U.S. patent application number 11/845326 was filed with the patent office on 2009-03-05 for material application apparatus and methods.
Invention is credited to William E. Donges, Randy R. Fidler, Justin E. Hall, Jeffrey J. Kruke, Vincent A. Prieto, Jeffrey A. Wasko, Timothy E. Wilson.
Application Number | 20090061100 11/845326 |
Document ID | / |
Family ID | 39885105 |
Filed Date | 2009-03-05 |
United States Patent
Application |
20090061100 |
Kind Code |
A1 |
Donges; William E. ; et
al. |
March 5, 2009 |
MATERIAL APPLICATION APPARATUS AND METHODS
Abstract
Apparatus for spraying glass bottle mold bodies, such as blanks
and rings in a molding machine, includes nozzles and spray guns
mounted on a plate such that the nozzles are positioned to spray
the mold bodies with a material such as a lubricant during normal
operation of the machine and without shutting the machine down. The
apparatus can be installed on an existing machine without changing
the molding machine. Rings may be sprayed while in motion during
normal machine operation. A nozzle is provided along with check
valves to produce a tight conical spray pattern.
Inventors: |
Donges; William E.;
(Wellington, OH) ; Prieto; Vincent A.; (Lorain,
OH) ; Kruke; Jeffrey J.; (Lorain, OH) ;
Fidler; Randy R.; (Double Oak, TX) ; Wilson; Timothy
E.; (Wakeman, OH) ; Hall; Justin E.; (Avon,
OH) ; Wasko; Jeffrey A.; (Brunswick, OH) |
Correspondence
Address: |
CALFEE, HALTER & GRISWOLD, LLP
800 SUPERIOR AVENUE, SUITE 1400
CLEVELAND
OH
44114
US
|
Family ID: |
39885105 |
Appl. No.: |
11/845326 |
Filed: |
August 27, 2007 |
Current U.S.
Class: |
427/427.1 ;
118/314; 118/317; 118/318 |
Current CPC
Class: |
C03B 40/027
20130101 |
Class at
Publication: |
427/427.1 ;
118/314; 118/317; 118/318 |
International
Class: |
B05D 1/02 20060101
B05D001/02; B05C 7/02 20060101 B05C007/02; B05C 7/06 20060101
B05C007/06 |
Claims
1. Apparatus for applying a material to a glass mold, comprising: a
mold body that opens and closes during a glass molding operation,
and a material application gun and nozzle assembly with a nozzle
aimed to project a material application pattern of material onto an
internal surface of the mold body.
2. The apparatus of claim 1 wherein said nozzle sprays said
internal surface from a location that is to a side and below said
surface.
3. The apparatus of claim 1 wherein the mold body comprises one or
both of: a pair of blank halves that form a glass bottle shape
during a pierce and blow glass molding process; and a pair of ring
halves that form a threaded opening of a glass bottle during a
pierce and blow glass molding process.
4. The apparatus of claim 1 wherein the mold body comprises two
blank halves that when joined together form a glass bottle mold,
and two ring halves that when joined together form a threaded
opening for the glass bottle.
5. The apparatus of claim 4 comprising at least two blank nozzles
that each direct material onto a respective blank half, and two
ring nozzles that each direct material onto a respective ring
half.
6. The apparatus of claim 1 wherein the mold body comprises one or
more parts that are sprayed by said material application gun and
nozzle assembly while said parts are moving from one position to
another position.
7. The apparatus of claim 1 wherein said material application gun
and nozzle assembly is installable on a preexisting glass mold
machine to replace manual application of material on said internal
surface.
8. The apparatus of claim 1 comprising a plurality of nozzles with
a first set of one or more nozzles spraying a mold body surface
that is stationary during a spraying operation and a second set of
one or more nozzles spraying mold body surface that is moving as it
is being sprayed.
9. The apparatus of claim 8 comprising a first material application
gun that supplies material under pressure to said first set of one
or more nozzles and a second material application gun that supplies
material under pressure to said second set of one or more
nozzles.
10. The apparatus of claim 9 comprising a third material
application gun that supplies material under pressure to a third
nozzle that forms part of said second set of one or more
nozzles.
11. The apparatus of claim 1 wherein said material application gun
and nozzle assembly comprises: a frame having a first end and at
least one leg extending from said first end, a material application
gun supported at said first end of said frame, a first nozzle
supported by said leg at a first distance from said gun, a second
nozzle supported by said leg at a second distance from said gun,
said gun operating to spray material through said first and second
nozzles.
12. The apparatus of claim 11 wherein said first and second nozzles
produce respective first and second spray patterns in different
directions with respect to each other.
13. The apparatus of claim 11 comprising a second material
application gun and a third nozzle supported by said leg at a third
distance from said second material application gun.
14. The apparatus of claim 13 wherein said third nozzle produces a
third spray pattern in a different direction with respect to said
first and second nozzles.
15. The apparatus of claim 11 wherein said frame comprises a second
leg extending from said first end and generally parallel to said
first leg with a space therebetween so that said frame has a
generally U-shape configuration in plan view.
