U.S. patent application number 15/965235 was filed with the patent office on 2018-12-06 for air masking nozzle.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Che-Sheng Chen, Dragan Jurkovic, Chien-Liang Yeh.
Application Number | 20180345300 15/965235 |
Document ID | / |
Family ID | 62683474 |
Filed Date | 2018-12-06 |
United States Patent
Application |
20180345300 |
Kind Code |
A1 |
Jurkovic; Dragan ; et
al. |
December 6, 2018 |
Air Masking Nozzle
Abstract
A nozzle dispenses a material, such as an adhesive, primer,
paint, or other coating, through a dispensing port on to a
substrate. The spray pattern provided by the nozzle defines, at
least in part, an application pattern of the material on to the
substrate. An air mask port integral with the nozzle or a separate
nozzle expels a mask stream of pressurized gas. The mask stream
projects toward the substrate to aid in limiting an application of
the material beyond an application line on the substrate. The
air-mask port and the dispensing port may be moved relative to the
substrate and/or the application line such that the mask stream
provides a barrier to the material being applied.
Inventors: |
Jurkovic; Dragan; (Taichung,
TW) ; Chen; Che-Sheng; (Huwei Townshipo, TW) ;
Yeh; Chien-Liang; (Changhua City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
62683474 |
Appl. No.: |
15/965235 |
Filed: |
April 27, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62513134 |
May 31, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B05B 12/18 20180201;
A43D 119/00 20130101; B05B 7/00 20130101; B05B 1/28 20130101; B05B
1/005 20130101; B05B 13/0431 20130101; A43D 25/183 20130101; B05B
12/004 20130101; B05B 15/40 20180201 |
International
Class: |
B05B 1/00 20060101
B05B001/00; B05B 7/00 20060101 B05B007/00; B05B 12/00 20060101
B05B012/00 |
Claims
1. A method of applying material from a nozzle, the method
comprising: positioning the nozzle relative to a substrate to which
material is to be applied from a dispensing port of the nozzle;
dispensing the material from the dispensing port, wherein a
dispensing axis extends through the dispensing port in a direction
the material is dispensed; concurrent to dispensing the material
from the dispensing port, discharging gas from an air-mask port,
wherein a masking axis extends through the air-mask port in a
direction the gas is discharged toward the substrate; an alignment
axis extends through the dispensing port and the air-mask port; and
while dispensing the material and discharging the gas, moving the
nozzle along an application line of the substrate such that the
dispensing axis intersects with the masking axis within 5 cm of a
substrate application surface of the substrate.
2. The method of claim 1, wherein positioning the nozzle and moving
of the nozzle is performed by a multi-axis robotic arm controlled
by a computing device.
3. The method of claim 1 further comprising determining a location
of the application line relative to the substrate.
4. The method of claim 3, wherein determining the location of the
application line comprises capturing an image of the substrate with
a vision system.
5. The method of claim 3, wherein determining the location of the
application line comprises retrieving a data file associated with
the substrate.
6. The method of claim 1, wherein the substrate is a portion of an
article of footwear.
7. The method of claim 1, wherein the substrate is non-planar.
8. The method of claim 1, wherein the material is one selected from
an adhesive, a primer, a coating, paint, and a dye.
9. The method of claim 1, wherein a second nozzle is comprised of
the air-mask port, the second nozzle is different from the
nozzle.
10. The method of claim 9 further comprising adjusting a position
or orientation of the second nozzle.
11. The method of claim 1, wherein dispensing the material is
achieved, at least in part, by propelling the material by a
pressurized gas discharged from the dispensing port.
12. The method of claim 1, wherein the air-mask port has a smaller
cross sectional area in a horizontal plane than a cross-sectional
area of the dispensing port in the horizontal plane.
13. The method of claim 1, wherein the air-mask port is on a first
side of the application line and the dispensing port is on a second
side of the application line during the moving of the nozzle along
the application line.
14. The method of claim 1, wherein the dispensing port is
maintained within an offset distance range from the substrate
during the moving of the nozzle along the application line.
15. The method of claim 1, wherein the alignment axis is maintained
perpendicular to the application line during the moving of the
nozzle along the application line.
16. The method of claim 1, wherein the nozzle further comprises a
physical mask that extends from the nozzle toward the
substrate.
17. The method of claim 16 further comprising directing an air
stream at a primary surface of the physical mask to clean the
primary surface.
18. The method of claim 1 further comprising activating a second
air-mask port that expels a gas stream that is offset from and
parallel to the dispensing axis.
19. A nozzle comprising: a dispensing port positioned on the nozzle
and effective to dispense a material by a pressurized fluid stream
through the nozzle at the dispensing port; and an air-mask port,
the air-mask port peripherally positioned on the nozzle relative to
the dispensing port and effective to expel a pressurized fluid
stream through the nozzle at the air-mask port, wherein a
cross-section area of the air-mask port in a horizontal plane is
less than a cross-sectional area of the dispensing port in the
horizontal plane.
20. The nozzle of claim 19, wherein the air-mask port is
peripherally offset from the dispensing port by a distance of at
least a width of the dispensing port as measured across an
alignment axis extending between the air-mask port and the
dispensing port.
21. A material dispensing system, comprising: a first nozzle having
a dispensing port positioned on the first nozzle and effective to
dispense a material by a pressurized fluid stream through the first
nozzle at the dispensing port, the first nozzle having a dispensing
axis extends through the dispensing port in a direction the
material is dispensed; and a second nozzle having an air-mask port,
the air-mask effective to expel a pressurized fluid stream through
the second nozzle at the air-mask port, wherein a masking axis
extends through the air-mask port in a direction the gas is
discharged, wherein the dispensing axis and the masking axis
intersect at a distance greater than 5 cm from the dispensing port.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of US. Provisional
Application 62/513,134 filed on May 31, 2017 and entitled Air Mask
Nozzle. The entirety of the aforementioned application is
incorporated by reference herein.
TECHNICAL FIELD
[0002] Controlled material application from a nozzle.
BACKGROUND
[0003] Materials, such as adhesive, paint, dye, or coatings, may be
applied to a substrate with a spraying action. The spraying action
may be controlled, in part, through a selection of a spray pattern
emanating from a nozzle. The spray pattern may vary in coverage
based on a variety of factors, such as material characteristics
(e.g., viscosity), pressure, volume, time, distance from substrate,
and the like. Because of this variability in the spray pattern,
physically covering a portion of the substrate not intended to
receive the material has been used to prevent over spraying and
referred to as masking.
BRIEF SUMMARY
[0004] Aspects herein contemplate a method of applying material
from a nozzle having an air-mask port and a dispensing port. The
method includes positioning the nozzle relative to a substrate to
which material is to be applied from the dispensing port and then
dispensing the material from the dispensing port. While dispensing
the material from the dispensing port, the method includes
discharging gas from the air-mask port. An alignment axis extends
through the air-mask port and the dispensing port of the nozzle.
Stated differently, the alignment axis extends between an origin of
the carrier stream and an origin of the masking stream. The method
continues with moving the nozzle along an application line of the
substrate such that the alignment axis intersects the application
line at an angle range of 75 degrees to 105 degrees while
dispensing the material from the dispensing port and while
discharging the gas from the air-mask port.
[0005] Another aspect contemplates a nozzle comprising a dispensing
port centrally positioned on the nozzle and effective to dispense a
material by a pressurized fluid stream through the nozzle at the
dispensing port. The nozzle also includes an air-mask port that is
peripherally positioned on the nozzle relative to the dispensing
port and effective to expel a pressurized fluid stream through the
nozzle at the air-mask port. A cross-section area of the air-mask
port in a horizontal plane is less than a cross-sectional area of
the dispensing port in the horizontal plane.
[0006] This summary is provided to enlighten and not limit the
scope of methods and systems provided hereafter in complete
detail.
