Application of fluidized material to a substrate using displacement transfer

A method of applying a fluidized material to a web in a series of application cycles, said method comprising the steps of:

• (a) moving said web along a path in a direction of travel;
• (b) introducing said fluidized material between said application cycles into at least one cavity formed by at least two materials, one of said materials being deformable and the other of said materials being rigid, said deformable material having an outer surface and an inner surface, said deformable material bonded to said rigid material, said cavity having a cavity surface, said outer surface of said deformable material forming at least a portion of said cavity surface, said fluidized material in contact with said outer surface of said deformable material;
• (c) moving said at least one cavity filled with said fluidized material to a point immediately adjacent to said web between said application cycles;
• and
• (d) discharging said fluidized material in said at least one cavity during said application cycles by momentarily impinging and forcing said inner surface of said deformable material towards said web at said point, said outer surface of said deformable material facing said web at said point, thereby temporarily collapsing said cavity and temporarily displacing said outer surface of said deformable material to a position where said fluidized material on said outer surface of said deformable material contacts said web and adheres to said web.

An apparatus for applying a fluidized material to a substrate, comprising:

• means for moving said substrate along a path;
• applicator means, said applicator means having a cavity for holding said fluidized material adjacent to said substrate, said cavity formed by at least two materials, one of said materials being deformable and the other of said materials being rigid, said deformable material having an outer surface facing toward said substrate and an inner surface facing away from said substrate, said deformable material bonded to said rigid material, said cavity having a cavity surface, said outer surface of said deformable material forming at least a portion of said cavity surface, said fluidized material in contact with said outer surface of said deformable material;
• supply means for providing said applicator means with said fluidized material;
• and
• displacement means for momentarily impinging and forcing said inner surface of said deformable material towards said substrate, thereby temporarily collapsing said cavity and temporarily displacing said outer surface of said material to a position where said fluidized material on said outer surface of said deformable material contacts said substrate and adheres to said substrate.

An apparatus for applying a fluidized material to a web in a series of application cycles, said apparatus comprising:

• means for moving said web along a path in a direction of travel;
• applicator means, said applicator means having at least one cavity formed by at least two materials, one of said materials being deformable and the other of said materials being rigid, said deformable material having an outer surface and an inner surface, said deformable material bonded to said rigid material, said at least one cavity having a cavity surface, said outer surface of said deformable material forming at least a portion of said cavity surface, said fluidized material in contact with said outer surface of said deformable material;
• supply means for replenishing said at least one cavity in said applicator means with said fluidized material between said application cycles;
• movement means for moving said at least one cavity in said applicator means to a point immediately adjacent to said web;
• and
• displacement means for momentarily impinging and forcing said inner surface of said deformable material towards said web at said point during each of said application cycles, said outer surface of said deformable material facing said web at said point, thereby temporarily collapsing said cavity and temporarily displacing said outer surface of said deformable material to a position where said fluidized material on said outer surface of said deformable material contacts said web and adheres to said web.

A displacement transfer applicator for applying a fluidized material to a web moving in a direction of travel during a series of application cycles, said displacement transfer applicator comprising:

• an application drum located above said web, said application drum having a circumferential periphery, axis, inner diameter, outer diameter and a hollow interior, said application drum having at least one slot machined in said circumferential periphery, said at least one slot in communication with said hollow interior and extending parallel to said axis of said application drum, said application drum adapted for rotation;
• wherein:
• said at least one slot is filled with deformable material from said inner diameter to just inside said outside diameter, said deformable material having an inner surface facing toward said hollow interior and an outer surface facing away from said hollow interior, said at least one slot having a cavity located between said outer surface of said deformable material and said circumferential periphery of said application drum;
• said displacement transfer applicator further comprising:
• a compression drum mounted eccentrically within said hollow interior of said application drum, said compression drum having a circumferential periphery and axis, said compression drum having at least one compression tip extending outwards from said circumferential periphery and parallel to said axis of said compression drum, said compression drum adapted for rotation;
• fluidized material application means, said fluidized material application means located adjacent to said application drum, said fluidized material application means filling said cavity with said fluidized material between each of said application cycles;
• and
• driving means for rotating said application drum and said compression drum whereby said compression tip impinges said inner surface of said deformable material in said at least one slot in said application drum at a point where said slot is immediately adjacent to said web, said compression tip temporarily collapsing said cavity and temporarily displacing said outer surface of said deformable material to a position beyond said outer diameter of said application drum where said fluidized material on said outer surface of said deformable material contacts said web and adheres to said web.