16. The apparatus of claim 15 comprising two or more nozzles
supported respectively on each of said first and second legs with
at least two nozzles supplied material from two different material
application guns supported at said first end of said frame.
17. The apparatus of claim 1 wherein said material application gun
and nozzle assembly comprises a spray gun, a first nozzle and a
first check valve disposed in a material flow path from said spray
gun outlet to said nozzle.
18. The apparatus of claim 17 wherein said check valve operates to
maintain a minimum pressure in a material flow path between said
spray gun and said check valve.
19. The apparatus of claim 18 wherein said check valve is disposed
closer to said nozzle than said check valve is disposed to said
spray gun.
20. The apparatus of claim 18 wherein said check valve has a
cracking pressure of at least 450 psi.
21. The apparatus of claim 20 wherein said spray gun outputs
material at a pressure of at least 500 psi.
22. The apparatus of claim 17 comprising first and second spray
guns and at least two nozzles, said spray guns being in fluid
communication with a manifold that has two separate material
inlets, two separate material flow paths and at least two material
outlets.
23. The apparatus of claim 17 comprising at least two nozzles that
are in fluid communication with a common flow path of a manifold
that is downstream said check valve.
24. The apparatus of claim 1 wherein said material application gun
and nozzle assembly produces at least one conical spray
pattern.
25. The apparatus of claim 24 wherein said conical spray pattern
extends from said nozzle to said internal surface across a distance
of about five inches to about eighteen inches or more.
26. The apparatus of claim 24 wherein said conical spray pattern
has a width of about one to about three inches for water sprayed at
500 psi to a target at ten inches from a nozzle and a flow rate of
about 0.03 to about 0.20 gallons per minute
27. The apparatus of claim 1 wherein said material jets from said
nozzle for a duration of less than about 70 msec.
28. A method for applying material to an internal surface of a
glass bottle mold, comprising the steps of: pressurizing the
material, and producing a spray of the material directed at said
surface.
29. The method of claim 28 comprising the step of producing said
spray by forcing said pressurized material through a nozzle
associated with a spray gun.
30. The method of claim 29 wherein said nozzle is aimed to direct a
spray pattern towards an interior surface of a blank used to mold a
glass bottle.
31. The method of claim 29 wherein said nozzle is aimed to direct a
spray pattern towards an interior surface of a threaded ring used
to mold a glass bottle.
32. The method of claim 31 wherein the ring is sprayed while it is
moving between a first position and a second position.
33. The method of claim 28 wherein the material is a lubricant that
is applied periodically to said internal surface, said spray being
produced to apply material to said internal surface without
interrupting a molding machine normal molding operations.
34. The method of claim 28 wherein said spray is produced when
pressurized material is forced through a nozzle from a spray gun
that is electrically actuated.
35. The method of claim 28 wherein said internal surface is one or
both of an internal surface of a blank and an internal surface of a
ring, said blank and ring forming a mold for a glass bottle.
36. The method of claim 28 wherein said spray is produced through
an orifice positioned to a side and below said surface.
36. Apparatus for applying a material to a glass mold, comprising:
a glass mold body that opens and closes, and a nozzle orifice aimed
to project a spray pattern of material onto an internal surface of
the mold body.
Description
TECHNICAL FIELD OF THE DISCLOSURE
[0001] The inventions relate to the art of applying material onto
surfaces. More particularly, the inventions relate to application
of material on surfaces such as, for example but not limited to,
internal surfaces of molds used during glass molding
operations.
BACKGROUND
[0002] Glass bottles are typically formed using a molding machine.
In a common process known in the art as pierce and blow, at a first
process station referred to herein as a parison forming station or
a pierce station, a gob of molten glass is dropped into a mold
through an opening or hole at the top of the mold, a baffle closes
the hole through which the gob was dropped into the mold, and a pin
pierces the gob to form a parison. The parison is transferred to a
second process station referred to herein as a blow station where
the bottle is blown into its final shape.
[0003] The molding machine typically includes a multi-piece mold
body assembly. The mold body for a single bottle commonly includes
two blank halves which together are used to shape the parison, and
two ring halves which together are used to form a top of the
bottle. A bottle top may be threaded or have another desired
configuration. Before the gob is dropped into the mold, the two
blank halves and two ring halves are fully assembled as a single
mold body. In order to remove the bottle, the mold blank halves are
swung apart and the mold ring halves are also separated. A
lubricant material, which also may serve as a release agent, is
periodically applied to the internal surfaces of the blanks and
rings. Typically, an upper region of the blanks has the lubricant
applied and the threads of the rings have lubricant applied. During
a normal molding operation, the blanks are opened to a stationary
position for a few seconds, but the rings are in motion between the
pierce station and the blow station. A single complete pierce and
blow cycle may typically last about four seconds.
[0004] All such molding apparatus for glass bottles require an
operator to apply the lubricant material manually to the internal
surfaces of the mold body, namely the rings and blanks. This is a
human intensive effort in close proximity to molten glass, and is
done with a brush. This effort is even more intense for machines
that include two or more molds. For example, a two bottle mold
machine has eight parison forming mold blank halves and four ring
halves. Because the rings are normally in motion between the pierce
and blow stations, the machine must be stopped in order to allow a
few seconds for the operator to apply the lubricant. This down time
necessarily equates into inefficiency and lost productivity Also,
there can be significant inconsistencies between different
operators as to the application of the lubricant under such extreme
conditions, including the reliance on manual application. If too
little or too much lubricant is applied, the result can be
defective bottles resulting in scrap, particularly for the first
few mold operations after the lubricant is applied.
