Valve-Needle Mounting for Dyestuff Applicator

Our present invention relates to a dyestuff applicator serving for the patterning of a substrate by the direct-spray technique, i.e. without the use of a printing screen.

In commonly owned U.S. patent application Ser. No. 709,550 filed July 28, 1976 by one of us, Hans Kudlich, now U.S. Pat. No. 4,141,23 , there has been disclosed such an applicator comprising an array of spray nozzles with discharge orifices closely spaced from a textile web to be patterned. Each nozzle has a housing with a discharge orifice which can be selectively blocked and unblocked by an electromagnetically actuated valve needle in line with the orifice axis. The selective energization of the electromagnetic needle actuators is carried out, under the control of a programmer, between intermittent advances of the textile web in a direction transverse to the nozzle array.

As further disclosed in that prior patent, each valve needle can be supported by a pair of parallel membranes which are interconnected at their centers by a spacing sleeve surrounding the needle, the rims of the membranes being firmly clamped in position at the inner housing wall. This mode of mounting insures a precise axial orientation of the needle while leaving it free to oscillate in response to the applied electromagnetic field, e.g. at frequencies on the order of 2000 to 3000 Hz.

An important object of our present invention is to provide an improved membrane for the mounting of such a valve needle, designed to facilitate its displacement at the frequencies referred to with low consumption of electrical or possibly other forms of energy.

Another object is to provide means in such a mounting for reducing the wear of the needle tip coacting with the discharge orifice.

In accordance with our present invention, the needle mounting includes a membrane (or, preferably, two substantially identical membranes interconnected in the aforedescribed manner) of resilient foil material, such as spring steel, comprising an outer ring centered on the orifice axis and a tongue integral with that ring projecting radially inward from a sector thereof toward a diametrically opposite sector, the tongue being split into two diverging branches which are interconnected near that opposite sector by an integral web with a reentrant formation extending radially in a gap between the branches and terminating in an inner ring also centered on the orifice axis. The latter ring, which may be connected by a spacing sleeve with a corresponding ring of a substantially identical second membrane, is in firm engagement with the valve needle.

The above and other features of our invention will now be described in detail with reference to the accompanying drawing in which:

FIG. 1 is an axial sectional view of a spray nozzle embodying our invention; and

FIG. 2 is a cross-sectional view of the spray nozzle taken on the line II--II of FIG. 1.

The nozzle shown in FIG. 1 comprises a cylindrical housing 1 which is centered on an axis 0 and is closed at its bottom by a wall member 2 held in position by a clamping nut 3 which presses that member against a sealing ring 4. The lower part of housing 1 defines a pressure chamber 5 with an entrance port 27 for the admission of liquid dyestuff. Chamber 5 is closed at its top by a diaphragm 18 of rubber or synthetic resin overlain by a stationary collar 17 against which that membrane comes to lie, under pressure of the dyestuff, as indicated in phantom lines.

Bottom wall 2 has an orifice 7, centered on axis 0, which converges generally frustoconically (or possibly frustopyramidally) toward a narrow exit end on a land 8 at the lower wall surface. This land 8 is formed with an annular ridge 8' bounding that exit end to keep the issuing dyestuff away from the surrounding area. Any dyestuff leakage adhering to that surrounding area may be picked up by an annular pad 9 of absorbent material. The wider entrance end of orifice 7 is lined by a bushing 6 of thermoplastic material, preferably polytetrafluoroethylene (Teflon).

Bushing 6 is resiliently deformable by the tip 10 of a valve needle 11 which freely traverses the collar 17 and is centered on axis 0, a shoulder 11' of that needle being fixedly secured to diaphragm 18. The extremity of the needle stem opposite tip 10 traverses an electromagnetic actuator 13 which may be of the type described in the above-identified U.S. Pat. No. 4,141,231 and serves to oscillate the needle as indicated by a double-headed arrow 12.

In accordance with an important feature of our invention, the part of the needle stem projecting above dyestuff chamber 5 is supported by a pair of parallel membranes 14, 15 of spring steel interconnected by a spacing sleeve 16. Each of these membranes has a configuration as particularly illustrated for membrane 14 in FIG. 2. Thus, the unitary membrane body is stamped from a thin foil forming an outer ring 19 which is clamped to the housing wall and has an inner periphery 20 merging into two slender branches 21', 21" of a radially inwardly projecting tongue 21 separated by a narrow arcuate clearance 28 from the diametrically opposite ring sector. Branches 21' and 21" diverge at an acute angle toward clearance 28 so as to form a generally triangular gap 22 between them. Each branch decreases in width up to its point of intersection with a transverse plane 23 passing through axis 0; beyond that point it broadens again and merges integrally with a web 25 interconnecting the free ends of these branches, the web having a re-entrant formation in the shape of a radially extending strip 25' which terminates in an inner ring 26 concentric with outer ring 19. It will be noted that the outer edges 24' and 24" of branches 21' and 21" are substantially straight but that their inner edges are bent at plane 23 so that the width of gap 22 remains substantially constant between that plane and the free end of tongue 21 adjacent clearance 28.

As also shown in FIG. 2, the inner ring 26 firmly engages the stem of needle 11. Sleeve 16 (not shown in FIG. 2) is secured to the respective inner rings of membranes 14 and 15 which are of substantially the same outer diameter as the sleeve. Their inner diameters may also be alike, with elimination of the cylindrical space shown to separate the sleeve 16 from the needle.

With the configuration described and illustrated, the needle-supporting rings 26 have a high degree of flexibility making the needle support very sensitive to an electromagnetic field applied by actuator 13. Thus, an upward attraction of the needle 11 from its illustrated position deflects the membrane portions 19, 21 and 25 into a generally Z-shaped structure (as exaggeratedly indicated in phantom lines in FIG. 1), with web 25 and ring 26 remaining parallel to ring 19. In the absence of an applied electromagnetic field, the membranes 14, 15 are inherently biased to hold the tip 10 against bushing 6 to establish the normal blocking position illustrated in FIG. 1. The presence of this bushing results in a reduced wear of the needle tip despite high oscillating frequencies.

The collar 17, here shown as having a frustoconical shape, could also be generally mushroom-shaped so as to have a convex undersurface backstopping the diaphragm 18.