DESCRIPTION OF THE DRAWINGS
[0007] The present invention is described in detail herein with
reference to the attached drawing figures, wherein:
[0008] FIG. 1 depicts a perspective view of an exemplary nozzle
having an air-mask port, in accordance with aspects hereof;
[0009] FIG. 2 depicts a side view of the nozzle from FIG. 1, in
accordance with aspects hereof;
[0010] FIG. 3 depicts a cross section view of the nozzle from FIG.
2 along cutline 3-3, in accordance with aspects hereof;
[0011] FIG. 4 depicts a bottom plan view of the nozzle from FIG. 1,
in accordance with aspects hereof;
[0012] FIG. 5 depicts an exemplary system utilizing the nozzle of
FIG. 1, in accordance with aspects hereof;
[0013] FIG. 6 depicts a cross section of a nozzle having an
air-mask port activated, in accordance with aspects hereof;
[0014] FIG. 7 depicts an exemplary sequence of a nozzle having an
air-mask port moving along an application line, in accordance with
aspects hereof;
[0015] FIGS. 8-11 depict alternative air-mask port configurations,
in accordance with aspects hereof;
[0016] FIG. 12 depicts a nozzle having an active air-mask port and
a supplemental gas knife on a common side of the dispensing port,
in accordance with aspects hereof;
[0017] FIG. 13 depicts a nozzle having an active air-mask port and
a supplemental gas knife on opposite sides of the dispensing port,
in accordance with aspects hereof;
[0018] FIG. 14 depicts an exemplary method for applying a material
from a nozzle having an air-mask port, in accordance with aspects
hereof;
[0019] FIG. 15 depicts a method of dispensing material from a
dispensing port and discharging gas from an air-mask port, in
accordance with aspects hereof;
[0020] FIG. 16 depicts a first nozzle having a dispensing port and
a second nozzle having an air-mask port, in accordance with aspects
hereof;
[0021] FIG. 17 depicts the first nozzle and the second nozzle of
FIG. 16 having a illustrative substrate surface at a distance
relative to one or more nozzles;
[0022] FIG. 18 depicts the first nozzle and the second nozzle of
FIG. 16 with the first nozzle having an optional physical mask
extension and an optionally integral air-mask port, in accordance
with aspects hereof;
[0023] FIG. 19 depicts an additional first nozzle having a
dispensing port and a second nozzle having an air-mask port, in
accordance with aspects hereof;
[0024] FIG. 20 depicts yet another first nozzle having a dispensing
port and a second nozzle having an air-mask port, in accordance
with aspects hereof;
[0025] FIG. 21 depicts a first nozzle having a physical mask
associated therewith, in accordance with aspects hereof;
[0026] FIG. 22 depicts versions of the first nozzle and the second
nozzle of FIG. 16 with the first nozzle having an optional physical
mask extension and an optionally third nozzle, in accordance with
aspects hereof; and
[0027] FIG. 23 depicts a bottom-up view of the first nozzle and the
third nozzle of FIG. 22, in accordance with aspects hereof.
DETAILED DESCRIPTION
[0028] A nozzle directs sprayed material at an intended target. For
example, a nozzle is effective to direct compressed air in a fluid
stream to atomize or propel a material, such as an ink, paint,
adhesive, or other liquid or powder material at a target.
Traditional nozzles are comprised of an air cap. The air cap is a
component that can be responsible for defining the spray
pattern.
[0029] Some air caps are referred to as external mixing spray caps.
An external mixing spray cap includes a series of jets that expel
compressed air in defined streams that interact with the spray
material (e.g., ink, paint, adhesive, primer) in close proximity to
the output of the spray material. The interaction between the spray
material and the defined streams of air transport the spray
material towards a target as a carrier stream. The spray material
is often atomized by the streams of air for transport to the
target. A spray line extends from the air cap to the target. The
spray line defines an axis about which the spray pattern is formed.
Because the spray pattern may radially extend outwardly from the
spray line as the material extends along the spray line from the
air cap, the spray line will be used as a reference for a straight
line between the application source (e.g., nozzle) and the
target.
[0030] An external air cap may also be comprised of an air horn. An
air horn expels a compressed fluid stream, such as air, at an angle
relative to the spray line to shape the carrier stream (i.e., to
shape the spray pattern). Air horn streams intersect the spray line
within a few millimeters of the spray material being atomized by
the carrier stream. This intersection, the angle of intersection,
the relative volume of fluid in the air horn stream, and the
relative speed of the fluid in the air horn stream all can
contribute to the resulting spray pattern of the carrier
stream.
[0031] Other air caps are referred to as internal mixing air caps.
An internal mixing air cap atomizes the spray material within the
nozzle prior to discharging the spray material from the nozzle.
This is in contrast to an external mixing air cap that atomizes the
spray material after the spray material is discharged from the air
cap.
[0032] While various air caps have been used in practice with
specific spray patterns, the adjustment of the spray pattern has
traditionally occurred in close proximity (e.g., 1-5 millimeters)
to a point of spray material discharge from the nozzle or where the
spray material has been atomized by the carrier stream. For
example, the air horn streams of an external mixing air cap
leverage an air stream to shape the resulting spray pattern, but
the interaction of the air horn stream and the carrier stream
occurs in close proximity (e.g., 1-5 millimeters) to the spray
material atomization point.
[0033] While traditional spray pattern forming, such as through the
use of an air horn, provides a macro-level control over spray
material deposition location, additional control of spray material
deposition may be implemented in exemplary aspects. For example,
aspects herein contemplate an air-mask port that expels a stream of
air, a masking stream, in a direction that intersects with the
carrier stream near or at the substrate to be sprayed. The air-mask
port, in an exemplary aspect, forms a masking axis that extends
between the air-mask port and a point of intersection at the
substrate. The masking axis, for a cylindrical air-mask port is
axially aligned with a longitudinal axis of the cylinder volume
that extends through an origin of a circular cross section of the
cylindrical air-mask port. The masking axis is substantially
parallel (e.g., within 10 degrees) with the spray axis in an
aspect. In yet another aspect, the masking axis is parallel with
the spray axis. The masking stream serves as a mask to limit or
prevent material being transported by the carrier stream to extend
through the masking stream. Stated differently, the masking stream
is contemplated to provide a barrier for controlling a spray
pattern at the substrate that provides a greater degree of control
and effectiveness than a traditional nozzle or air horn
configuration.
[0034] Aspects hereof contemplated a method of applying material
from a nozzle. The method comprises positioning the nozzle relative
to a substrate to which material (e.g., adhesive, colorant, and
primer) is to be applied from a dispensing port of the nozzle. The
method includes dispensing the material from the dispensing port. A
dispensing axis extends through the dispensing port in a direction
the material is dispensed (e.g., in a line extending between the
nozzle and the substrate in a material flow direction). Concurrent
to dispensing the material from the dispensing port, the method
includes discharging gas from an air-mask port. The air-mask port
may be a different nozzle or the same nozzle has the nozzle
comprised of the dispensing port. A masking axis extends through
the air-mask port in a direction the gas is discharged toward the
substrate (e.g., in a line extending from the air-mask port to the
substrate in a gas-flow direction). In this example, an alignment
axis extends through the dispensing port and the air-mask port
(e.g., an alignment axis intersects the dispensing axis and the
masking axis). While dispensing the material and discharging the
gas, moving the nozzle, such as through a multi-axis robot
controlled by a computing system, along an application line of the
substrate such that the dispensing axis intersects with the masking
axis within 5 cm (e.g., 5 cm above or below) of a substrate
application surface of the substrate.
[0035] Another aspect herein contemplates a method of applying
material from a single nozzle having an air-mask port and a
dispensing port. The method includes positioning the nozzle
relative to a substrate (e.g., a component of an article of
footwear or any material, such as a knit, woven, braided, non-woven
material) to which material (e.g., adhesive, primer, paint, and
dye) is to be applied from the dispensing port and then dispensing
the material from the dispensing port. While dispensing the
material from the dispensing port, the method includes discharging
gas from the air-mask port. An alignment axis extends through the
air-mask port and the dispensing port of the nozzle. Stated
differently, the alignment axis extends between an origin of the
carrier stream and an origin of the masking stream. The method
continues with moving the nozzle along an application line of the
substrate such that the alignment axis intersects the application
line at an angle range of 75 degrees to 105 degrees while
dispensing the material from the dispensing port and while
discharging the gas from the air-mask port.