SUMMARY OF THE INVENTIONS
[0005] The present disclosure presents a number of inventive
aspects for both apparatus and methods relating to the application
of a material, such as a lubricant for example, to interior
surfaces of a mold body. A typical mold body in one embodiment for
glass bottle manufacturing includes blanks and rings, but the
present disclosure is not limited to molds per se or molds used for
glass bottle manufacturing.
[0006] In accordance with one inventive aspect, apparatus is
provided for applying material to interior or exposed surfaces,
such as for example mold body surfaces, without manual application.
In one embodiment, the material is sprayed onto the surfaces from a
nozzle that receives pressurized material from a material
application gun. In a specific embodiment, the gun may be
electronically triggered on and off so that there is no operator
involvement required.
[0007] The disclosure also contemplates methods embodied in the use
of such apparatus. The disclosure further presents inventive
methods including a method for applying material to an internal
surface of a glass bottle mold, comprising the steps of
pressurizing the material, and producing a spray of the material
directed at the internal surface.
[0008] Further inventive aspects, advantages and benefits will
become apparent to those skilled in the art after considering the
following description in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a front elevation, simplified schematic of a glass
bottle molding machine pierce or parison forming station in use
with an embodiment of the invention;
[0010] FIG. 2 is a plan view of the arrangement of FIG. 1;
[0011] FIG. 3 is a side elevation of the arrangement of FIG. 1;
[0012] FIG. 4 is a simplified schematic of a glass molding machine
including a pierce station and a blow station, in use with an
embodiment of the invention;
[0013] FIG. 5 is an isometric of a first embodiment of a gun and
nozzle assembly;
[0014] FIG. 5A is an elevation of the assembly of FIG. 5;
[0015] FIG. 6 is a plan view of the assembly of FIG. 5;
[0016] FIG. 7 is a simplified hydraulic schematic suitable for use
with the apparatus of FIGS. 1-6;
[0017] FIG. 8 is an isometric of a second embodiment of a gun and
nozzle assembly;
[0018] FIGS. 9A-9C illustrate embodiments of a nozzle tip and tip
holder assembly as used in the embodiments of FIGS. 1-8.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] The inventions described herein are explained and
illustrated in the context of glass bottle molding systems.
However, many of the inventions herein will find utility and be
applicable to different molding apparatus, and even outside the
technological area of glass molding. For example, the inventions
herein may be used to apply material to surfaces other than the
internal surfaces of mold bodies. Additionally, the terms `spray`
and `spray pattern` are intended to be understood in their broadest
meaning to include not only those processes commonly referred to as
`spray` or `spraying` but additionally any application technique
involving the directing of a material across a space towards a
target. The spray pattern may be abut need not be atomized. When
used, atomization may be based on pressure, air, or both or other
atomization techniques and combinations thereof. Still further, the
terms `spray` and `spray patterns` are not to be limited to any
particular time duration that the material is directed towards the
target. In other words, very short bursts of material or narrow
jets of material are still to be construed as falling within the
understanding herein of the word `spray` and `spray pattern`.
Although the exemplary embodiments herein utilize liquid material,
the inventions herein may also find application with non-liquid
materials such as powders or powder/liquid mixtures for
example.
[0020] While various inventive aspects, concepts and features of
the inventions may be described and illustrated herein as embodied
in combination in the exemplary embodiments, these various aspects,
concepts and features may be used in many alternative embodiments,
either individually or in various combinations and sub-combinations
thereof. Unless expressly excluded herein all such combinations and
sub-combinations are intended to be within the scope of the present
inventions. Still further, while various alternative embodiments as
to the various aspects, concepts and features of the
inventions--such as alternative materials, structures,
configurations, methods, circuits, devices and components,
software, hardware, control logic, alternatives as to form, fit and
function, and so on--may be described herein, such descriptions are
not intended to be a complete or exhaustive list of available
alternative embodiments, whether presently known or later
developed. Those skilled in the art may readily adopt one or more
of the inventive aspects, concepts or features into additional
embodiments and uses within the scope of the present inventions
even if such embodiments are not expressly disclosed herein.
Additionally, even though some features, concepts or aspects of the
inventions may be described herein as being a preferred arrangement
or method, such description is not intended to suggest that such
feature is required or necessary unless expressly so stated. Still
further, exemplary or representative values and ranges may be
included to assist in understanding the present disclosure;
however, such values and ranges are not to be construed in a
limiting sense and are intended to be critical values or ranges
only if so expressly stated. Moreover, while various aspects,
features and concepts may be expressly identified herein as being
inventive or forming part of an invention, such identification is
not intended to be exclusive, but rather there may be inventive
aspects, concepts and features that are fully described herein
without being expressly identified as such or as part of a specific
invention, the scope of the inventions instead being set forth in
the appended claims or the claims of related or continuing
applications. Descriptions of exemplary methods or processes are
not limited to inclusion of all steps as being required in all
cases, nor is the order that the steps are presented to be
construed as required or necessary unless expressly so stated.
