1. An industrial-scale atomizing apparatus for applying a liquid coating onto materials which require porosity, acoustical transparency, or very light coating weight, the apparatus comprising a discharge nozzle of a specified length, the discharge nozzle which extends longitudinally is capable of discharging a uniform stream of atomized liquid droplets at a uniform velocity at least along the entire specified length of the discharge nozzle.
2. The industrial-scale atomizing apparatus of claim 1, comprising first and second opposed air streams positioned proximate the discharge nozzle, each of the first and second opposing air streams extending longitudinally and in parallel relation to the discharge nozzle.
3. The industrial-scale atomizing apparatus of claim 1, wherein the liquid coating comprises from about 40% to about 70% solids by weight.
4. The industrial-scale atomizing apparatus of claim 3, wherein the liquid coating comprises from about 50% to about 60% solids by weight.
5. The industrial-scale atomizing apparatus of claim 1, whereby a minimum deviation is achieved in the acoustic capability of the acoustical material to which the liquid coating is applied.
6. The industrial-scale atomizing apparatus of claim 1, whereby the apparatus provides a coating which has minimal impact on the light reflectance, color, and gloss of the material to which the coating is applied.
7. A method of spray coating a moving object comprising the steps of:
(a) providing an industrial-scale coating apparatus having a longitudinally extending discharge nozzle having a specified length;
(b) positioning the industrial-scale coating apparatus above a conveyor, the conveyor having a direction of travel such that the longitudinally extending discharge nozzle extends in a direction transverse the direction of travel of a conveyor; and
(c) discharging a linear stream of atomized droplets onto the surface of an object moving on the conveyor, the linear stream of atomized droplets being discharged from the nozzle at a uniform velocity along the entire specified length of the nozzle.
8. The method of claim 7, wherein in step (c) the linear stream of atomized droplets extends uniformly over a cross-machine width of the moving object.
9. The method of claim 8, wherein in step (c) first and second opposing air streams are positioned proximate the discharge nozzle, the air streams discharging air which atomizes the liquid coating.
10. The method of claim 9, wherein the first and second air streams extend in the longitudinal direction of the discharge nozzle.
11. The method of claim 10, wherein the first air stream is located upstream of the discharge nozzle.
12. The method of claim 11, wherein the second air stream is located downstream of the discharge nozzle.
13. The method of claim 7, wherein the moving object is a fibrous mat.
14. The method of claim 13, wherein the fibrous mat has a top surface having perforations therein.
15. The method of claim 13, wherein the fibrous mat is an acoustical ceiling panel.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. An air handling unit, comprising:
an enclosure comprising:
an air inlet;
an air outlet; and
a fluid duct that extends from the air inlet to the air outlet;
a heater assembly comprising a base plate that (1) comprises an inner surface and an outer surface and (2) is configured to form at least a portion of the fluid duct; and
a heat exchanger assembly configured to selectively receive the heater assembly.
2. The air handling unit of claim 1, wherein the heater assembly is carried by the heat exchanger assembly.
3. The air handling unit of claim 1, wherein the heater assembly is disposed between a left slab and a right slab of the heat exchanger assembly.
4. The air handling unit of claim 1, wherein the heater assembly is disposed downstream from the heat exchanger assembly with respect to airflow through the fluid duct.
5. The air handling unit of claim 1, wherein the heater assembly is disposed adjacent to the air outlet.
6. The air handling unit of claim 1, wherein the inner surface of the base plate is configured to form a fluid tight seal with a complimentary mounting surface of a heat exchanger assembly.
7. The air handling unit of claim 1, wherein the base plate is configured to carry a plurality of electronic components disposed on the outer surface of the base plate.
8. The air handling unit of claim 1, wherein the heater assembly comprises at least one heater element that is carried by the base plate and that is disposed within the fluid duct.
9. The air handling unit of claim 1, wherein the heater assembly comprises a heater rack that is attached to the base plate.
10. The air handling unit of claim 9, wherein the heater rack is configured to carry at least one heater element.
11. The air handling unit of claim 10, wherein the heater rack comprises at least one alignment pin.
12. The air handling unit of claim 11, wherein the heat exchanger assembly comprises at least one alignment pin hole that is configured to selectively receive the alignment pin.
13. A method of forming a fluid duct in an air handling unit, comprising:
providing an enclosure comprising an air inlet, an air outlet, and a fluid duct that extends from the air inlet to the air outlet;
providing a heater assembly comprising a base plate that (1) comprises an inner surface and an outer surface and (2) is configured to form at least a portion of a fluid duct in an air handling unit; and
providing a heat exchanger assembly configured to selectively receive the heater assembly.
14. The method of claim 13, further comprising:
disposing the heater assembly between a left slab and a right slab of the heat exchanger assembly.
15. The method of claim 13, further comprising:
disposing the heater assembly downstream from the heat exchanger assembly with respect to an airflow through the fluid duct.
16. The method of claim 13, further comprising:
disposing the heater assembly adjacent to the air outlet.
17. The method of claim 13, wherein the inner surface of the base plate is configured to form a fluid tight seal with a complimentary mounting surface of a heat exchanger assembly.
18. The method of claim 13, wherein the base plate is configured to carry a plurality of electronic components disposed on the outer surface of the base plate.
19. The method of claim 13, wherein the heater assembly comprises at least one heater element that is carried by the base plate and that is disposed within the fluid duct.
20. The method of claim 13, wherein the heater assembly comprises a heater rack that is attached to the base plate and that is configured to carry at least one heater element.