[0036] Another aspect contemplates a nozzle comprising a dispensing
port centrally positioned on the nozzle and effective to dispense a
material by a pressurized fluid stream through the nozzle at the
dispensing port. The nozzle also includes an air-mask port that is
peripherally positioned on the nozzle relative to the dispensing
port and effective to expel a pressurized fluid stream through the
nozzle at the air-mask port. A cross-section area of the air-mask
port in a horizontal plane (e.g., a plane perpendicular to the
carrier stream, the masking stream) is less than a cross-sectional
area of the dispensing port in the horizontal plane (e.g., the
cross-sectional area of the air-mask port is 50%, 35% 25%, 15%, or
10% of the cross sectional area of the dispensing port in the
horizontal plane).
[0037] FIG. 1 depicts a perspective view of a nozzle 100 having an
air-mask port 202 and a dispensing port 102, in accordance with
aspects hereof. While an internal-mixing cap is generally depicted,
it is contemplated that an external-mixing cap may also be used in
connection with concepts provided herein. The nozzle 100 may be
affixed to a spraying device, such as an adhesive spraying gun. The
spraying device may have one or more controls, such as valves, that
control the flow of gas, such as a pressurized gas like pressurized
air, from one or more ports. For example, a first valve may be
effective to control a volume, pressure, and/or velocity of gas
expelled from the optional air-mask port 202. Similarly, a control,
such as a valve, may control a volume, pressure, and/or velocity of
spray material and/or pressurized fluid from the dispensing port
102. The controls of the dispensing port 102 and the air-mask port
202 may be operated in cooperation or independently. For example,
in some applications of spray material, the masking stream (i.e.,
expelled gas from the air-mask port 202) may be on and it may be
off depending on a location of the nozzle 100 relative to the
substrate. Stated differently, in some aspects it is contemplated
that the controls controlling the masking stream may allow for the
masking stream to form a mask in some locations (e.g., along a
perimeter or biteline on an article of footwear component) while
not forming a mask in other location (e.g., an internal portion
intended to achieve for spray material coverage).
[0038] While FIG. 1 depicts a single nozzle having both of the
dispensing port and the air-mask port for illustration purposes, it
is contemplated that the air-mask port and the dispensing port may
be in different nozzles that are physically joined or physically
independent of each other, such as that depicted in FIGS. 16-20,
hereinafter. Therefore, while aspects herein illustrate a single
nozzle, it is contemplated that features and limitations discussed
in connection with the single nozzle may equally apply and be
contemplated with a multi-nozzle approach. Similarly, features and
limitations discussed in connection with a multi-nozzle
implementation may equally apply and be contemplated with a
single-nozzle approach.
[0039] In the example of FIG. 1 it is contemplated that the nozzle
100 may be posited proximate a substrate (e.g., 5 millimeters to 1
meter) at a first location in a tool path. A control is activated
to allow a dispensing of material from the dispensing port 102 to
the substrate. The material is dispensed in a spray pattern. The
spray pattern is defined by the nozzle 100. The spray pattern may
be selectively defined further by the use of a mask stream
emanating from the air-mask port 202, as will be discussed in
greater detail hereinafter. Once the material is being dispensed,
such as being atomized by a stream of gas, the nozzle 100 is moved,
such as by a multi-axis robotic arm. The movement of the nozzle is
controlled, in an exemplary aspect, by a computing device having a
processor and memory that converts one or more computer-readable
instructions into a motion path. The computer-readable instructions
define a tool path for moving the nozzle in at least two dimensions
if not in three dimensions.
[0040] During the application of material from the dispensing port
102, the nozzle 100 may selectively activate a discharge of a
masking stream from the air-mask port 202. The air-mask port 202 is
configured to provide a stream of fluid, such as a gas stream, in a
defined pattern, such as a laminar flow that provides a known
barrier stream that is effective to prevent or reduce the outward
dissemination of the spraying material. For example, as the nozzle
100 is moved along the tool path at a spray material application
line (e.g., a line beyond which the spray material is not intended
to be applied to the substrate), the air-mask port emits the
masking stream to prevent the spray material from being applied
across the application line. Stated differently, the masking stream
modifies the spray pattern at the substrate surface to selectively
apply the spray material to the substrate based on a relative
location of the air-mask port, the dispensing port, and the
application line. This relative position will be discussed in FIG.
7 hereinafter.
[0041] FIG. 2 depicts a side profile of the nozzle 100 of FIG. 1,
in accordance with aspects hereof. A distal surface 106 of the
nozzle 100 is depicted. The distal surface 106 is a surface from
which the spray material is emitted though the dispensing port 102.
FIG. 3 depicts a cross-sectional view along a cutline 3-3 of FIG.
2, in accordance with aspects hereof.
[0042] As depicted, in FIG. 3, it is contemplated that the nozzle
100 uses a common fluid stream to both propel the spray material
out of the dispensing port 102 and to generate the masking stream
from the air-mask port 202. However, as provided above, the
air-mask port may instead be an independently controlled stream
having a different fluid or fluid source than the carrier
stream.
[0043] While FIG. 3 has been simplified with respect to internal
ports, channels, and the like, a portion of a delivery mechanism
103 for the spray material to a carrier stream is depicted (e.g., a
fluid connector, a valve, a dispensing nozzle, a pressure/pump
source, a material source). The delivery mechanism may be a conduit
through which the material (e.g., adhesive, primer, colorant) is
delivered to a distal end 105 proximate (e.g., with 5 mm) the
dispensing port 102. Gas (e.g., air) that is flowing internal to
the nozzle and supplied to both (or individually) the air-mask port
202 and/or the dispensing port 102 may then propel the material
from the distal end 105 of the delivery mechanism 103 for
dispensing towards the substrate.
[0044] FIG. 4 depicts a distal surface plan view of the nozzle 100,
in accordance with aspects hereof. A dispensing diameter 104 of the
dispensing port is depicted. A masking diameter 204 of the
air-masking port is depicted. An alignment axis 110 is depicted
extending between the air-mask port and the dispensing port. A
cross axis 112 is depicted extending through the dispensing port
and perpendicular to the alignment axis 110.
[0045] In an exemplary aspect, the masking diameter 204 is less
than the dispensing diameter 104. For example, the masking diameter
may be in a range of 1.5 millimeters (mm) to 0.25 mm and the
dispensing diameter 104 may be in a range of 3.5 mm to 1.5 mm. It
is contemplated that a cross-sectional area of the air-mask port is
less than a cross-section area of the dispensing port in a plane
parallel to the distal surface 106. For example, the air-mask port
may have a cross-section area of 0.2 square mm and the dispensing
port has a cross-section area of 3.8 square mm. In other examples,
the cross sectional area of the air-mask port may be at least half
that of the dispensing port.
[0046] Further, it is contemplated that the air-mask port is offset
to the periphery from the dispensing port by a distance 108. The
distance 108 may be any distance, such as 1.5 mm, 2 mm, 3 mm, 4 mm,
5 mm, 6 mm, or 7 mm. The distance 108 may be at least 125% the
dispensing diameter 104 in an exemplary aspect to achieve an
effective air-mask configuration.
[0047] FIG. 5 depicts a system for implementing the nozzle 100, in
accordance with aspects hereof. The nozzle 100 is coupled with a
robotic arm 510. The robotic arm 510 is a multi-axis movement
mechanism able to position and move the nozzle 100 in accordance to
one or more instructions from a computing device 514. The computing
device 514 is logically coupled with the robotic arm 510 to control
movement of the robotic arm 510 and the attached nozzle 100. A
vision system 512 is also logically coupled with the computing
device 514. It is understood that a separate computing device may
be logically coupled to one or more of the components depicted or
contemplated with respect to the system of FIG. 5. A fluid source
518 is also depicted being fluidly coupled 516 with the nozzle 101.