[0021] With reference to FIGS. 1-4, an exemplary use of an
embodiment of one or more of the present inventions is illustrated
in a schematic manner. In this example, a pierce or parison forming
station or section of a glass bottle molding machine S (FIG. 4) of
a glass bottle production line is generally indicated with the
reference letter A. The molding machine S also includes a blow
station M the details of which, as well as the details of the
parison forming station A, are well known and not pertinent to the
present inventions. The parison forming station apparatus A
includes a saddle B having first and second arms C and D. The
saddle and arms support one or more pairs of blank halves E and F
which are used to shape a parison to a desired configuration. In
the illustrated example, there are two mold bodies used in the
molding machine S to form two parisons, thus there are two pairs of
blank halves and two pairs of ring halves. The parison shape
facilitates the formation of the final glass bottle shape over at
the blow station. The blank halves E and F are opened and closed
during a molding operation. In a typical machine, the blank halves
may be separated by about fifty-nine degrees, but other angles of
separation may be used as needed when in the open position as
illustrated in FIGS. 1 and 2. When the machine A closes the mold
body, the blank halves are joined together at a centerline or axis
X of the machine. Note that in FIG. 3 the blank halves are omitted
for clarity and a pair of rings J are schematically illustrated as
they move between the blow station and the parison forming station.
In FIGS. 1 and 2, the rings are omitted and the blank halves are
shown in a stationary position between molding operations.
[0022] In addition to the blank halves E and F, a typical mold body
for a glass bottle may include a pair of ring halves that when
joined together form a ring J (FIG. 3). Thus, one pair of mating
blank halves and one pair of mating ring halves form a parison mold
body for a glass bottle that is blown to final form at the blow
station M. Each ring J when assembled is used to form a cap end of
the bottle.
[0023] For a normal molding operation, with the blanks open, a
transfer arm L swings the rings J down into position on top of
respective support blocks K. The blanks E and F (two mating pairs)
are then closed around their respective ring J which is positioned
at the lower end of the joined blanks, thus forming two mold
bodies. A gob of molten glass is next dropped into each mold body
and collects near the bottom of the mold at the ring J, and a
respective baffle (not shown) covers the top of each mold. A pin
(not shown) then rises from each support block K and pierces the
gob to produce a parison. The blank halves E and F open and the
transfer arm L swings the parisons, each still attached to their
respective ring J, about 180.degree. to a second process or blow
station M (FIG. 4). Each parison is positioned inside a bottle mold
and the gob is blown to form the final bottle shape. Each bottle
cools sufficiently so that the bottle mold can be opened and the
ring halves separated to fully release the bottle, but the hot
bottle will retain its shape. The opened ring halves are re-closed
and the transfer arm L then transfers the rings J back to the first
or parison forming station A onto their respective support blocks
K.
[0024] The molding process requires periodic application of a
lubricant to the mold parts, specifically the internal threaded
region of the ring and an upper region of the blanks, heretofore
done manually with a brush. These target areas are specific to a
glass bottle molding process, but the inventions herein may direct
material application to any selected target surface depending on
the particular machine and process they are used with.
[0025] In accordance with one inventive aspect of the present
disclosure, a material application apparatus 10 is provided that
may be used to automatically apply material to the parison mold
body surfaces without manual application by an operator. The
apparatus 10 in one basic embodiment includes one or more nozzles
that direct a pattern of material at a targeted surface. High
pressure material is supplied to the nozzles in relatively short
bursts from one or more material application guns. A sufficient
number of nozzles may be provided to apply material to the required
surface areas. In the exemplary embodiment herein, two sets of
rings and blanks or eight total target areas have material applied
thereto, but the inventions may be used for as few as a single area
of coverage or any other number of target areas. Thus in the
exemplary embodiment, eight nozzles are provided.
[0026] The number of guns that are used to provide pressurized
material to the nozzles will be determined in part by how much
independent control is needed for each nozzle. In the exemplary
embodiment, three guns are used. A first gun is used to supply four
nozzles that direct material at the four stationary blank halves, a
second gun is used to supply two nozzles that direct material at
two of the moving ring halves and the third gun is used to supply
material to two nozzles that direct material at the other two
moving ring halves (keeping in mind that the rings when moving are
each a single body comprising two joined rings halves). In
different applications, greater or fewer than three guns may be
used. For example, if a particular system only needs all nozzles to
apply material at the same time, a single gun may be used. On the
other hand, some applications may need each nozzle to be
independently controlled so that there may be a gun for each
nozzle, or some other way to independently control the on/off state
of each nozzle.
