coupled to a stationary structure or to a broader treatment apparatus.FIG. 11 illustrates an example mobile apparatus that is a mobile container within which the components of thematerial application device 12 described herein may be contained. In particular, the mobile device with thematerial application device 12 includes the one or more additive material manifolds and the plurality of additive material applicators. The mobile device also includes the supply tubes that are coupled to or that may be coupled to one or more material sources that are retained in the mobile device or that are separate from the mobile device. The mobile device also includes the programmable material delivery controller. It may include one or more pumps for transferring the additive material or materials to the one or more manifolds. The mobile device may also or alternatively include couplings to connect to power and/or fluid transfer devices such as pumps. The mobile device may be wheeled as shown inFIG. 11 for ease of transfer such as when a substrate having a large area is to be treated with the applied material. - When the one or more additive materials includes one or more nanoparticles and/or other solid materials, the components of the
material application device 12 that contact those types of materials are preferably treated with, or made of, materials that minimize additive material buildup thereon. For example, thesupply tubes 54, theinlet 40, the mixingchamber 42, and thenozzles 44 are fabricated of a low-surface-tension material such as Nylon or Teflon, for example. Alternatively, at least the additive material contact surfaces of those components are treated with low-surface-tension material. - The optional step of warming the substrate material to the point that its components are in a state of viscosity increases the adhesion of the additive material or materials on and into the fabric, yarn, or a surface to be treated. The apparatus and method of the present invention improve the uniformity and certainty of additive material inclusion in and on a fabric, yarn or surface while reducing drying time and overall expense of such an effort.
- While the step of warming has been described herein with respect to modification of a material's physical properties specifically, it is to be understood that the invention is not limited thereto. The invention includes the process of applying the additive material described to any substrate wherein either or both the substrate and the additive material are warmed to a temperature suitable to enhance the adhesion of the additive material to the substrate. The substrate may be a solid or a fluid material. The substrate may also be a component of a product. For example, the additive material is shown in
FIG. 10 adhere to fiber of a fabric wherein the additive has been applied to the fabric. However, the additive may be applied to a component of the fabric before it is manufactured into a fabric. That component may be for example, a yarn or yarns used to make the fabric. That component may be fibers of the yarn or yarns used to make the fabric. - In a situation where individual fibers are treated with an additive material, the
material application device 12 or another type of device can be used to direct fluid material onto fibers. The fluid material may be warmed to facilitate adhesion of the additive material to the fibers. The fibers may be warmed to facilitate that adhesion. Both the fluid additive material(s) and the fibers may be warmed to enhance the adhesion. The fibers may be warmed by applying heat to them prior to or while they are twisted into a yarn. For man-made fibers that are fabricated from a polymeric fluid that passes through a spinneret and cooled to form fibers. The additive material may be applied to the fibers either before or after the fibers exit the spinneret while in a semi-solid state prior to twisting into a yarn through various methods of introduction into the screw extrusion or application after yarn stabilization. - Fibers to be treated with the additive material may be of any shape, including those of uniform cross section, those of non-uniform cross section and those that are at least partially voided, such as fibers referred to as hollow fibers. The fibers of non-uniform cross-section, such as those with a plurality of lobes including, but not limited to X-shaped, Y-shaped and W-shaped fibers, for example are suited for additive adhesion, whether warmed or not warmed, as they have perimeters that are greater than fibers of uniform cross-section, such as round fibers. Moreover, fibers with non-uniform cross section effectively are formed with valleys, pockets and other entrapment configurations that are more likely to retain desired additive material or materials joined on and/or into the fiber structure than fibers having smooth perimeters. Nevertheless, the additive material may be applied to fibers of any shape. Application of one or more desired additive materials at the fiber level enhances the effectiveness of the one or more additive materials when the fibers form part of a product because the additive material is integrated throughout the product rather than at the surface of the perimeter of the product.
- Further, while the
material application device 12 or the mobile example described herein may be used to apply one or more additive materials to selectable fibers, the one or more additive materials may be applied to fibers by using other types of application devices, as well as by contacting them with the additive material such as by placing them on, or immersing them into, a bath of fluid containing the one or more additive materials, whether or not warmed. The one or more additive materials may also be incorporated into the polymeric fluid prior to extruding the fibers through the spinneret. - The application of one or more additive materials having desirable characteristics to individual fibers results in the formation of new fiber products having such characteristics. Further, products such as yarns and fabrics made with such fibers are also new products having such characteristics. More generally, the present invention produces enhanced products of all types because of the effective integration of the one or more additive materials on and into those products, wherein at least a portion of those one or more additive materials are nanoparticles.
- The present invention of an apparatus and method for applying one or more additive materials to a substrate such as a fabric has been described with respect to specific components and method steps. Nevertheless, it is to be understood that various modifications may be made without departing from the spirit and scope of the invention. All equivalents are deemed to fall within the scope of this description of the invention as identified by the following claims.
