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.

What is claimed is: 
     
         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.