U.S. patent application number 16/994550 was filed with the patent office on 2020-12-03 for apparatus and method for applying materials to substrates and related products.
This patent application is currently assigned to FUZE BIOTECH, LLC. The applicant listed for this patent is FUZE BIOTECH, LLC. Invention is credited to Andrew L. Peterson.
Application Number | 20200378062 16/994550 |
Document ID | / |
Family ID | 1000005060152 |
Filed Date | 2020-12-03 |
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United States Patent
Application |
20200378062 |
Kind Code |
A1 |
Peterson; Andrew L. |
December 3, 2020 |
APPARATUS AND METHOD FOR APPLYING MATERIALS TO SUBSTRATES AND
RELATED PRODUCTS
Abstract
An apparatus and method for applying one or more materials, such
as one or more additive materials, to a substrate. The substrate
may be a fabric, fiber or yarn but not limited thereto. The
apparatus includes an array of a plurality of applicators arranged
in proximity to the substrate while the substrate is moving or in a
static position. The applicators are arranged to deliver a mixture
of one or more materials and a material delivery vehicle to the
substrate sufficient to bond at least a portion of the one or more
materials into the substrate or adhere the one or more materials to
the surface of the substrate. The material delivery vehicle may be
air. The applicators include nozzles configured to generate a
dispersion pattern that provides substantially uniform and
substantially complete coverage of the one or more materials onto
and/or in the substrate. The apparatus may include an optional
heater to warm the substrate to improve adhesion of the one or more
materials on and into the substrate.
Inventors: |
Peterson; Andrew L.; (West
Jordan, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FUZE BIOTECH, LLC |
Portsmouth |
NH |
US |
|
|
Assignee: |
FUZE BIOTECH, LLC
Portsmouth
NH
|
Family ID: |
1000005060152 |
Appl. No.: |
16/994550 |
Filed: |
August 14, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2019/018467 |
Feb 19, 2019 |
|
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16994550 |
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62632308 |
Feb 19, 2018 |
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62744490 |
Oct 11, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 11/42 20130101;
D06M 23/06 20130101 |
International
Class: |
D06M 23/06 20060101
D06M023/06; D06M 11/42 20060101 D06M011/42 |
Claims
1. An apparatus for bonding one or more materials into or onto a
fabric or a yarn, the apparatus comprising: one or more manifolds
coupled to a source of a material delivery vehicle; a plurality of
applicators removably affixed to each of the one or more manifolds,
wherein each of the plurality of applicators is coupled to a source
of one or more materials to be applied to the fabric or yarn,
wherein each applicator includes a nozzle configured to direct a
mixture of the one or more materials and the material delivery
vehicle to the fabric or yarn sufficient to embed or adhere at
least a portion of the one or more materials therein, and wherein
the apparatus is configured to deliver one or more nanoparticles
with minimal clogging; and a delivery controller coupled to the
plurality of applicators and configured to regulate delivery of the
mixture to the fabric or the yarn.
2. The apparatus of claim 1, wherein the plurality of applicators
on each of the one or more manifolds are arranged to deliver the
mixture in a uniform dispersion to the fabric or yarn.
3. The apparatus of claim 1, wherein the apparatus is arranged to
deliver the mixture to the fabric or yarn when the fabric or yarn
is static or moving.
4. The apparatus of claim 1, wherein the material delivery vehicle
is air.
5. The apparatus of claim 1, wherein the one or more materials are
one or more additives selected from one or more gases, one or more
liquids, one or more particles or any combination thereof.
6. The apparatus of claim 5, wherein the one or more additives
include nanoparticles of Diamond, Gold, Silver, Jade, Copper, Zinc,
or any combination thereof.
7. The apparatus of claim 1, further comprising a heater arranged
to warm the fabric or yarn to manipulate the thermal dynamic
properties of the materials to prepare them for enhanced particle
adhesion.
8. The apparatus of claim 1, wherein each of the applicators
includes a delivery vehicle inlet port, a material inlet port and a
mixing chamber arranged to mix the delivery vehicle and the one or
more materials therein.