The fluid source 518 provides the fluid, such as air, to the
air-mask port 202 forming a mask stream 508. A material source 520
is fluidly coupled with the nozzle 100 to provide the material for
application, such as an adhesive, primer, paint, or dye as a
material stream 506. As depicted in FIG. 5, the material stream 506
has a spray pattern that is affected by the mask stream 508.
[0048] An exemplary substrate is depicted as a component for an
article of footwear 500, such as a shoe upper. Other substrates are
contemplated, such a knit, woven, braided, non-woven textiles. The
substrate may be planar or non-planar (e.g., dimensional article).
For example the substrate may be a material to be formed into a
garment (e.g., shirt, shorts, pants, jackets, hat, socks and the
like) or it may be the garment itself. In the example of FIG. 5,
the material stream 506 is applied to the article of footwear 500
to form a covered area 504. The covered area 504 has been coated
with material from the material source 520 as applied from the
nozzle 100. The material is, however, prevented or substantially
prevented from being applied to the substrate beyond an application
line 502. In this example, the application line 502 is a biteline.
A biteline is a junction between a shoe upper and a shoe sole.
Traditionally adhesive is applied in the covered area 504 up to the
application line 502 by hand. If adhesive extends beyond the
application line 502 the adhesive may be visible on the shoe upper
and create a non-conforming aesthetic shoe. If the adhesive fails
to substantially reach the application line 502, the sole may be
more prone to becoming un-adhered to the article of footwear 500.
Therefore, an ability to apply material up to the application line
502 without substantially over applying the material beyond the
application line 502 allows for efficient production of an
article.
[0049] In use, it is contemplated that one or more tool paths are
stored in the computing device 514. The vision system 512 is
effective, in a first example, to identify the article of footwear
500 by capturing an image of the substrate and comparing the image
to a database of stored articles. In response to identifying the
article of footwear 500, the associated tool path is determined. A
determination of the tool path may include retrieving a stored tool
path in the computer-readable memory for the identified article.
Alternatively, the computing device 514 is effective to generate a
tool path based on information captured by the vision system 512.
Regardless, information captured by the vision system may be
effective to determine a location on the substrate for positioning
the tool path. Alternatively, one or more manufacturing jigs (e.g.,
registration apertures, tooling registrations) may be used to
mechanically identity a location from which the tool path should
originate on the substrate. Further yet, it is contemplated that
other identification systems are implemented (e.g., barcode, RFID,
user entry, and the like) to determine the article of footwear 500
for generation or retrieval of an appropriate tool path. The vision
system 512 may also or alternatively be used to monitor material
application to adjust one or more parameters of the system. For
example, material dispensing from the dispensing port 102 and/or
fluid expelling from the air-mask port 202 may be adjusted based on
information captured by the vision system 512 during an applying
stage.
[0050] The fluid source 518 may be a tank, pump, generator, or
other source of pressure. The fluid source 518 may be a compressor
that pressurizes atmospheric air. The fluid source 518 may be a
tank of non-atmospheric gas (e.g., N2, O2, and CO2) that has been
pressurized.
[0051] The material source 520 may be a tank having the material
contained therein. The material source may also be a mechanical
element, such as a pump, to feed the material to the nozzle 100.
The material source may maintain a liquid or solid material. For
example, the material may be a powder coating to be applied. The
material may be a liquid composition to be applied.
[0052] In combination, the components of FIG. 5 may be used to
apply a material to a substrate in a manner that prevents
application of the material beyond the application line through use
of an air-mask port emitting a mask stream. One or more of the
components depicted in FIG. 5 may be omitted or adjusted in size,
shape, and/or quantity (e.g., multiple computing devices 514 are
contemplated). Additional components are contemplated within the
scope of FIG. 5. For example, one or more material conveyance
mechanisms to move or otherwise position the substrate(s) are
contemplated.
[0053] While a single nozzle is depicted in FIG. 5 for illustration
purposes, it is contemplated that two (or more) nozzles may be
implemented in actuality with the other components depicted. For
example, a first nozzle having a dispensing port may be joined with
a second nozzle having an air-mark port, such that a common
conveyance mechanism (e.g., a robot, and X-Y plane table), may move
both the first and the second nozzle in unison. Alternatively, it
is contemplated that a first nozzle having a dispensing port and a
second nozzle having an air-mask port may be moved independent of
each other by discrete movement mechanisms. Further yet, it is
contemplated that a first nozzle and a second nozzle may be moved
on a macro scale by a common movement mechanism (e.g., a multi-axis
robot), while each nozzle may be moved independently by another
movement mechanism positioned between the macro-movement mechanism
and each nozzle (e.g., an pivoting adjuster, such as a pneumatic
cylinder for adjusting a relative angle between the first and
second nozzles). In examples having more than nozzle, it is
contemplated that independent and discrete systems discussed in
connection with FIG. 5 may be implemented for each nozzle.
Alternatively, it is contemplated that one or more of the
systems/components discussed in connection with FIG. 5 may service
both of the first and second nozzle, in an exemplary aspect.
[0054] FIG. 6 depicts a cross sectional view of material
application as modified by a mask stream 604, in accordance with
aspects hereof. Material is dispensed from the dispensing port 102
as a material stream 602 towards a substrate. The mask stream 604
is expelled from the air-mask port 202. The mask stream 604
interferes with the defined spray pattern of the material stream
602 at the application line 502 on the substrate. As such, the
material from the material stream 602 does not extend (or at least
does not substantially extend) beyond the application line 502.
This deformation of the spray pattern is demonstrated by a distance
y 610 that is greater than a distance x 608. The distance x 608 is
from a dispensing axis to the application line 502 along the
alignment axis that extends between the air-mask port and the
dispensing port. The distance y 610 is from the dispensing axis to
the spray pattern intersection with the substrate along the
alignment axis that extends between the air-mask port and the
dispensing port. If the mask stream 604 was to be omitted, distance
x 608 and distance y 610 may be equal. However, because of the mask
stream 604, the material is applied up to the application line 502,
which is less than the emitted spray pattern coverage.
[0055] As provided herein, an "axis" (i.e., masking axis,
dispensing axis, alignment axis) is a line that extends from a
first point to a second point, but the line is not physically
present. It is a reference line for measurement and positioning.
For example, because a gas stream emanating from a port may change
shape as it extends from the port, a common reference is a single
line that represents a parallel path of the fluid (e.g., air
stream) as it emits from the port. Generally this axis emanates
from a central location of the port and is oriented parallel to an
average material stream orientation from the port as it emanates.
In a traditional port, the axis extends parallel to sidewalls by
which the fluid passes defining the port.
[0056] The nozzle is maintained a distance 606 from the substrate.
The distance 606 may be any distance, such as 5 mm to 1 meter. As
can be appreciated from the FIG. 6, a parallel relationship is
formed between the mask stream 604 and a spray line extending
through the dispensing port 102. As the distance 606 increases, the
outward projecting material stream 602 increases the distance y
610. However, because of the parallel relationship of the mask
stream 604, the distance x 608 remains substantially constant with
a changing distance 606. This is a distinction from traditional
spray pattern modifiers (e.g., an air horn) that modify the spray
pattern proximate to the material dispensing port (e.g., the
modifying stream is angled into the spray line as opposed to
parallel with the spray line). In the illustrated example, as the
distance increases or changes, such as by applying material to a
three-dimensional article having different curves and angles, less
control over the distance 606 may be used to ensure application of
the material to the application line 502; because the mask stream
604 ensures the spray pattern terminates at the application line
502. As such, a distance maintained between the nozzle and the
substrate may have a more relaxed tolerance when using the air-mask
port 202 instead of when not using the air-mask port 202, in an
exemplary aspect.
[0057] While FIG. 6 (and FIGS. 12, 13, 19, and 20) depicts a
parallel relationship between the mask stream and the spray line,
it is contemplated that a non-parallel relationship between the
mask stream (e.g., masking axis) and the spray line (e.g.,
dispensing axis) is used to create and intersection between the two
stream proximate the substrate (e.g., within 10 cm, within 5 cm,
within 1 cm), as will be depicted in FIGS. 17 and 18
hereinafter.