[0027] In the illustrated embodiment, the glass molding machine and
the parison forming station A in particular actually include two
distinct parison mold bodies with each mold body comprising two
blank halves and two ring halves, for a total of eight mold body
parts that periodically need to have lubricant material applied
thereto (FIG. 4 illustrates two rings J, for example). In a typical
molding process, the lubricant needs to be applied about every
twenty minutes or so depending on the run rate of the machine as
well as other process parameters. Different material application
intervals may be used however, with the present inventions. During
each normal operating cycle of the machine A, the blanks E and F
open to a stationary position for about two seconds or so, when the
parison is released for transfer to the blow station. This
stationary period thus provides an opportunity to spray material
onto the blanks. The rings, however, are either in a state of
motion or contain hot glass when not in motion, so that the rings
can only have material sprayed on them as they return to the
parison forming station before the next gob is dropped into the
parison mold body. Accordingly, the rings must be sprayed while
they are in motion, when transferring from the blow station to the
parison forming station.
[0028] Since the two rings J travel different arcs from the blow
station M to the parison forming station A, they may be sprayed at
different times. Alternatively, as in the exemplary embodiments
herein, in some applications it may be desired to spray the rings
at a specific angle of inclination from the support blocks K so as
to optimize the application of material to the targeted surface
inside the rings. Since the two rings J will hit this angle at the
same time, the rings are sprayed at the same time in the exemplary
embodiment. If different angles of inclination can be used to spray
the rings, then the rings for example may be sprayed at different
times. The use of two guns for controlling spraying of the rings
allows flexibility to the designer as to when the moving rings are
sprayed.
[0029] The use of a material application apparatus 10 not only
eliminates the need for an operator to manually apply lubricant
material to the blanks and rings (it should be noted that the terms
"non-manual" or "automatic" application does not preclude manual
triggering of the spray guns, but rather only refers to eliminating
manual application of material to the target surfaces such as with
a brush), but also improves the uniformity and consistency of
material applied. Since the rings can be automatically sprayed
while in motion, there also is no need to stop the molding machine
during its normal operation. In the exemplary embodiment, the
material application apparatus also may be installed on an
existing, operational machine as a retrofit, without having to make
any significant modifications of the molding machine. Further,
since material is only sprayed on the blanks and rings about every
twenty minutes or so, the apparatus 10 can be serviced and even
replaced without shutting down or otherwise interrupting normal
operation of the molding machine.
[0030] With reference next to FIGS. 5, 5A and 6, an embodiment of a
material application apparatus 10 includes a generally flat frame
or mounting plate 12 that is formed generally in the shape of a U,
with two legs 14, 16 extending generally transversely from an end
portion 18. The mounting plate 12 is preferably but need not be a
unitary member. The U-shape configuration provides a central
extended space 20 that allows for the apparatus 10 to be slideably
positioned around and under the saddle (FIGS. 1-3) so that the legs
14, 16 extend to a region below the blanks and rings. In this
manner the apparatus 10 may be easily installed and removed from an
existing machine. Alternatively, of course, the apparatus 10 may be
incorporated or integrated into a mold machine design. The legs 14,
16 may be provided with bolts 22 that allow the apparatus 10 to be
anchored to a base (not shown) that the mold machine A rests on.
The apparatus 10 when installed has a forward edge 24 of the end
portion 18 abutting a back side of the saddle as a positioning and
alignment aid if needed. The legs 14, 16 may also be provided with
standoffs 26 to provide mechanical support for the legs since they
are cantilevered in this embodiment.
[0031] The U-shape configuration may be modified to any shape or
profile that is needed to adapt the apparatus 10 for a particular
use. Additionally, although the exemplary embodiment illustrates
three spray guns and eight nozzles, these numbers are exemplary.
The inventions may be used with any number of nozzles and guns as
needed for a particular application. Still further, although the
exemplary embodiments illustrate spraying from nozzle orifices that
are positioned below and to a side of each target surface, the
apparatus 10 may easily be modified for spraying level with or from
above the target surfaces, or a combination of multiple directions
and orientations. Still as another alternative, the blanks and
rings may also be individually sprayed from different orientations
and locations of the nozzles and their respective orifices.
[0032] With continued reference to FIGS. 5, 5A and 6, a supply
manifold 28 may be used as an interface between the spray guns and
the nozzles, since one gun may serve a plurality of nozzles. In
this example, the supply manifold 28 is disposed on the end portion
18 of the mounting plate 12. One or more spray guns 30 are mounted
on an outside face 28a of the supply manifold 28. In this manner,
as best illustrated in FIGS. 1-3, the spray guns 30 are positioned
behind the molding machine for easier access for servicing and
maintenance, and also thus positioned somewhat away and protected
from the hot molten glass on the other side of the saddle. In this
embodiment, there are three spray guns 30A, 30B and 30C. Each gun
has a respective material inlet connection 32, such as a
quick-connect, to a supply of the material to be applied. Material
may be supplied under pressure from any suitable pump 34 (FIG. 4)
through respective supply hoses 36 (FIG. 4). Typical input
pressures to the spray guns 30 might be in the range of about 800
psi but will be selected based on the particular application. A
suitable but not exclusive pump supply 34 is a pump model 25B
pumping system available from Nordson Corporation, Westlake,
Ohio.
[0033] The spray guns 30 may be mounted to respective input ports
38 of the supply manifold 28 by any convenient mechanism as needed.
The supply manifold 28 includes internal flow passages that connect
the input ports to selected ones of output ports 40, which are
coupled in fluid communication with a number of nozzles 50. In this
example, there are eight nozzles 50 supported on the legs 14, 16.
Input port 38B which is connected to blanks spray gun 30B (the
middle gun as viewed in the drawings), is connected by internal
passages in the supply manifold 28 to outputs 40C and 40F. This gun
is used to supply the four nozzles that spray the blanks. Input
port 38A which is connected to a first rings spray gun 30A, is
connected by internal passages to outputs 40A and 40D. This gun is
used to supply two of the nozzles that spray two of the ring
halves. Input port 38C which is connected to the second rings spray
gun 30C, is connected by internal passages to outputs 40B and 40E.
This gun is used to supply two of the nozzles that spray the other
two of the ring halves.
[0034] The type of spray gun 30 selected will depend on the overall
system design and spraying requirements. An exemplary spray gun is
model A20A available from Nordson Corporation, Westlake, Ohio. This
type gun is electrically controllable by input signals supplied to
electrical inputs 31. In this embodiment, the molding machine
controller 33 (FIG. 5) generates appropriate control signals to the
spray guns when the guns are to be turned on and off, in accordance
with the spray gun specifications. Alternative control techniques
may be used. For example, it is possible that in some systems a
manually controlled actuation signal may be supplied to the guns,
although this would be less useful for spraying moving rings. Also,
proximity sensors and timing circuits may be used to sense when the
spray times should begin and end.
[0035] The supply manifold 28 output ports 40 are connected with
tubing sections 42 respectively. The tubing sections 42
respectively extend out to the nozzle region 44 of the apparatus
10. The tubing may be, for example, stainless steel tubing with
appropriate end connections as needed. Each tubing run is connected
at a distal end to the input end of a check valve 46. In the
exemplary embodiment, there are four nozzles on each leg 14, 16
with three tubing runs that supply material to the nozzles. Two of
the nozzles have a common source and each of the other two nozzles
have an independent source of material. For example, a first tubing
section 42A connects outlet 40A to the inlet of a first check valve
46A. The first check valve 46A outlet communicates with an inlet to
a first nozzle manifold block 48A. A first nozzle 50A is disposed
on the nozzle manifold 50A and sprays material that is received
through the associated check valve 46A via an internal passage 52A
in the first nozzle manifold 48A. Second and third nozzles 50B and
50C may also be mounted on the first nozzle manifold 48A and share
a common internal passage 52B that connects the nozzles in fluid
communication with a second check valve 46B. The second check valve
46B has an output connected to a second input of the first nozzle
manifold 48A and has an input connected to a second tubing run 42B
that is connected to outlet 40C of the supply manifold 28. The
outlet 40C receives material from the blanks spray gun 30B. A
fourth nozzle 50D is disposed on a first nozzle block 54. A third
tubing run 42C connects an outlet 40B (FIG. 5) from the supply
manifold 28 to an inlet of a third check valve 46C. The outlet of
the third check valve is connected to an inlet of the first nozzle
block 54 which in turn is in fluid communication with the fourth
nozzle 50D via internal passage 56 in the first nozzle block
54.
[0036] Two separate nozzle mounting arrangements (nozzle manifold
48A and nozzle block 54) are used because it is desirable in some
cases, as in the exemplary embodiments, to control separate
supplies of material to different nozzles. This may be desirable,
for example, so that the ring spraying nozzles may be used to spray
the rings at different times from each other and from when the
blanks are sprayed. But in other designs, still further separate
spraying times may be desired for each nozzle, or in some designs
all the nozzles may spray at the same time and therefore could
share a single common supply of material.
[0037] The other leg 16 of the apparatus 10 comprises similar
structure, although such need not be the case in all designs. Thus,
a fourth tubing run 42D provides a material flow path from a fourth
outlet 40D to an input of a fourth check valve 46D, with the fourth
check valve having an outlet connected to an inlet of a second
nozzle manifold 48B, in turn connected in fluid communication to a
fifth nozzle 50E via an internal passage 58. A fifth tubing run 42E
provides a material flow path from a fifth outlet 40F to an input
of a fifth check valve 46E, with the fifth check valve having an
outlet connected to a second inlet of the second nozzle manifold
48B, in turn connected in fluid communication to a sixth nozzle 50F
and a seventh nozzle 50G via a common internal passage 60. An
eighth nozzle 50H is disposed on a second nozzle block 62. A sixth
tubing run 42F connects an outlet 40E (FIG. 5) from the supply
manifold 28 to an inlet of a sixth check valve 46F. The outlet of
the sixth check valve is connected to an inlet of the second nozzle
block 62 which in turn is in fluid communication with the eighth
nozzle 50H via internal passage 64 in the second nozzle block
62.
[0038] Overall, the number of nozzles 50, nozzle manifolds 48, and
nozzle blocks 54,62, as well as the number of check valves 46 and
supply manifold outlets 40 and spray guns 30, will largely be a
matter of overall design choice and spraying needs. The check
valves 46 may be optional in some system designs depending on the
nature of the spray pattern desired and the operational features of
the spray guns 30.