9. The apparatus of claim 1, wherein the delivery controller is
coupled to a pump apparatus arranged to regulate the flow of the
one or more materials to the applicators.
10. The apparatus of claim 1, wherein the apparatus is configured
to deliver one or more nanoparticles with minimal clogging
thereof.
11. The apparatus of claim 10, wherein one or more components of
the apparatus are made completely or partially of
low-surface-tension material.
12. The apparatus of claim 11, wherein the low-surface-tension
material is selected from Nylon and Teflon.
13. A method for treating a fabric or yarn to modify one or more
characteristics of the fabric, the method comprising the steps of:
delivering the fabric or yarn to a material application device
including a plurality of applicators, wherein each of the plurality
of applicators is coupled to a source of one or more materials to
be applied to the fabric or yarn, and wherein each applicator
includes a nozzle arranged to direct a mixture of the one or more
materials and a material delivery vehicle to the fabric or yarn
sufficient to embed or adhere at least a portion of the one or more
materials into the fabric or yarn; and applying the mixture at a
selectable rate and in a selectable pattern onto the fabric or
yarn.
14. The method of claim 13, wherein the selectable rate of applying
the mixture is selected from continuous, periodic, or sporadic.
15. The method of claim 13, further comprising the step of heating
the fabric or yarn prior to delivering the fabric or yarn to the
material application device.
16. The method of claim 13, wherein the fabric or yarn is retained
in a static position during the step of applying.
17. The method of claim 13, wherein the fabric or yarn is moved
continuously to pass the plurality of applicators during the step
of applying.
18. The method of claim 13 wherein one or more components of the
device are made completely or partially of low-surface-tension
material.
19. A method for treating a substrate with one or more materials,
wherein at least one of the one or more materials is a nanoparticle
material, the method comprising the steps of: applying the one or
more materials on a surface of the substrate using a material
application device including a plurality of applicators, wherein
each of the plurality of applicators is coupled to a source of the
one or more materials to be applied to the surface, and wherein
each applicator includes a nozzle arranged to direct a mixture of
the one or more materials and a material delivery vehicle to the
surface, wherein the one or more materials include at least one
nanoparticle material; and regulating a rate and a pattern of
applying the mixture onto the surface.
20. The method of claim 19, wherein the selectable rate of spraying
the mixture is selected from continuous, periodic, or sporadic.
21. The method of claim 19, wherein one or more components of the
device are made completely or partially of low-surface-tension
material.
22. The method of claim 19, wherein the one or more materials
include nanoparticles of Diamond, Gold, Silver, Jade, Copper, Zinc,
or any combination thereof.
23. A method of treating a fiber to enhance one or more
characteristics thereof using one or more materials, the method
comprising the steps of: combining a polymeric material used to
make the fiber with the one or more materials; and forming the
polymeric material into the fiber.
24. The method of claim 23 wherein the one or more materials
include nanoparticles of Diamond, Gold, Silver, Jade, Copper, Zinc,
or any combination thereof.
25. The apparatus of claim 1 wherein the apparatus is contained in
a mobile container.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to improving the
characteristics of fabrics and other substrates that may or may not
be related to fabrics. More particularly, the present invention
relates to effective and cost-efficient application of materials
such as additives to substrates including but not limited to
fabrics, down feathers, fill, leather, synthetics, and yarn, which
are generally referred to herein as materials. The present
invention is an apparatus and a method for applying materials to
substrates by spraying or otherwise directing the materials on to
the substrate to infuse them on and/or into the substrate.
2. Description of the Prior Art
[0002] Fabrics and applicable substrates mentioned are widely used
throughout the world to make finished products such as clothing,
bedding, and towels, to name just three. There are many desirable
characteristics that product manufacturers seek to establish in
their products. These characteristics vary widely and can include,
but not be limited to feel, temperature control, moisture control
and microbe control. Manufacturers also seek to maintain the
product integrity and the desired characteristics through many
cycles of cleaning and usage. It is therefore important to treat
materials effectively to enable desired characteristics. It is also
important to be able to do so in a cost-effective manner.