[0058] FIG. 7 depicts a sequence 700 of the air nozzle 100
following a tool path along the application line 502, in accordance
with aspects hereof. The nozzle is depicted as moving from a
location identified as 710 to a location 730 with an in-order
location listing of 712, 714, 716, 718, 720, 722, 724, 726, and
728. Stated differently, the nozzle moves along the application
line 502 from the position 710 to the location 730 as depicted in
FIG. 7.
[0059] In each aspect, the rotational alignment of the nozzle is
maintained such that an alignment axis 702 extending between the
dispensing port 102 and the air-mask port 202 (or any other air
mask port or physical mask) is perpendicular 704 (or substantially
perpendicular to within 15 degrees) to the application line 502.
Stated differently, by maintaining the alignment axis 702 in a
perpendicular relationship to the application line 502 during
application of the mask stream, an effective air mask is created to
prevent material application beyond the application line 502
opposite a side on which the dispensing port 102 is positioned. In
an exemplary aspect the air-mask port 202 or any other port used to
define the alignment axis is on a first side of the application
line 502 and the dispensing port 102 is on a second side of the
application line 502. In yet another aspect, both the air-mask port
202 and the dispensing port 102 are on a first side of the
application line 502. In yet another aspect, the air-mask port 202
is positioned on the application line 502. Further, an alignment
axis is contemplated to also extend between an air-mask port and a
dispensing port even when a first nozzle has the dispensing port
and a second nozzle has the air-mask port. Stated differently, an
alignment axis is present regardless of if a single or a
multi-nozzle approach is implemented.
[0060] By maintaining a substantially perpendicular relationship
between the alignment axis 702 and the application line 502, the
mask stream is effective to reduce or prevent material application
beyond the application line. For example, it is contemplated that
the mask stream is laminar in flow and therefore provides a
consistent mask to the material. A consistent mask allows for a
predictable obstruction to the spray pattern of the material to
effectively dispense the material in predicted locations of the
substrate, in an exemplary aspect. In yet other aspects, having an
orientation of the alignment line to the application line outside
of a defined range (e.g., 75 degrees to 105 degrees) causes the air
mask to interfere with application of material along the
application line instead of aiding in the application of material
along the application line.
[0061] The alignment axis 702, while based on the dispensing port
102 and the air-mask port 202 in FIG. 7, it is contemplated that
the alignment axis 702 may alternatively be based on a dispensing
port and any air-mask port, such as an air-mask port of a second
nozzle and/or a third nozzle (e.g., the air-mask port 2210 of FIG.
22). Stated alternatively, the alignment axis may extend through a
dispensing port and an air-mask port, such as the air-mask port
2210 of FIG. 22. Therefore, while the discussion of FIG. 7 is
generally directed to the specific air-mask port 202 of FIG. 7, the
disclosure is intended to and contemplated to equally apply to an
alignment axis extending between a dispensing port and a mask, such
as an air-mask port (e.g., the air-mask port 202 of FIG. 7, the
air-mask port 2210 of FIG. 22) or a physical mask (e.g., the
physical mask 1914 of FIG. 19, the physical mask 2202 of FIG. 22).
As such, this disclosure represents maintaining a perpendicular
relationship (or any defined angular relationship) between an
application line and an alignment axis.
[0062] Further yet, it is contemplated that the alignment axis 702
may be based on a dispensing port and a physical mask. Stated
differently, an alignment axis that is maintained perpendicular to
an application line may be determined as extending through a
dispensing port and a mask (e.g., a physical mask and/or air mask).
For reasons discussed in connection with FIG. 7, the perpendicular
relationship between the alignment axis and an application line
allows for controlled application of material along the application
line.
[0063] FIGS. 8-11 depict alternative air-mask port configurations,
in accordance with aspects hereof. FIG. 8 depicts a configuration
800 similar to that previously discussed in FIGS. 1-4. The air-mask
port 202 and the dispensing port 102 are both circular in the
horizontal cross section. The air-mask port 202 has a diameter of
204 that is less than a diameter 104 of the dispensing port 102.
Furthermore, the air-mask port 202 is peripherally offset from the
dispensing port 102 by a distance 802. In an exemplary aspect, the
distance 802 is greater than the diameter 104, and the diameter 104
is greater than the diameter 204. This relative sizing of the
various elements and position allows for an effective masking of
material dispensed from the dispensing port 102, in an exemplary
aspect.
[0064] FIG. 9 depicts a configuration 900 of an air-mask port 902
having an elliptical cross section in the horizontal plane, in
accordance with aspects hereof. The air-mask port 902 has a major
axis perpendicular to the alignment axis and a minor axis parallel
with the alignment axis. The air-mask port 902 has a width measured
along the alignment axis of distance 904. The distance 904 is less
than a diameter of the dispensing port 102. The air-mask port 902
may be effective to generate a linear mask stream, in an exemplary
aspect.
[0065] FIG. 10 depicts a configuration 1000 of an air-mask port
1002 having a rectilinear cross section in the horizontal plane, in
accordance with aspects hereof. The air-mask port 1002 has a major
axis perpendicular to the alignment axis and a minor axis parallel
with the alignment axis. The air-mask port 1002 has a width
measured along the alignment axis of distance 1004. The distance
1004 is less than a diameter of the dispensing port 102. The
air-mask port 1002 may be effective to generate a linear mask
stream, in an exemplary aspect.
[0066] FIG. 11 depicts a configuration 1100 of dual air-mask ports
202 and 203, in accordance with aspects hereof. The dual air-mask
ports 202 and 203 are aligned on the alignment axis 702 with each
on a different side of the dispensing port 102. In this example,
control at the substrate surface may be achieved for the material
application. Therefore, if material is intended to be applied in a
strip on the substrate defined between the dual air-mask ports 202
and 203, both air-mask ports may simultaneously expel a mask
stream. Alternative, the air-mask port 202 may be used exclusive of
the air-mask port 203. Instead of rotating the nozzle 180 degrees,
a different air-mask port may emit a mask stream. Stated
differently, it is contemplated that a nozzle may have two or more
air-mask ports that are independently activated to produce air mask
streams relative to the portion of the nozzle on the substrate
while reducing movement of the nozzle to achieve a given mask
stream at a given orientation.
[0067] Additionally, it is contemplated that two or more air-mask
ports may be independently controllable on a nozzle (or multiple
nozzles) with the air-mask ports having different size, shape,
and/or orientation. Therefore, instead of changing out a nozzle for
a different spray material or application line; a different
independently controlled air-mask port may be activated to generate
a varied or alternative mask stream.
[0068] FIGS. 12 and 13 depict additional aspects of the nozzle
having a gas knife 1202, in accordance with aspects hereof. FIG. 12
depicts the gas knife 1202 positioned along the alignment axis on a
same side of the dispensing port 102 as the air-mask port 202. In
this example, the gas knife 1202 can serve as a supplemental
barrier to over spraying of the material to a substrate 1201. For
example, the primary spray stream is depicted as 602. The mask
stream 604 is depicted as forming a mask of the material. However,
in some aspect the material may extend through the mask stream 604
as overspray 1208. In this situation, the gas knife 1202 has an
exit port 1204 that expels gas, such as pressurized air, to form a
secondary masking stream 1206. Therefore, the gas knife 1202 is
effective to produce a secondary masking effect for overspray 1208
that extends through the mask stream 604. In this example, the gas
knife 1202 is a secondary spray pattern adjuster having a parallel
fluid stream to a spray line. Therefore, the exit port 1204 is
offset a greater distance from the dispensing port 102 than the
air-mask port 202 is offset from the dispensing port 102.
[0069] A gas knife is a discrete type of air mask. A gas knife is
an air mask formed in a separate nozzle from the dispensing port.
The nozzle having the air knife may be physically joined (e.g.,
integrally formed or discretely joined) and statically positioned
or it may be physically separated and dynamically positioned
relative to the nozzle having the dispensing port. Therefore,
reference herein to an air mask and associated features (e.g.,
air-mask port) is inclusive of a gas knife and associated
disclosure herein.
