APPARATUS AND METHOD FOR APPLYING MATERIALS TO SUBSTRATES AND RELATED PRODUCTS

Abstract

An apparatus and method for applying one or more materials, such as one or more additive materials, to a substrate. The substrate may be a fabric, fiber or yarn but not limited thereto. The apparatus includes an array of a plurality of applicators arranged in proximity to the substrate while the substrate is moving or in a static position. The applicators are arranged to deliver a mixture of one or more materials and a material delivery vehicle to the substrate sufficient to bond at least a portion of the one or more materials into the substrate or adhere the one or more materials to the surface of the substrate. The material delivery vehicle may be air. The applicators include nozzles configured to generate a dispersion pattern that provides substantially uniform and substantially complete coverage of the one or more materials onto and/or in the substrate. The apparatus may include an optional heater to warm the substrate to improve adhesion of the one or more materials on and into the substrate.

Claims

1. An apparatus for bonding one or more materials into or onto a fabric or a yarn, the apparatus comprising: one or more manifolds coupled to a source of a material delivery vehicle; a plurality of applicators removably affixed to each of the one or more manifolds, wherein each of the plurality of applicators is coupled to a source of one or more materials to be applied to the fabric or yarn, wherein each applicator includes a nozzle configured to direct a mixture of the one or more materials and the material delivery vehicle to the fabric or yarn sufficient to embed or adhere at least a portion of the one or more materials therein, and wherein the apparatus is configured to deliver one or more nanoparticles with minimal clogging; and a delivery controller coupled to the plurality of applicators and configured to regulate delivery of the mixture to the fabric or the yarn.

2. The apparatus of claim 1, wherein the plurality of applicators on each of the one or more manifolds are arranged to deliver the mixture in a uniform dispersion to the fabric or yarn.

3. The apparatus of claim 1, wherein the apparatus is arranged to deliver the mixture to the fabric or yarn when the fabric or yarn is static or moving.

4. The apparatus of claim 1, wherein the material delivery vehicle is air.

5. The apparatus of claim 1, wherein the one or more materials are one or more additives selected from one or more gases, one or more liquids, one or more particles or any combination thereof.

6. The apparatus of claim 5, wherein the one or more additives include nanoparticles of Diamond, Gold, Silver, Jade, Copper, Zinc, or any combination thereof.

7. The apparatus of claim 1, further comprising a heater arranged to warm the fabric or yarn to manipulate the thermal dynamic properties of the materials to prepare them for enhanced particle adhesion.

8. The apparatus of claim 1, wherein each of the applicators includes a delivery vehicle inlet port, a material inlet port and a mixing chamber arranged to mix the delivery vehicle and the one or more materials therein.

9. The apparatus of claim 1, wherein the delivery controller is coupled to a pump apparatus arranged to regulate the flow of the one or more materials to the applicators.

10. The apparatus of claim 1, wherein the apparatus is configured to deliver one or more nanoparticles with minimal clogging thereof.

11. The apparatus of claim 10, wherein one or more components of the apparatus are made completely or partially of low-surface-tension material.

12. The apparatus of claim 11, wherein the low-surface-tension material is selected from Nylon and Teflon.

13. A method for treating a fabric or yarn to modify one or more characteristics of the fabric, the method comprising the steps of: delivering the fabric or yarn to a material application device including a plurality of applicators, wherein each of the plurality of applicators is coupled to a source of one or more materials to be applied to the fabric or yarn, and wherein each applicator includes a nozzle arranged to direct a mixture of the one or more materials and a material delivery vehicle to the fabric or yarn sufficient to embed or adhere at least a portion of the one or more materials into the fabric or yarn; and applying the mixture at a selectable rate and in a selectable pattern onto the fabric or yarn.

14. The method of claim 13, wherein the selectable rate of applying the mixture is selected from continuous, periodic, or sporadic.

15. The method of claim 13, further comprising the step of heating the fabric or yarn prior to delivering the fabric or yarn to the material application device.

16. The method of claim 13, wherein the fabric or yarn is retained in a static position during the step of applying.

17. The method of claim 13, wherein the fabric or yarn is moved continuously to pass the plurality of applicators during the step of applying.

18. The method of claim 13 wherein one or more components of the device are made completely or partially of low-surface-tension material.

19. A method for treating a substrate with one or more materials, wherein at least one of the one or more materials is a nanoparticle material, the method comprising the steps of: applying the one or more materials on a surface of the substrate using a material application device including a plurality of applicators, wherein each of the plurality of applicators is coupled to a source of the one or more materials to be applied to the surface, and wherein each applicator includes a nozzle arranged to direct a mixture of the one or more materials and a material delivery vehicle to the surface, wherein the one or more materials include at least one nanoparticle material; and regulating a rate and a pattern of applying the mixture onto the surface.

20. The method of claim 19, wherein the selectable rate of spraying the mixture is selected from continuous, periodic, or sporadic.

21. The method of claim 19, wherein one or more components of the device are made completely or partially of low-surface-tension material.

22. The method of claim 19, wherein the one or more materials include nanoparticles of Diamond, Gold, Silver, Jade, Copper, Zinc, or any combination thereof.

23. A method of treating a fiber to enhance one or more characteristics thereof using one or more materials, the method comprising the steps of: combining a polymeric material used to make the fiber with the one or more materials; and forming the polymeric material into the fiber.

24. The method of claim 23 wherein the one or more materials include nanoparticles of Diamond, Gold, Silver, Jade, Copper, Zinc, or any combination thereof.

25. The apparatus of claim 1 wherein the apparatus is contained in a mobile container.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a front perspective view of an example of a fabric treatment apparatus including the material application device of the present invention.

[0012] FIG. 2 is a rear perspective view of the apparatus of FIG. 1.

[0013] FIG. 3 is a front view of the apparatus of FIG. 1.

[0014] FIG. 4 is a side view of the apparatus of FIG. 1.

[0015] 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.

[0016] FIG. 6 is a perspective view of an embodiment of the applicator array of the material application device.

[0017] FIG. 7 is a side view of the applicator manifold of the material application device without applicator nozzles.

[0018] FIG. 8 is an end view of the applicator manifold and its two end caps.

[0019] 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.

[0020] 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.

[0021] FIG. 11 is a simplified representation of a mobile version of the material application device of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0022] 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.

[0023] FIGS. 1-4 illustrate a fabric treatment apparatus 10 including a material application device 12 forming part thereof. It is to be understood that while 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. In addition, the fabric treatment apparatus 10 may form part of a larger fabric manufacturing system. For the example of the present invention represented in the drawings, 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.

[0024] 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.

[0025] With reference to FIGS. 1-2 and 4-5, 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.

[0026] As illustrated in FIG. 5, 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. For example, the fabric heater 100 may be a radiant heater or a convection heater with a directed blowing mechanism but not limited thereto.

[0027] 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 the fabric 30 with viscous fibers, the additive material is retained in and on the fibers, particularly as those fibers cool while passing from the additive application device 12 through to the fabric recovery section 20. That is, the additive material applied using the applicators 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 the material application device 12 described herein.

[0028] With respect to FIG. 6 and the other drawings, 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. While the application device 12 is described herein as using a pump or other form of mechanical mechanism for moving the mixture through the nozzles 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.

[0029] 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, 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.

[0030] 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. 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 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.

[0031] Referring to FIGS. 6 and 9, 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. In addition, the 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.

[0032] 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 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. For example, 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.

[0033] 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 the material application device 12.

[0034] 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. For example, and not limited thereto, 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. In particular, 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.

[0035] 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, 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. Alternatively, at least the additive material contact surfaces of those components are treated with low-surface-tension material.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.