[0003] Presently, for the most part, components, or materials such
as additives are applied to fabric items in a wet condition, such
as in a bath, by conventional spraying, coating, or foam.
Application of material in a liquid state as currently accomplished
is costly in terms of the amount of additive material used, the
amount of liquid used to deliver the additive material and the
energy required to dry the material after liquid immersion.
Moreover, the additive material delivery vehicle in the form of
solvents and adherence-enhancing chemicals are increasingly
undesirable components of the treatment that may remain in the
substrate material and/or be exposed in the effluent downstream.
Nevertheless, the desired material characteristics achieved by
liquid additive application currently outweigh the negative
consequences. In addition, existing methods for treating materials
by applying additives thereto involve simply coating the substrate
material rather than applying the additives in a way that
integrates or embeds them into the material and so, while enhancing
material characteristics, additive materials applied by current
processes do not improve those characteristics as much as is
possible.
[0004] The described limitations of additive material introduction
to substrates also limit the number, form and type of desired
additives that can be applied to fabrics particularly to improve
their characteristics. Some additives may not be suitable for
dispersion in a liquid and/or uniform introduction to the material.
It may not be possible to combine a plurality of additives in a
single liquid mixture and so multiple applications may be required.
These and other limitations reduce the manufacturer's options for
improving materials in a desired but cost-effective way. Therefore,
what is needed is an apparatus and method for the effective
application of one or more materials such as additives to a
substrate by adhering and/or embedding the one or more materials on
and/or into the substrate material. Further, what is needed is such
an apparatus and method that provides additive application in a
cost-effective process. In addition, what is needed is an apparatus
and method to apply one or more sprayable materials to other types
of substrates as well as components of materials, particularly
nanoparticle additives but not limited thereto. Relatedly, the
present invention forms new products including such additive
materials.
SUMMARY OF THE INVENTION
[0005] It is an objective of the present invention to provide an
apparatus and method for the effective application of one or more
materials, such as additive materials, to a substrate such as a
fabric but not limited thereto. The applied materials may be
sprayable or otherwise transferable onto and into the substrate. It
is also an objective of the present invention to provide such an
apparatus and method that improves additive material application in
a cost-effective process.
[0006] These and other objectives are achieved with the present
invention, which is a material application device that may be a
stand-alone apparatus or that may form part of a more comprehensive
system, such as a fabric or fill production and treatment
apparatus. The material may be an additive, for example. The
application device includes a plurality of applicators arranged in
an array to provide a substantially uniform dispersion of the
atomized material, which may be a plurality of materials, such as
additives, onto a substrate so that at least a portion of the one
or more applied materials is retained within, or at least attached
to the surface of, the substrate. The focus of the description of
the present invention is directed to application of one or more
additives to fabrics and/or the components of fabrics; however, it
is not limited to that substrate alone. For example, but not
limited thereto, it is to be understood that the present invention
may be used to adhere and/or embed one or more additive materials
on and/or into fibers, yarns, down, fills, leather, and other
synthetic or natural substrates, that may include porous and
nonporous substrates. The substrate items may be stationary, or
they may be moving during the application process. The number and
arrangement of applicators in the array is selectable. The
applicators include nozzles that are selectably positioned with
respect to the substrate item or items to ensure substantial
uniformity of additive material dispersion and substantially
complete contact of applied material with the substrate. The device
includes one or more manifolds to which the applicators are
connected. The manifold supplies an additive material delivery
vehicle, which may be air, to the applicators. The additive
material or additive materials are also supplied to the applicators
with the delivery vehicle and transmitted through applicator
nozzles. The nozzles are configured to generate a dispersive
pattern of the mixture, such as in a conical arrangement, for
example, but not limited thereto. The delivery vehicle is
configured to disperse the one or more additive materials onto the
substrate with minimal liquid inclusion. As a result, the substrate
is treated with the additive material(s) with minimal liquid and
decreased drying requirements.