[0070] The gas knife 1202 may be independently activated and
controlled from the air-mask port 202 and/or the dispensing port
102. As such, the gas knife 1202 may be activated along some
portions of the tool path and not active along other portions of
the tool path. The gas knife 1202 may use the same fluid or a
different fluid or fluid source from the air-mask port 202. The gas
knife 1202 may expel a greater volume and/or a great pressure of
fluid than the air-mask port 202. In an exemplary aspect, as the
gas knife 1202 is further from the application line than the
air-mask port 202, this greater pressure and/or volume is
acceptable as more turbulence in fluid flow is allowable further
from the application line, in some aspects.
[0071] FIG. 13 depicts the gas knife 1202 positioned along the
alignment axis on a different side of the dispensing port 102 as
the air-mask port 202. In this example, the gas knife 1202 can
serve as a barrier to over spraying 1210 of the material on the
substrate 1201. For example, if the dispensing port 102 forms an
obstruction, clog, or other spray-pattern-varying defect (e.g.,
residual material altering the shape of the dispensing port 102),
the gas knife 1202 can aid in reducing the overspray 1210 from
being applied beyond the gas knife 1202. It is contemplated that a
combination of air knifes may be used in combination or
individually.
[0072] FIG. 14 depicts a range of orientations that a nozzle may be
in relative to an application line 502', in accordance with aspects
hereof. The alignment axis 702 extending between the air-mask port
202 and the dispensing port 102 is depicted in a perpendicular
relationship with the application line 502'. However, it is
contemplated that the nozzle may be oriented in some examples
between 75 degrees and 105 degrees relative to the application line
502'. For example, an alignment axis 702' extends from the air-mask
port in an orientation 202'. The alignment axis 702' interests the
application line 502' at 105 degrees. In another example, an
alignment axis 702'' extends from the air-mask port in an
orientation 202''. The alignment axis 702'' interests the
application line 502' at 75 degrees. In some aspects, the relative
position of the alignment axis to the application line may be
within the 75 degree to 105 degree orientation to provide a
sufficient mask stream to the application of material to a
substrate along the application line 502'.
[0073] FIG. 15 illustrates a method 1500 of applying material from
a nozzle having an air-mask port and a dispensing port, in
accordance with aspects hereof. At a block 1502, the nozzle is
positioned relative to the substrate. In an exemplary aspect, the
nozzle may be posited by a movement mechanism, such as a robotic
arm. The position at which the nozzle is place relative to the
substrate may be defined by a tool path associated with the
substrate. The tool path may be provided by and/or determined by a
computing device. The computing device may use one or more
components, such as a vision system having a camera, to identify
the substrate and where a tool path should be positioned on the
substrate. The vision system may confirm the nozzle is positioned
appropriately along the tool path, in an exemplary aspect.
[0074] At a block 1504, material is dispensed from a dispensing
port of the nozzle. The material may be a liquid or a solid (e.g.,
powder). The material may be an adhesive, primer, paint, dye, or
other material to be deposited on the substrate. The material may
be dispensed through a material stream of gas that atomizes and
transports the material to the substrate. The material may be
dispensed as a pressurized stream of liquid from the dispensing
port. The dispensing may be controlled by the computing device.
[0075] At a block 1506, a gas is expelled or discharged from an
air-mask port associated with the same nozzle or a different nozzle
(e.g., an air knife). The gas may be a pressurized atmospheric air.
The expelling of the gas may for a virtual wall that the material
being dispensed cannot or has difficult breaching. Therefore, the
pressurized air stream, referred to herein as a mask stream,
creates a virtual masking of the substrate from the material being
dispensed. The mask stream may be independently controlled from the
dispensing of the material. Or, alternatively, the mask stream may
be coupled to the dispensing operation such that when dispensing of
material occurs so does the mask stream, in an exemplary
aspect.
[0076] At a block 1508, the nozzle is moved along an application
line of the substrate such that an alignment axis of the nozzle
intersects the application line at an angle range of 75 degrees to
105 degrees. The movement of the nozzle while dispensing material
and discharging the mask stream may be controlled by a movement
mechanism (e.g., a robotic arm) in combination with a computing
device. In some example, the air-mask port is on a first side of
the application line and the dispensing port is on an opposite
second side of the application line. In an alternative exemplary
aspect, the air-mask port and the dispensing port are on a common
side of the application line and the air-mask port is closer in
proximity to the application line than the dispensing port.
[0077] FIG. 16 depicts a first nozzle 1602 having a dispensing port
1606 and a second nozzle 1604 having an air-mask port 1612, in
accordance with aspects hereof. An orientation of the first nozzle
1602 and the second nozzle 1604 is such that resulting streams
emanating therefore intersect proximate (e.g., 10 cm, 5 cm, 1 cm, 5
mm, 1 mm) a substrate surface 1618. The intersection of a spray
stream 1610 and an air-mask stream 1614 may be identified by a
material intersection 1624 and/or by an intersection 1626 of a
dispensing axis 1620 and a masking axis 1622. For consistency and
simplicity, an intersection between a first nozzle stream and a
second nozzle stream will be in reference to the axial intersection
(e.g., intersection 1626) as the various streams have
characteristics that may be adjusted (e.g., size, shape).
[0078] An angle 1628 between the dispensing axis 1620 and the
masking axis 1622 is set to ensure the intersection 1626 occurs
within a predefined distance of the substrate surface 1618. For
example the angle 1628 may be defined to ensure the intersection
1626 occurs within 10 cm, 5 cm, 1 cm, 5 mm, or 1 mm of the
substrate surface 1618. The purpose of the angle 1628, in some
aspects is to ensure the material applied from the first nozzle
1602 does not extend past an application line, such as an
application line at the intersection 1624. While some aspects
herein contemplate a parallel relationship between an masking axis
and a dispensing axis to provide a virtual wall that is relatively
independent of a distance of a nozzle from the substrate, having
the angle 1628 may provide greater control of the material
application along an application line when a distance between the
one or more nozzles and the substrate surface 1618 is
controlled.
[0079] As a non-planar surface to have material is contemplated
(e.g., a three-dimensional shoe upper), it is contemplated that a
movement mechanism may maintain a known distance between the first
nozzle 1602 and the surface, the movement mechanism may adjust a
position of the first nozzle 1602 relative to the application lien
to compensate for a distance between the surface and the first
nozzle 1602. For example, as the dispensing port 1606 gets closer
to the surface, a distance in the alignment axis between the
dispensing axis 1620 and the application line is reduced. Further
yet, it is contemplated that the angle 1628 may be dynamically
adjusted by a movement mechanism based on a distance of the
dispensing port 1606 (or first nozzle 1602) from the substrate. As
such, a non-parallel relationship between the masking axis 1622 and
the dispensing axis 1620 may be leveraged to achieve a controlled
distribution of material while compensating for variations in
distance between the first nozzle 1602 and the substrate.
[0080] Additionally, it is contemplated that the first nozzle 1602
may comprise an air-mask port 1608. The air-mask port 1608 is
optionally included and/or optionally utilized, as depicted in FIG.
22 hereinafter as being optionally omitted. Further, the air-mask
port 1608 is depicted as being positioned between the first nozzle
1602 and the second nozzle 1604. In this depicted relative
position, the air-mask port 1608 may direct a stream of fluid to
further guide or shape the spray stream 1610. Alternatively, the
air-mask port 1608 may be positioned opposite the second nozzle
1604 to aid in shaping or otherwise forming the spray stream 1610
on an opposite side from the second nozzle 1604. The air-mask port
1608, in an exemplary aspect, functions as described in connection
with the air-mask port 202 of FIG. 1, hereinabove. The air-mask
port 1608 is selectively activated to dispense a fluid, such as
compressed gas, in an exemplary aspect. As such, in some modes of
operation the air-mask port 1608 dispenses a fluid and in other
modes of operation the air-mask port 1608 does not dispense a
fluid.