[0039] As best illustrated in FIGS. 2, 5, 5A and 6, the various
nozzles 50 are angled and aimed as appropriately needed to direct a
spray or jet of material towards a selected target surface of one
of the mold pieces. Since the blank halves, when open for spraying,
are supported on either side of the axis X, the blank spray nozzles
are aimed across the axis X and will crisscross each other relative
to the axis X but do not hit each other. The crisscross spray
directions for the blanks E and F are shown schematically in FIG.
2. Lines 51 represent spray directions from the four nozzles 50
that each spray a blank by spraying across to the opposite side, or
in other words, across the X axis. Thus, nozzles 50B and 50C are
aimed to spray respective blank halves that are positioned on the
lower side of the central axis X (as viewed in FIG. 6), and nozzles
50F and 50G are aimed to spray respective blank halves on the upper
side of the axis X (as viewed in FIG. 6). For spraying the rings,
the ring spray nozzles 50A and 50D spray interior portions of the
two ring halves that are opposite the axis X from those nozzles,
and ring spray nozzles 50E and 50H spray interior portions of the
two ring halves that are opposite the axis X from those
nozzles.
[0040] Although in the exemplary embodiments herein the spray
patterns are directed across the X axis in a crisscross manner,
such is not required. For example, any one or more nozzles may
spray to a target area that is on the same side of the X axis as
the nozzle lies. This alternative is schematically represented by
the dashed lines 53 in FIG. 2. The spray directions may thus be
determined as a matter of design convenience to optimize the
application of material to the target surfaces.
[0041] The rings are sprayed while in motion, and in the exemplary
embodiment each ring is sprayed when it is at an angle .theta., for
example, of about 17.degree. above horizontal (see FIG. 3). Since
the two rings reach this angle at the same time, associated pairs
of the ring spray nozzles (pair 50A and 50E, and pair 50D and 50H)
spray at the same time. But alternatively, the nozzles may spray at
different times simply by changing the timing signals to the spray
guns 30. The use of two spray guns 30 for the rings allows for this
added flexibility in spraying the ring portions at different times.
Similarly, additional spray guns may be used for spraying different
blanks at different times. In the case of the rings, using two guns
(for the situation of having two rings to spray) allows for faster
response times between the gun signal from the molding machine
controller and creating the spray pattern. The response time
(response time referring to the delay between sending a gun on
signal from the molding machine controller to the time when the
spray pattern is produced from the nozzles 50) is affected in part
by pressure drops from the spray gun to the nozzle tips. Therefore,
using two guns reduces the effect of this pressure drop on response
time, which is helpful since the time window for spraying the rings
may be in the millisecond range. In contrast, since the blanks stay
stationary for a longer period of time, response time due to
pressure drops between the gun and nozzles is not as significant a
design criteria.
[0042] Relative to the spray guns, the blank spray gun 30B provides
material to all four nozzles 50B, C, F, G and all four spray at the
same time. First ring spray gun 30A provides material to ring spray
nozzle pair 50A and 50E, and the second ring spray gun 30C provides
material to ring spray nozzle pair 50D and 50H. Since associated
nozzles for each ring are supplied by the same gun, they can spray
at a time that is different from the other pair of ring spray
nozzles. If needed, all nozzles can have a dedicated gun for total
independent spray time control.
[0043] The check valves 46 may be but need not be all the same. In
the exemplary embodiment, the check valves 46 have a cracking
pressure of about 450 psi, but this value may be selected as
needed. By having a high cracking pressure, the check valves assure
that there is a significant pressure build up of the material close
to the associated nozzles, so that when the associated spray gun is
triggered, the spray pattern is created very quickly and cleanly
with well defined edges and boundaries. Likewise, when the spray
gun is turned off, the check valves 46 close quickly. The check
valves 46 therefore help to provide a sharp and well defined spray
pattern that does not exhibit spray pattern variation and drip. The
check valves 46 help compensate for what would otherwise be
pressure drops between the guns 30 and the nozzles 50. Thus it is
preferred that the check valves be positioned close to the nozzles
50, so that the distance back to the guns is not critical. This
distance to the guns allows the guns 30 to be positioned behind the
saddle of the molding machine for easy maintenance and replacement
access and safer access for the operator from the molten glass.
[0044] FIG. 7 illustrates schematically the hydraulic pressures for
the exemplary embodiment, wherein the supply pump and regulator
system 70 (including, for example, the pump 34 of FIG. 4) takes
material from a supply 72 and provides the material at a pressure
of about 800 psi to the spray guns 30 inlets. There is about a 100
psi pressure loss to the check valves in the exemplary embodiment,
so the nozzles 50 are provided material at about 700 psi. When the
guns 30 are off and the check valves closed, the system pressure at
the inlets to the check valves is about 450 psi. The selected
operating pressures will vary depending on overall system design
criteria. In the exemplary embodiments, higher pressures are used
at the nozzles to produce well defined and narrow spray patterns
because the target areas are rather small and the nozzles must
direct the spray pattern across distances of 10 inches or more to
the surfaces being sprayed. Exemplary pressure ranges for the
exemplary embodiment may be on the order of at least 500 psi at the
nozzles 50. However, if check valves with lower cracking pressures
are used, then the nozzle pressure may be lower.