[0007] The device optionally includes a heater used to warm the
additive material enough to manipulate the physical properties
thereof. The material substrate, particularly synthetic fibers but
not limited thereto, may have thermoplastic characteristics that
allow the physical properties of such substrates to be modified
when manipulated with and exposed to heat. The process of warming a
substrate material to enhance additive adhesion is not limited to
use of the additive application device described herein. That is,
the mechanism of warming may be employed separate from the additive
apparatus as described, with the one or more additives directed to
the substrate material in an alternative way provided that the one
or more additive materials or at least a portion thereof are
embedded into or adhered onto the substrate. The warming of the
substrate may also be accomplished by other means not limited to a
heater placed adjacent to the substrate. For example, the substrate
may be warmed due to a process of making it, such as when synthetic
materials are thermally set but not limited thereto.
[0008] The material application device of the present invention may
be used to improve characteristics of substrate items and any
resultant product made using such substrate items. Prior systems
for adding materials to substrates often involved immersing the
substrate material in water or another solvent that included such
additives or simply coating the surface of the substrate material
with a treatment. On the other hand, the present invention enables
introduction of the materials, such as additives, in a form that is
close to dry relative to the immersion method while enabling
integration of at least a portion of the additive into or onto the
substrate. There is less energy required to complete drying, less
water (with its corresponding waste removal obligations) used and
the substrate is of a better quality with less residual dampness
therein. The method of the present invention involves generating an
additive material formulation, an additive material delivery
vehicle and directing a dispersion of that mixture to the substrate
material to be treated. The dispersed additive material formulation
uses an efficient amount of moisture to allow the additive material
to adhere to the substrate material or embed into the surface of
the substrate material. The additive formulation is directed to the
substrate material in a pattern and at a rate selected to provide
substantially uniform dispersion on the substrate with enough
speed, power, and pressure to ensure integration and while
maximizing the efficiency of the additive material usage. The use
of a relatively dry delivery vehicle reduces the time and energy
required to dry the substrate to completion after additive material
application.
[0009] As noted, the apparatus of the present invention may also be
used to apply one or more additives to a surface, such as a wall, a
carpet, a chair, a computer keyboard, and any other substrate where
it is of interest to treat at least the surface thereof with
nanoparticle additives. For such types of additives, the apparatus
used to deliver a formulation of additives and the material
delivery vehicle includes components that come in contact with the
additive that are made of, or treated with, low surface tension
substrate materials. The nanoparticles tend to adhere to interior
surfaces of components such as pump walls, tubes, valves, and
applicator nozzles when those interior surfaces are relatively
rough. The surfaces of the components of the apparatus of the
present invention that are designed to contact nanoparticle
additives are either coated with low-surface-tension materials or
are made of low-surface-tension materials. That includes
nonmetallic materials such as Nylon and Teflon, for example.
[0010] These and other advantages of the invention will become more
apparent upon review of the following detailed description, the
accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front perspective view of an example of a fabric
treatment apparatus including the material application device of
the present invention.
[0012] FIG. 2 is a rear perspective view of the apparatus of FIG.
1.
[0013] FIG. 3 is a front view of the apparatus of FIG. 1.
[0014] FIG. 4 is a side view of the apparatus of FIG. 1.
[0015] FIG. 5 is a side view of the material application device of
the present invention showing a section of a fabric substrate
arranged for treatment therein and including an optional fabric
heating component.
[0016] FIG. 6 is a perspective view of an embodiment of the
applicator array of the material application device.
[0017] FIG. 7 is a side view of the applicator manifold of the
material application device without applicator nozzles.
[0018] FIG. 8 is an end view of the applicator manifold and its two
end caps.
[0019] FIG. 9 is an example representation of the material delivery
controller of the material application device for transfer of
additive material to the applicator manifold.
[0020] FIG. 10 is a photograph of fibers of a fabric or yarn
substrate subjected to the application of an additive material
using the apparatus and method of the present invention wherein the
additives are embedded into or adhered onto the fabric or yarn.
[0021] FIG. 11 is a simplified representation of a mobile version
of the material application device of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0022] While the following description is directed for the
embodiment of the invention wherein one or more materials such as
additives are delivered to a substrate such as a fabric, it is to
be understood that the invention is not limited thereto. Instead,
the present invention provides an apparatus and method to
facilitate the introduction and adhesion of one or more materials
to a substrate with minimal after drying and processing required.
In addition, the present invention improves the opportunity to
enhance the characteristics of treated substrate through a more
effective integration of the material or materials into the
interstices of the substrate. Additionally, the present invention
provides a method for substrate material enhancement using the
apparatus described. The steps of the method as described may be
done in different orders without deviating from the scope of the
invention. The method of the present invention involving the
application of one or more additive materials to a substrate of
interest results in the fabrication of products having improved
characteristics due to the integration of one or more materials
into and on the substrate so that it is effectively joined
thereto.
[0023] FIGS. 1-4 illustrate a fabric treatment apparatus 10
including a material application device 12 forming part thereof. It
is to be understood that while the material application device 12
is shown as part of the fabric treatment apparatus 10 that includes
other components, the device 12 may be a stand-alone device as
well. In addition, the fabric treatment apparatus 10 may form part
of a larger fabric manufacturing system. For the example of the
present invention represented in the drawings, the apparatus 10
includes a fabric introduction section 14, a fabric roller section
16, an optional fabric treatment section 18, a fabric recovery
section 20, and the material application device 12. While this
description describes the treatment of a fabric substrate, it is to
be understood that it may also be used to treat other substrates in
a similar way.
[0024] The fabric introduction section 14 includes a plurality of
preparation rollers 22 and an optional pretreater 24 that can be
used to prepare a fabric for subsequent processing in the apparatus
10. The fabric roller section 16 is used to configure the fabric in
a desired alignment and for controlling the rate of fabric passage
through the apparatus 10. The fabric recovery section 20 is used to
spool treated fabric for subsequent delivery and later processing
into finished product. It is to be understood that the fabric
introduction section 14, the fabric roller section 16, the optional
fabric treatment section 18, and the fabric recovery section 20 are
all elements of a fabric processing system known to those of skill
in the art. The apparatus 10 shown in FIGS. 1-4 represents examples
of such known components and that representation is not intended to
be limiting. The material application device 12 renders the
apparatus 10 novel.
[0025] With reference to FIGS. 1-2 and 4-5, the material
application device 12 includes one or more additive material
manifolds 26 and a plurality of additive material applicators 28.
Each manifold 26 is constructed to supply a dispersion vehicle to
the applicators 28. Each applicator 28 is constructed to deliver
one or more materials, such as additives, to fabric 30 wherein the
one or more additive materials are combined with the dispersion
vehicle in a way that disperses the one or more additive materials
in a selectable spray pattern on and into the fabric 30. The
dispersion vehicle may be air or another gaseous material. The one
or more additive materials may be in solid, liquid, or gaseous form
prior to the combination with the dispersion vehicle. The material
application device 12 shown in the figures includes structural
support members 32 to position the one or more manifolds 26 in a
desired proximity to the fabric 30 as the fabric 30 is conveyed
from the fabric introduction section 14 to the fabric recovery
section 20. The mechanism of conveyance of the fabric is of any
form known to those skilled in the art and can include, but not be
limited to, a belt-and-pulley system powered by a motor.
[0026] As illustrated in FIG. 5, the material application device 12
may optionally include a substrate heater such as fabric heater 100
that may be positioned on either or both sides of the fabric 30.
The fabric heater 100 may optionally be used to warm the fabric 30
to a selectable temperature prior to introducing the one or more
additives to the fabric via the applicators 28. The fabric heater
100 may be any sort of heating apparatus suitable for applying heat
at a selectable temperature over a desired area. For example, the
fabric heater 100 may be a radiant heater or a convection heater
with a directed blowing mechanism but not limited thereto.
[0027] It has been observed that at least some additive materials
bind better to the fibers of the fabric 30 when those fibers have
been warmed to a point of increased viscosity, more particularly,
at or greater than glass transition temperature. When the one or
more additives contact the fabric 30 with viscous fibers, the
additive material is retained in and on the fibers, particularly as
those fibers cool while passing from the additive application
device 12 through to the fabric recovery section 20. That is, the
additive material applied using the applicators 28 adhere well to
the fabric fibers. The resultant improved fabric has a better
chance of retaining the desired characteristics imparted by the one
or more additives for a longer period than when the one or more
additives are applied to fabric that is cooler. This additive
adhesion improvement resulting from additive material application
when the fabric fibers are in a viscous state is not limited to
additive introduction with a device such as the material
application device 12 described herein.
[0028] With respect to FIG. 6 and the other drawings, the material
application device 12 may be configured so that there is a
plurality of manifolds 26 wherein the manifolds are in opposing
positions with the applicators 28 facing one another so that when
the fabric 30 passes into space 34 between the opposing manifolds
26, the one or more additive materials are sprayed onto both sides
of the fabric 30. It is to be understood that the one or more
materials may be applied to just one side of the fabric 30 if that
is desired. As shown in FIGS. 6-8, the applicators 28 are removably
coupled to ports 36 of the manifold 26. Each of the applicators 28
includes a dispersion vehicle inlet 38, a material additive inlet
40, a mixing chamber 42 and a nozzle 44. The inlets 38 and 40 may
be of any sort suitable to direct fluids into the mixing chamber
42. The mixing chamber 42 is configured to receive the additive
material dispersion vehicle from the manifold 26 and enable
turbulent fluid flow therein with the one or more additive
materials introduced through the inlet 40 so that the one or more
additive materials are well interspersed with the additive
dispersion vehicle. While the application device 12 is described
herein as using a pump or other form of mechanical mechanism for
moving the mixture through the nozzles 44, it is to be understood
that alternative delivery mechanisms may be employed including, but
not limited to, ultrasonic atomization, electrostatic atomization,
and air atomization.
[0029] The nozzles 44 are selected to maintain integrity and
minimize clogging based on the materials selected to pass
therethrough. In an embodiment of the invention, the nozzles 44
include conical inserts 45 selected and arranged to generate a
conical pattern on the fabric 30 passing by. It is to be understood
that the nozzles 44 may be configured to generate any desired spray
pattern not limited to a conical pattern. The nozzles 44 are
arranged on the manifold 26 and the force of the applied pattern is
selected to ensure substantially that the dispersions of additive
material from adjacent nozzles 44 overlap. That configuration, the
dispersion force selected, and the additive materials chosen are
designed in combination to enhance the likelihood that the material
application to the fabric 30 is complete and uniform over the
entire surface of the fabric 30.
[0030] Each manifold 26 includes a first end cap 46 and a second
end cap 48. The first end cap 46 seals interior cavity 50 of the
manifold 26 so that any dispersion vehicle introduced into the
cavity 50 can only exit through the ports that are coupled to the
dispersion vehicle inlets 38 of the applicators 28. The second end
cap 48 includes a supply port 52 that may be coupled to a
dispersion vehicle supply. For example, when air is used as the
dispersion vehicle, the dispersion vehicle supply may be an air
compressor having a supply tube removably coupled to the supply
port 52 of the manifold 26. The dispersion vehicle is maintained at
a force sufficient to cause turbulent mixing with the one or more
additive materials in the mixing chamber 42 of the applicator 28
and sufficient to force the material-dispersion vehicle mixture to
pass through the nozzle 44 with enough force to reach the fabric 30
passing by or retained in position adjacent to the manifolds
26.
[0031] Referring to FIGS. 6 and 9, the inlet 40 of each applicator
28 is removably coupled to an additive material supply tube 54. The
supply tubes 54 are coupled to one or more material sources
represented by material source 56. The amount, type, and rate of
the one or more materials contained in the material source 56 is
determined by programming of delivery controller 58. The delivery
controller 58 controls flow rate and flow volume through the supply
tubes 54 by managing operation of pump apparatus 60, which may be
formed of a plurality of pumps, one for each of the supply tubes
54. It is to be noted that the number and size of the supply tubes
54 is selectable and that the number of supply tubes 54 in
operation for any material delivery event may also be selectable
through the programming of the controller 58. In addition, the
controller 58 may be programmed to deliver the one or more
materials on a continuous, periodic, or sporadic basis. That
control of material delivery rate and timing may be accomplished
throughout the entire array of applicators 28 and it may be
accomplished on a per applicator basis.
[0032] The material application device 12 of the present invention
may be used to improve characteristics of a substrate such as a
fabric, and any resultant product made using such substrate.
Whereas prior systems for adding materials to fabrics often
involved submerging the fabric in water or another solvent that
included such materials, the present invention enables introduction
of the material or materials in a form that is close to dry
relative to the immersion method. There is less energy required to
complete drying, less solvent (with its corresponding waste removal
obligations) used and the fabric is of a better quality with less
residual dampness therein. The method of the present invention
involves generating a mixture of additive material and additive
material delivery vehicle and directing a dispersion of that
mixture to fabric to be treated. The dispersed mixture is
sufficiently damp to cause the material to adhere to the fabric
while the delivery vehicle is selected to be relatively dry, such
as a gas like air, for example. The mixture is directed onto the
fabric in a pattern and at a rate selected to provide substantially
uniform dispersion on the fabric and embed into or adhere onto the
fabric while maximizing the efficiency of additive material usage.
The use of a relatively dry delivery vehicle reduces the time and
energy required to dry the fabric to completion after additive
material application. It is to be understood that the material
application device 12, or at least those components used to combine
the one or more additive materials with the delivery vehicle and
the applicator 28 may be employed to treat a surface with desired
materials. For example, the material application device 12 so
configured can be used to apply one or more additive materials to a
wall, a floor, a chair, a keyboard, and any other surface of
interest.
[0033] The type of additive material that may be used and the
number of additive materials used in a single dispersion process is
selectable. The additive material is preferably in a fluid form,
such as a gas, a liquid, solid particles, or any combination
thereof but not limited thereto. Examples of materials that may be
deployed on and into a substrate such as a fabric using the present
invention include, but are not limited to, anti-microbials, dyes,
moisture suppressors, insulative materials and fluid transport
regulators. Nanoparticles of materials may be applied to fabric
with the present invention. Examples of suitable nanoparticles
include, but are not limited to, Diamond, Gold, Silver, Jade,
Copper, Zinc, and combinations thereof. Other types of particles
may also be added or substituted. In addition, while nanoparticles
are suitable additive materials in the present invention, additive
materials sized in a manner so that they may not qualify as
nanoparticles as conventionally understood are also contemplated as
suitable additives in the present invention. FIG. 10 shows a fabric
having nanoparticles bonded to fibers thereof. Such nanoparticles
may also be used to treat other types of surfaces, such as walls,
floors, chairs, keyboards, or any other substrate of interest using
the mixing and delivery components of the material application
device 12.
[0034] The material application device 12 is shown in the drawings
as part of the more comprehensive and stationary fabric treatment
apparatus 10. It is to be understood that alternative
configurations exist for the material application device 12. For
example, and not limited thereto, the material application device
12 may be operated as a mobile device that is not specifically
coupled to a stationary structure or to a broader treatment
apparatus. FIG. 11 illustrates an example mobile apparatus that is
a mobile container within which the components of the material
application device 12 described herein may be contained. In
particular, the mobile device with the material application device
12 includes the one or more additive material manifolds and the
plurality of additive material applicators. The mobile device also
includes the supply tubes that are coupled to or that may be
coupled to one or more material sources that are retained in the
mobile device or that are separate from the mobile device. The
mobile device also includes the programmable material delivery
controller. It may include one or more pumps for transferring the
additive material or materials to the one or more manifolds. The
mobile device may also or alternatively include couplings to
connect to power and/or fluid transfer devices such as pumps. The
mobile device may be wheeled as shown in FIG. 11 for ease of
transfer such as when a substrate having a large area is to be
treated with the applied material.
[0035] When the one or more additive materials includes one or more
nanoparticles and/or other solid materials, the components of the
material application device 12 that contact those types of
materials are preferably treated with, or made of, materials that
minimize additive material buildup thereon. For example, the supply
tubes 54, the inlet 40, the mixing chamber 42, and the nozzles 44
are fabricated of a low-surface-tension material such as Nylon or
Teflon, for example. Alternatively, at least the additive material
contact surfaces of those components are treated with
low-surface-tension material.
[0036] The optional step of warming the substrate material to the
point that its components are in a state of viscosity increases the
adhesion of the additive material or materials on and into the
fabric, yarn, or a surface to be treated. The apparatus and method
of the present invention improve the uniformity and certainty of
additive material inclusion in and on a fabric, yarn or surface
while reducing drying time and overall expense of such an
effort.
[0037] While the step of warming has been described herein with
respect to modification of a material's physical properties
specifically, it is to be understood that the invention is not
limited thereto. The invention includes the process of applying the
additive material described to any substrate wherein either or both
the substrate and the additive material are warmed to a temperature
suitable to enhance the adhesion of the additive material to the
substrate. The substrate may be a solid or a fluid material. The
substrate may also be a component of a product. For example, the
additive material is shown in FIG. 10 adhere to fiber of a fabric
wherein the additive has been applied to the fabric. However, the
additive may be applied to a component of the fabric before it is
manufactured into a fabric. That component may be for example, a
yarn or yarns used to make the fabric. That component may be fibers
of the yarn or yarns used to make the fabric.
[0038] In a situation where individual fibers are treated with an
additive material, the material application device 12 or another
type of device can be used to direct fluid material onto fibers.
The fluid material may be warmed to facilitate adhesion of the
additive material to the fibers. The fibers may be warmed to
facilitate that adhesion. Both the fluid additive material(s) and
the fibers may be warmed to enhance the adhesion. The fibers may be
warmed by applying heat to them prior to or while they are twisted
into a yarn. For man-made fibers that are fabricated from a
polymeric fluid that passes through a spinneret and cooled to form
fibers. The additive material may be applied to the fibers either
before or after the fibers exit the spinneret while in a semi-solid
state prior to twisting into a yarn through various methods of
introduction into the screw extrusion or application after yarn
stabilization.
[0039] Fibers to be treated with the additive material may be of
any shape, including those of uniform cross section, those of
non-uniform cross section and those that are at least partially
voided, such as fibers referred to as hollow fibers. The fibers of
non-uniform cross-section, such as those with a plurality of lobes
including, but not limited to X-shaped, Y-shaped and W-shaped
fibers, for example are suited for additive adhesion, whether
warmed or not warmed, as they have perimeters that are greater than
fibers of uniform cross-section, such as round fibers. Moreover,
fibers with non-uniform cross section effectively are formed with
valleys, pockets and other entrapment configurations that are more
likely to retain desired additive material or materials joined on
and/or into the fiber structure than fibers having smooth
perimeters. Nevertheless, the additive material may be applied to
fibers of any shape. Application of one or more desired additive
materials at the fiber level enhances the effectiveness of the one
or more additive materials when the fibers form part of a product
because the additive material is integrated throughout the product
rather than at the surface of the perimeter of the product.
[0040] Further, while the material application device 12 or the
mobile example described herein may be used to apply one or more
additive materials to selectable fibers, the one or more additive
materials may be applied to fibers by using other types of
application devices, as well as by contacting them with the
additive material such as by placing them on, or immersing them
into, a bath of fluid containing the one or more additive
materials, whether or not warmed. The one or more additive
materials may also be incorporated into the polymeric fluid prior
to extruding the fibers through the spinneret.
[0041] The application of one or more additive materials having
desirable characteristics to individual fibers results in the
formation of new fiber products having such characteristics.
Further, products such as yarns and fabrics made with such fibers
are also new products having such characteristics. More generally,
the present invention produces enhanced products of all types
because of the effective integration of the one or more additive
materials on and into those products, wherein at least a portion of
those one or more additive materials are nanoparticles.
[0042] The present invention of an apparatus and method for
applying one or more additive materials to a substrate such as a
fabric has been described with respect to specific components and
method steps. Nevertheless, it is to be understood that various
modifications may be made without departing from the spirit and
scope of the invention. All equivalents are deemed to fall within
the scope of this description of the invention as identified by the
following claims.
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