Claims (25)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/994,550 US20200378062A1 (en) | 2018-02-19 | 2020-08-14 | Apparatus and method for applying materials to substrates and related products |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201862632308P | 2018-02-19 | 2018-02-19 | |
US201862744490P | 2018-10-11 | 2018-10-11 | |
PCT/US2019/018467 WO2019161350A1 (en) | 2018-02-19 | 2019-02-19 | Apparatus and method for applying additives to substrates and related products |
US16/994,550 US20200378062A1 (en) | 2018-02-19 | 2020-08-14 | Apparatus and method for applying materials to substrates and related products |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2019/018467 Continuation-In-Part WO2019161350A1 (en) | 2018-02-19 | 2019-02-19 | Apparatus and method for applying additives to substrates and related products |
Publications (1)
Publication Number | Publication Date |
---|---|
US20200378062A1 true US20200378062A1 (en) | 2020-12-03 |
Family
ID=67618792
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/994,550 Pending US20200378062A1 (en) | 2018-02-19 | 2020-08-14 | Apparatus and method for applying materials to substrates and related products |
Country Status (3)
Country | Link |
---|---|
US (1) | US20200378062A1 (en) |
CN (1) | CN111819318A (en) |
WO (1) | WO2019161350A1 (en) |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3905326A (en) * | 1973-12-04 | 1975-09-16 | Solbern Corp | Product spreading machine and method |
US5921472A (en) * | 1994-12-13 | 1999-07-13 | Spraying Systems Co. | Enhanced efficiency nozzle for use in fluidized catalytic cracking |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4072772A (en) * | 1973-08-09 | 1978-02-07 | Ppg Industries, Inc. | Linear curtain spray applicator |
US6379465B1 (en) * | 1999-09-17 | 2002-04-30 | Nordson Corporation | Coating system with centralized control panel and gun mapping |
KR100655791B1 (en) * | 2005-11-09 | 2006-12-08 | 정상래 | Injection device for nano silver |
US7878420B2 (en) * | 2005-12-08 | 2011-02-01 | Nordson Corporation | Purge arrangement for fast powder change |
US8236376B2 (en) * | 2008-09-02 | 2012-08-07 | Pascale Industries, Inc. | Production of nanoparticle-coated yarns |
KR101147305B1 (en) * | 2010-10-12 | 2012-05-18 | 나노씨엠에스(주) | Silver thin-film spread apparatus by means of deposition of nano metallic silver |
US20150004392A1 (en) * | 2013-06-28 | 2015-01-01 | The Boeing Company | Whisker-reinforced hybrid fiber by method of base material infusion into whisker yarn |
CN104278456B (en) * | 2014-09-30 | 2017-02-01 | 盐城工学院 | Electrostatic spraying method of anti-ultraviolet fabrics |
CN106757896A (en) * | 2016-12-14 | 2017-05-31 | 天津纶依特地毯有限公司 | A kind of atomizing carpet dyeing device |
-
2019
- 2019-02-19 CN CN201980013937.3A patent/CN111819318A/en active Pending
- 2019-02-19 WO PCT/US2019/018467 patent/WO2019161350A1/en active Application Filing
-
2020
- 2020-08-14 US US16/994,550 patent/US20200378062A1/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3905326A (en) * | 1973-12-04 | 1975-09-16 | Solbern Corp | Product spreading machine and method |
US5921472A (en) * | 1994-12-13 | 1999-07-13 | Spraying Systems Co. | Enhanced efficiency nozzle for use in fluidized catalytic cracking |
Also Published As
Publication number | Publication date |
---|---|
CN111819318A (en) | 2020-10-23 |
WO2019161350A1 (en) | 2019-08-22 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US9907705B2 (en) | Dispensing apparatus for applying adhesive on an elastic strand in assembly of a personal disposable hygiene product | |
US20020197396A1 (en) | Treated yarn and methods for making same | |
CN101351315B (en) | Granulation-coating machine for glass fiber granules | |
KR930011715B1 (en) | Method and apparatus for applying powdered materials to filaments | |
US20130240122A1 (en) | Method of manufacturing a personal hygiene product | |
US20200378062A1 (en) | Apparatus and method for applying materials to substrates and related products | |
US20140261967A1 (en) | Method of manufacturing a personal hygiene product | |
CN102877245B (en) | For the treatment of the method and apparatus of textiles | |
US9789499B2 (en) | Filament extension atomizers | |
US20140134346A1 (en) | System and method for application of nano staple | |
US11186025B2 (en) | Method and apparatus for producing fibre-reinforced plastic mouldings | |
AU2019344436B2 (en) | Manifold with auxiliary heat for distributing heated epoxy for spray application | |
KR101385124B1 (en) | Method for manufacturing collagen fabric and the collagen fabric manufactured by the same | |
JP4348653B2 (en) | Pile coating method | |
JP4452963B2 (en) | Pile coating method and pile coating apparatus | |
US7361227B2 (en) | Gas supply system for a powder-fluidizing apparatus | |
AU2019343883B2 (en) | Hose and manifold for distributing heated epoxy for spray application | |
KR20020087567A (en) | a mineral coating process for woven fabrics | |
NZ773979B2 (en) | Hose and manifold for distributing heated epoxy for spray application | |
BE1021411B1 (en) | TREATMENT SYSTEM FOR FIXED FIBER-MATERIALS | |
JPS6142355A (en) | Powder jet head | |
NZ773978B2 (en) | Manifold with auxiliary heat for distributing heated epoxy for spray application | |
RU2003100585A (en) | METHOD FOR THERMAL PROCESSING OF SYNTHETIC ROLL MATERIAL | |
CN109475831A (en) | System and method for mixing wet and drying material | |
WO2000015895A1 (en) | Method and apparatus for production of carburized fibres |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: FUZE BIOTECH, LLC, NEW HAMPSHIRE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PETERSON, ANDREW L.;REEL/FRAME:053505/0865 Effective date: 20200812 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |