Self-cleaning spray valve assembly

Patent metadata

Field	Value
Publication number	US-9566599-B2
Application number	US-201313800439-A
Country	US
Kind code	B2
Filing date	Mar 13, 2013
Priority date	Nov 9, 2012
Publication date	Feb 14, 2017
Grant date	Feb 14, 2017

Abstract

Systems and methods for producing consistent spray patterns and for diminishing clogging experienced when applying spray adhesive from a spray gun are provided. One system includes an automatic non-atomizing spray valve operably coupled to a first and second flow valve. The spray and flow valves are electronically controlled using logic running on a processing unit. The logic is programmed to carry out a spray cycle that involves dispensing a first liquid from the spray valve (first phase) and then dispensing a second liquid through the same spray valve (second phase). Because the first liquid (e.g., water-based adhesive) has the potential to clog a nozzle of the spray valve, a short burst of the second liquid (e.g., cleaning fluid) is introduced to prevent the nozzle from clogging. The spray valve is configured as a pulse width modulated spray gun to further reduce clogging and to generate an evenly distributed spray pattern.

First claim

What is claimed:

1. A method for dispersing a fluid from a spray valve assembly according to a spray cycle to produce a spaced application pattern on a substrate, the method comprising:
sending a first indication to an electrically controlled, first flow valve to allow a liquid adhesive to flow to a first inlet of a spray valve during a first phase of the spray cycle;
during the first phase of the spray cycle, directing the spray valve to disperse the liquid adhesive in a pulsing non-atomized stream for a predefined period of time to apply liquid adhesive to a substrate;
sending a second indication to the first flow valve to disallow the liquid adhesive to flow to the first inlet of the spray valve during a second phase of the spray cycle;
emitting a liquid cleaner from the spray valve onto the substrate during the second phase of the spray cycle; and
adjusting a spaced application pattern of adhesive applied to the substrate without interrupting a relative motion between the substrate and the spray valve assembly by changing the spray cycle,
wherein the spaced application pattern of adhesive applied to the substrate comprises a plurality of segments of adhesive aligned in a row.

2. The method of claim 1 , wherein changing the spray cycle comprises changing a proportion of the duration of the first phase of the spray cycle to the duration of the second phase of the spray cycle.

3. The method of claim 2 , wherein duration of the first phase of the spray cycle is three times longer than the duration of the second phase of the spray cycle.

4. The method of claim 2 , further comprising altering the spray cycle while the spray valve assembly is operating to produce a different adhesive application pattern on the substrate, without interrupting operation of the spray valve assembly.

5. The method of claim 1 , wherein changing the spray cycle comprises changing a frequency the first and second indications are sent to the first flow valve.

6. The method of claim 5 , further comprising altering the frequency the first and second indications are sent to the first flow valve to produce a different adhesive application pattern on the substrate while the spray valve assembly is operating, without interrupting operation of the spray valve assembly.

7. A method for dispersing a fluid from a spray valve assembly according to a spray cycle, the method comprising:
sending a first indication to an electrically controlled, first flow valve to allow a liquid adhesive to flow to a first inlet of a spray valve during a first phase of the spray cycle;
during the first phase of the spray cycle, directing the spray valve to disperse the liquid adhesive in a non-atomized stream for a first predefined period of time to apply adhesive to a substrate;
sending a second indication to the first flow valve to disallow the liquid adhesive to flow to the first inlet of the spray valve during a second phase of the spray cycle;
sending a third indication to an electrically controlled, second flow valve to allow a liquid cleaner to flow to a second inlet of the spray valve during a second phase of the spray cycle;
during the second phase of the spray cycle, directing the spray valve to disperse the liquid cleaner onto the substrate in a non-atomized stream for a second predefined period of time;
sending a fourth indication to the second flow valve to disallow the liquid cleaner to flow to the second inlet of the spray valve; and
adjusting a spaced application pattern of adhesive applied to the substrate without interrupting a relative motion between the substrate and the spray valve assembly by changing the spray cycle.

8. The method of claim 7 , wherein the first predefined period of time is greater than the second predefined period of time.

9. The method of claim 7 , wherein the second phase of the spray cycle begins immediately after the first phase of the spray cycle ends.

10. The method of claim 7 , wherein the liquid cleaner comprises at least one of the following:
water;
a water-based cleaner; and
a cleaner having a lubricating additive.

11. The method of claim 7 , wherein changing the spray cycle comprises changing one or more of:
a proportion of the duration of the first phase of the spray cycle to the duration of the second phase of the spray cycle, and
a frequency the first and second indications are sent to the first flow valve.

12. The method of claim 2 , wherein the duration of the second phase of the spray cycle is three times longer than the duration of the first phase of the spray cycle.

13. The method of claim 2 , wherein the duration of the first phase of the spray cycle and the second phase of the spray cycle are equal.

14. The method of claim 5 , wherein changing the frequency the first and second indications are sent to the first flow valve comprises changing the frequency from 1.5 hertz to 6 hertz.

15. A method of adjusting a spaced application pattern of fluid dispersed from a spray valve assembly onto a conveyed substrate according to a spray cycle without interrupting the conveyance of the substrate, the method comprising:
providing a spray valve assembly positioned proximate to a moving substrate for dispersing a spaced application pattern of liquid adhesive onto the moving substrate, the spray valve assembly having an electrically controlled, first flow valve, a first inlet of the spray valve, an electrically controlled, second flow valve, a second inlet of the spray valve, and a nozzle for dispersing fluid from the spray valve;
providing a controller for sending indications to the first flow valve to initiate and terminate a first phase of the spray cycle and for sending indications to the second flow valve to initiate and terminate a second phase of the spray cycle, the first phase beginning when the first flow valve allows a liquid adhesive to flow to the first inlet of the spray valve in response to a first indication sent from the controller, the first phase ending when the first flow valve disallows the liquid adhesive to flow to the first inlet of the spray valve in response to a second indication sent from the controller, the second phase beginning when the second flow valve allows a liquid cleaner to flow to the second inlet of the spray valve in response to a third indication sent from the controller, the second phase ending when the second flow valve disallows the liquid cleaner to flow to the second inlet of the spray valve in response to a fourth indication sent from the controller, wherein the second phase begins at the conclusion of the first phase and ends when the first phase of the spray cycle begins to repeat;
dispersing the spaced application pattern of liquid adhesive onto the conveyed substrate during the spray cycle, wherein the liquid adhesive is emitted onto the substrate during the first phase of the spray cycle and a liquid cleaner is emitted onto the substrate during the second phase of the spray cycle;
adjusting the spaced application pattern of adhesive applied to the conveyed substrate by changing one or more of:
(1) the proportionate duration of the first phase of the spray cycle to the second phase of the spray cycle, and
(2) the frequency the controller sends indications to the first flow valve.

16. The method of claim 15 , further comprising:
sending a first indication to an electrically controlled, second flow valve to allow the liquid cleaner to flow to a second inlet of the spray valve during the second phase of the spray cycle; and
sending a second indication to the second flow valve to disallow the liquid cleaner to flow to the second inlet of

Assignees

• L & P Property Management Co
• L&P Property Man Co

Inventors

• Mccune Richard L
• Smallwood Matthew
• Myers Terrance L

Classifications

• B05B12/02

  for controlling time, or sequence, of delivery · CPC title

• B05B12/06

  for effecting pulsating flow {(nozzles, spray heads or other outlets with means for generating a discharge of pulsating nature B05B1/08)} · CPC title

• B05B15/55

  using cleaning fluids · CPC title

• B05B7/0846 Primary

  with jets being only jets constituted by a liquid or a mixture containing a liquid · CPC title

• B05B15/04 Primary

  Operations & Transport · mapped topic