[0081] FIG. 17 depicts the first nozzle and the second nozzle of
FIG. 16 having an illustrative substrate surfaces 1704 at a
distance 1706 relative to the first nozzle 1602, in accordance with
aspects hereof. Specifically, FIG. 17 depicts that a substrate may
be positioned within the distance 1706 of the first nozzle 1602 as
measured from a distal surface 1702. Is this example, an
intersection 1708 of the dispensing axis 1620 and the masking axis
1622 occurs at the substrate surface 1704. However, as depicted in
FIG. 16, an intersection of the masking axis and the dispensing
axis may occur subsequent to the substrate surface in a material
flow direction. Similarly, it is contemplated that the intersection
may occur prior to the substrate surface in the material-flow
direction. The distance 1706, in an exemplary aspect is greater
than 10 cm, 5 cm, and 1 cm. This is in contrast to the previously
discussed air horn concepts. An air horn may have an air stream
that intersect the material stream, but that intersection occurs in
close proximity to the ports expelling the air stream and/or the
material stream. The aspect provided herein instead contemplates an
intersection (e.g., intersection 1708) that occurs within 10 cm, 5
cm, 1 cm (in both the positive and negative direction) of the
surface. Use of a traditional air horn at a distance that would
move the air stream and the mask stream to the range provided
herein would not provide a reasonable or workable distance for the
traditional air horn nozzle. In that example to have the
intersection of a traditional air horn stream within the provided
ranges herein, the air horn itself would obscure the surface from
view and results in a material pattern of such a small size that it
would not be practical for application to articles contemplated
herein, such as an article of footwear.
[0082] FIG. 18 depicts the first nozzle 1602 and the second nozzle
1604 of FIG. 16 with the first nozzle 1602 having an optional
physical mask extension 1802 and an optionally integral air-mask
port, in accordance with aspects hereof. The physical mask
extension 1802 is a tangible element that physically blocks the
material spray pattern or interrupts the material spray pattern.
The physical mask extension 1802 has a primary surface 1810 that is
positioned towards the material spray pattern and the dispensing
port. It is the primary surface 1810 that may contact material
emitted from the dispensing port to prevent further expansion of
the material spray pattern in the direction of the physical mask
extension 1802. Unlike an air mask, the physical mask extension
1802 can provide a physical mask to the dispensed material, but it
may also require cleaning and other maintenance. Further the
physical mask extension 1802 has a distal end 1804 that may be
spaced from the substrate surface 1806 by a distance 1808. The
distance 1808 may be minimized to provide greater control of the
masking effect provided by the physical mask extension 1802;
however, the distance 1808 may be 1 mm or greater to prevent
physical interference between the distal end 1804 and the substrate
surface 1806 as the first nozzle 1602 is moved to follow an
application line. If the substrate is a married thickness material
and or dimensional in nature, as is common for an article of
footwear in exemplary aspect, the distance 1808 is greater than 1
mm. The physical mask extension 1802 may be positioned on a first
side of the dispensing port while an air-mask may be positioned on
a second side. First it is contemplated that the physical mask
extension 1802 is on a first side of the dispensing port on an
alignment axis as compared to an air-mask port. The physical mask
extension 1802 may be used in connection with an air mask port that
is integral to the nozzle to which the physical mask extension 1802
is positioned (e.g., first nozzle 1602). Additionally, it is
contemplated that a second nozzle (e.g., the second nozzle 1604)
may me positioned opposite of the physical mask extension 1802
relative to the distribution port of the first nozzle. This
relative positioning of the air mask and the physical mask
extension 1802 may be such that the air mask is implemented when
known interference between the mask (e.g., air stream) and the
material will occur continuously and the physical mask extension
1802 may be implemented when interference between the mask (e.g.,
physical element) occurs as an exception (e.g., less than 10% of
material volume dispensing results in contact with the mask).
[0083] FIG. 19 depicts an additional first nozzle 1902 having a
dispensing port 1906 and a second nozzle 1904 having an air-mask
port 1920 and an integrated physical mask 1914, in accordance with
aspects hereof. In this example, the air-mask port 1910 is oriented
having a masking axis that is substantially parallel with a
dispensing axis of the dispensing port 1906. The second nozzle 1904
is sized and positioned to also serve as a physical mask of a
material stream 1908. For example, a prominent surface of the
second nozzle 1904 provides a physical masking surface that can
enhance, substitute, or augment an air-mask stream 1912. The use of
the physical mask 1914 and the air-mask stream 1912 provides a
configuration where a majority of material from the material stream
1908 is directed by the air-mask stream 1912 and exceptional
material (e.g., errant material from the dispensing port 1906) is
masked by the physical mask 1914. The shape and size of the
physical mask 1914 is selected to achieve an intended application
pattern of the material stream 1908. It is contemplated that the
second nozzle 1904 may be moved relative to the first nozzle 1902
to adjust a position of the physical mask 1914 to adjust the
material stream 1908. Additionally, it is contemplated that the
air-mask stream 1912 and the material stream 1908 may be
independently operated and/or varied.
[0084] FIG. 20 depicts yet another first nozzle 2002 having a
dispensing port 2006 and a second nozzle 2004 having an air-mask
port 2010, in accordance with aspects hereof. The configuration of
FIG. 20 highlights variations in relative positions of the first
nozzle 2002 and the second nozzle 2004. For example, the dispensing
port 2006 and the air-mask port 2010 are offset in a material flow
direction by a distance. This distance may be about 1 mm, 5 mm, 1
cm, 2 cm, 5 cm, or any value there between. An offset in the
dispensing port 2006 and the air-mask port 2010, in an exemplary
aspect, allows for a concentrated air-mask stream 2012 to be
expelled at a point closer to intersection with a material stream
2008. By reducing a distance between the air-mask port 2010 and an
intersection of the air-mask stream 2012 and the material stream
2008 through the offsetting of the respective ports, the air-mask
stream 2012 may be more effective as a mask to the material stream
2008, in an exemplary aspect. Similarly is contemplated that a
lateral position (e.g., left and right in the FIG. 20) may also be
adjusted to influence an intersection (e.g., interaction) position
of the air-mask stream 2012 and the material stream 2008, in
exemplary aspects.
[0085] FIG. 21 depicts a nozzle 2102 having a physical mask 2106
joined therewith, in accordance with aspects hereof. The physical
mask 2106 has a prominent surface 2108 that interacts with a
material stream 2104 to adjust the material pattern, in accordance
with aspects hereof. The configuration of FIG. 21 highlights that
an air-mask stream may be optionally omitted in aspects hereof
and/or that an air-mask stream, when included, may be independently
and separately operated from the material stream 2104, in aspects
hereof.
[0086] As such, it is contemplated in the various configurations
provided herein that one or more elements (e.g., nozzle, port,
physical masks) may be positioned at different locations to
influence the material stream. Positioning include vertical and
lateral positioning changes. Additionally, positioning also include
orientation changes. For example, one element (e.g., a first
nozzle) may be rotated relative to another element (e.g., second
nozzle). Further yet, it is contemplated that one or more elements
may be omitted or added. For example, a first nozzle having a
dispensing port may also have an integral air-ask port. In this
same example, a second nozzle may be provided that has one or more
ports (e.g., a second air-mask port). The air-mask port, the second
air-mask port, and the dispensing port may be independently and
separately operated, in exemplary aspects.
[0087] FIG. 22 depicts the first nozzle 1602 and the second nozzle
1604 of FIG. 16 with the first nozzle 1602 having an optional
physical mask 2202 and an optionally third nozzle 2214, in
accordance with aspects hereof. While the nozzles from FIG. 16 are
depicted and referenced, it is contemplated that any nozzle
provided herein may be implemented in any combination. For example,
the second nozzle 1604 may be omitted all together in some aspects.
Further, while the first nozzle 1602 is depicted in FIG. 22 having
the air-mask port (e.g., air-mask port 1608 of FIG. 16), it is
contemplated that the air-mask port may be omitted or positioned
differently, in alternative aspects.