[0045] FIG. 8 is similar in all respects to FIG. 5 except also
shows that covers 66 may be used to help protect the nozzles 50.
The covers 66 are installed on the mounting plate 18 with
appropriate screws or other means and have openings 68 that allow
the nozzles to direct spray patterns towards the mold pieces.
[0046] In the exemplary embodiment, and with reference to FIGS. 9A,
9B and 9C, each nozzle 50 includes a tube 74 that may be welded or
otherwise secured to its respective nozzle manifold or nozzle block
so as to be in fluid communication with the internal passage to
receive material. The distal end of the tube 74 is provided with a
nozzle tip and nozzle tip holder assembly 76. Alternatively, the
nozzle tips 86 (FIGS. 9B and 9C embodiments) may be recessed in
counterbores formed at appropriate angles in the respective nozzle
manifolds and nozzle blocks so that the nozzle tips 86 may be
recessed and protected. As illustrated in FIG. 9A, the nozzles may
be designed to produce a tight, narrow conical spray pattern 78.
The narrow well-defined pattern minimizes material overspray and
waste, and also helps assure consistent and repeatable application
of material to the targeted surfaces. In a typical system, the
nozzles 50 may spray the blanks over a distance of about twelve to
fifteen inches, and spray the rings over a distance of about five
to seven inches. These distances however are exemplary as they will
vary based on machine design. For example, an exemplary range may
be about five to about eighteen inches or more.
[0047] The conical pattern also eliminates any need for nozzle
orientation. The conical shape is not hollow but contains material
distributed throughout the pattern 78, and is well suited for
spraying the curved interior surfaces of the blanks and rings, but
for other applications different spray pattern profiles may be used
as needed. In one example, a 1.5 inch pattern may be sprayed at a
distance of fifteen inches from the nozzle tip with a gun time of
less than 70 milliseconds. In another example, a spray pattern of
about one to three inches is produced for water sprayed at 500 psi
to a target ten inches away from the nozzle and at a flow rate of
about 0.03 to about 0.2 gallons per minute. The tight focused
pattern is also facilitated by the high pressure input of the
material to the nozzle tip, which also allows the spray pattern to
be directed across distances as great as fifteen inches or more
from the nozzle tip to the target surface. In further combination
with the high pressure check valves, a sharp clean non-drip spray
pattern is quickly generated to minimize wasted material and
overspray. The spray patterns in the exemplary embodiment can be
thought of as a jetting action due to the narrow tight spray
pattern and short spray times of around 70 milliseconds or less.
The flow rates, pressures, nozzle orifice size and shape and check
valve design will all be interrelated and design criteria for each
system, based further on the type of material being applied (such
as its viscosity, for example), the distances between the nozzles
and the target areas, and the tightness of the spray pattern needed
(for example, to reduce overspray).
[0048] As illustrated in the embodiment of FIG. 9B, each nozzle 50
comprises a tube section 74 having a first end 80 that is connected
to the nozzle manifold or block as the case may be. This connection
may be welded or brazed, for example, or joined by any other
suitable process. A nozzle tip holder 82 is inserted in the spray
end of the tube 74. The tip holder 82 may also be welded, threaded
or otherwise attached to the tube 74. The tip holder 82 includes a
recessed pocket 84 that receives and retains a nozzle tip 86. The
tip 86 includes one or more orifices 88 through which pressurized
material flows from a tapered slot 90 to produce a spray pattern,
such as for example the tight conical pattern exemplified in FIG.
9A. The nozzle holder and tip are available from Nordson
Corporation, Westlake, Ohio. Other spray patterns and nozzle tip
and tip holder designs however may be used as needed for particular
spraying applications. In the embodiment of FIG. 9C, a tip holder
92 may include an end 94 that is press fit into the end of the tube
74, with a compressible seal ring 96 carried on the tip holder 92
body. The ring 96 is captured within the tube end 74 to secure the
nozzle tip holder 92 in the tube 74.
[0049] The spray gun and nozzle assembly 10 is quite flexible in
that it may easily be modified to include different numbers of
nozzles, guns and check valves, and the orientation or spraying
directions of the nozzles can be easily changed as needed. For
example, a simple tool may be used to bend the nozzles at different
angles or to optimize their angle based on test runs of the
apparatus with particular molding machines. This allows a designer
to construct an arrangement that can spray different numbers of
mold pieces including more than two mold bodies (i.e. more than
eight mold pieces as in the exemplary embodiment) and to adjust for
different spatial positioning of the blanks and rings during
spraying. The exemplary design allows for easy and fast
installation and removal of the apparatus 10 without modification
of the existing molding machine. While the U-shape mounting plate
18 is particularly well-suited for the type of molding machine
illustrated herein, the shape and configuration of the apparatus 10
may be designed based on the particular molding machine that it is
intended to interface with, and could be integrated with the
molding machine as another alternative.
[0050] The inventions have been described with reference to the
exemplary embodiments. Modifications and alterations will readily
occur to others upon a reading and understanding of this
specification and drawings. It is intended to include all such
modifications and alterations insofar as they come within the scope
of the appended claims or the equivalents thereof.
* * * * *