[0088] The physical mask 2202 extends from the first nozzle 1602
(or extends along the first nozzle 1602) in a direction of the
spray pattern from the first nozzle 1602. The physical mask 2202
may have a curvature, such as a curvature that parallels the
exterior surface of the first nozzle 1602. The curvature may have
any diameter, such as a diameter that is greater or lesser than a
diameter of the first nozzle 1602. Further, the curved profile of
the physical mask 2202, in an exemplary aspect, provides a physical
masking surface that closer aligns with a spray pattern of the
first nozzle 1602.
[0089] The physical mask 2202 includes a primary surface 2220 and
an opposite secondary surface 2222. The primary surface 2220 is a
surface exposed to the spray pattern of the associated nozzle, such
as the first nozzle 1602. The primary surface 2220 serves as a
physical mask to control the spray pattern emitted from the
associated nozzle. The primary surface 2220 may accumulate
material, such as an adhesive, emitted from the associated nozzle.
Eventually, accumulated material may interfere with or otherwise
disrupt the spray pattern from the associated nozzle in an
unintended manner. The accumulated material may prevent an intended
spray pattern and resulting application of material on a target
surface. Therefore, aspects herein contemplate a physical mask
cleaning solution.
[0090] A port 2224 directs a fluid 2226, such as compressed air, on
the primary surface 2220 to dislodge accumulated material from the
primary surface 2220. The fluid 226 is supplied to the port 2224
through a source 2218. The source 2218 may be a tube (e.g.,
pneumatic line) or other fluid conduit to transfer the fluid 2226
to the port 2224. The fluid 2226 may be supplied from a compressor,
a reservoir, or other source. The port 2224, in an exemplary
aspect, extends through the physical mask 2202 from the secondary
surface 2222 to the primary surface 2220. At the primary surface
2220, the port 2224 is configured (e.g., directed outlet) to direct
the fluid 2226 along the primary surface 2220. Stated differently,
an air stream is directed to the primary surface 2220 of the
physical mask 2202 to remove accumulated material from the primary
surface 2220. The fluid 2226 is effective to remove material, such
as accumulated material, from the primary surface 2220. In use, it
is contemplated that the port 2224 expels the fluid 2226 to clean
the primary surface 2220. The fluid 2226 is expelled, in an
exemplary aspect, on request. For example, the fluid 2226 may be
expelled when the first nozzle 1602 is not expelling a material.
Stated differently, the port 2224 operates independently from the
first nozzle 1602. The port 2224 operates (e.g., expels air) at
times that do not interfere with the spray of material from the
first nozzle 1602, such as after the first nozzle 1602 completes a
material dispensing operation.
[0091] The third nozzle 2214 is depicted in FIG. 22; however, it is
optional and may be omitted in some aspects. In examples where the
third nozzle 2214 is implemented, the third nozzle 2214 emits an
air mask 2212. The third nozzle 2214 expels the fluid from an
air-mask port 2210 and is supplied by a supply line 2216. The
supply line 2216 is fluidly coupled with a source, such as a
compressor, tank, or other supply. The air mask 2212 projects
towards the secondary surface 2222. The air mask 2212, in an
exemplary aspect, serves as an air mask between a distal end of the
physical mask 2202 and the surface to which the material from the
first nozzle 1602 is to be applied. When optionally used, the air
mask 2212 allows the physical mask 2202 to maintain physical
clearance (e.g., offset distance without contact) from the surface
to which material is to be applied. By maintaining the physical
clearance, interference of the physical mask 2202 and the surface
and/or applied material may be avoided as the physical mask 2202
moves relative to the surface.
[0092] The third nozzle 2214 is adjustable in position and
orientation, such as along any axis 2232 in direction and/or
rotation. It is contemplated that a position of the third nozzle
2214 may be adjusted with respect to one or more of the depicted
components, such as the first nozzle 1602, the second nozzle 1604,
and/or the physical mask 2202. The adjustable position may include
an offset distance horizontally from one or more components of FIG.
22. The adjustable position may include an offset distance 2230 in
the vertical direction from the substrate to which the air mask
2212 is directed. An orientation, such as an angle formed between
the air mask 2212 and the physical mask 2202 may be adjusted and
maintained. An orientation, such as an angle 2228 formed between
the air mask 2212 and the substrate is also contemplated. The
adjustability of position and/or orientation of the third nozzle
2214 allows for the appropriate placement of the air mask 2212
expelled from the air-mask port 2210. This adjustment of position
and/or orientation can compensate for varied spray patterns of
material from the first nozzle 1602 and/or varied tolerances of
errant material from the first nozzle 1602.
[0093] FIG. 23 depicts a bottom-up plan view of a portion of
components from FIG. 22, in accordance with aspects hereof.
Specifically, the first nozzle 1602, the physical mask 2202, and
the third nozzle 2214 are depicted in FIG. 23. FIG. 23 depicts the
physical mask having a curved form that conforms to the curvature
of the first nozzle 1602. The curvature of the physical mask 2202
may also conform to a spray pattern emitted from the dispensing
port 1606, in an exemplary aspect. For example, the dispensing port
1606 is depicted as a circular port that emits a conical stream.
The curvature of the primary surface 2220 of the physical mask 2202
may have a radius that corresponds to a conical radius of the
emitted stream from the dispensing port 1606 at an intersection of
the emitted stream and the physical mask 2202. Further, while FIG.
23 depicts the primary surface 2220 and the secondary surface 2222
having parallel curved surfaces, it is contemplated that the
secondary surface 2222 may have a different (e.g., linear) surface
than the primary surface 2220, in exemplary aspects. For example,
in an exemplary aspect, the secondary surface has a linear surface
such that an interaction with an air mask stream from the third
nozzle 2214 forms a straight edge at an intersection with a stream
from the dispensing port 1606 beyond the physical mask 2202 distal
end. In yet another example, the secondary surface 2222 is a curved
surface, as depicted in FIG. 23, to provide a curved intersection
profile of the air mask stream from the third nozzle 2214 as it
interacts with the emitted stream from the dispensing port 1606
proximate the substrate beyond the distal end of the physical mask
2202. While depicted as being curved, it is contemplated that the
primary surface 2220 may alternatively have a different surface
configuration in the bottom-up plan view, such as a linear
surface.
[0094] The port 2224 is depicted as being positioned between the
primary surface 2220 of the physical mask 2202 and the dispensing
port 1606. The port 2224 is depicted as having a non-circular
(e.g., annular quad-sided structure) plan shape. However, it is
also contemplated that the port 2224 may have a circular, linear,
polygonal, and the like shape. The shape of the port 2224 may be
adjusted to complement the physical mask 2202 shape, the primary
surface 2220 shape, and/or the spray pattern from the dispensing
port 1606.
[0095] The air-mask port 2210 is depicted as a rectilinear port on
the third nozzle 2214. However, aspects contemplate a port shape
forming an air mask having a curved profile, such as a curved
profile that match or corresponds with a fluid stream from the
dispensing port 1606, in an exemplary aspect. As discussed with
respect to FIG. 22, it is contemplated that the third nozzle 2214
may be positioned in any orientation or position relative to other
components, such as the first nozzle 1602 and/or the physical mask
2202. The position and orientation movement can help form an
effective air mask for controlling the output from the first nozzle
1602 as it interacts with the target substrate.
[0096] From the foregoing, it will be seen that this invention is
one well adapted to attain all the ends and objects hereinabove set
forth together with other advantages which are obvious and which
are inherent to the structure.
[0097] It will be understood that certain features and
subcombinations are of utility and may be employed without
reference to other features and subcombinations. This is
contemplated by and is within the scope of the claims.
[0098] While specific elements and steps are discussed in
connection to one another, it is understood that any element and/or
steps provided herein is contemplated as being combinable with any
other elements and/or steps regardless of explicit provision of the
same while still being within the scope provided herein. Since many
possible embodiments may be made of the disclosure without
departing from the scope thereof, it is to be understood that all
matter herein set forth or shown in the accompanying drawings is to
be interpreted as illustrative and not in a limiting sense.
* * * * *