System and method for preparing, dispensing, and curing epoxy

A method for dispensing epoxy comprising the step of degassing an epoxy. The method further comprises the step of associating the epoxy with an epoxy injector comprising a dispensing end. The method further comprises the step of a computer receiving data representative of a selected container to receive the epoxy. The method further comprises the step of a computer determining a dispensing rate and a dispensing amount, based on the received data. The method further comprises the step of a computer causing the epoxy injector to dispense the determined dispensing amount of epoxy, via the dispensing end, at the determined dispensing rate. The method further comprises the step of a computer causing a dispensing arm, supporting the dispensing end, to retract the dispensing end while the epoxy injector is dispensing the epoxy. The method further comprises the step of curing the dispensed epoxy.

BACKGROUND

Epoxy is commonly used to assemble fiber optic cable with fiber optic connectors. Epoxy is injected into a connector using a needle or syringe. The syringe is then withdrawn and a fiber cable is inserted in the connecter. The fiber optic cable/connecter assembly is then cured. If not assembled properly, however, fiber optic cable connector assemblies can breakdown and fail. Specifically, inclusion of bubbles inside a fiber optic cable/connector assembly can result in structural failure during the life of the product.

Incorrectly withdrawing the syringe from a connecter after injecting the epoxy can lead to structural failure of the product as well. Specifically, when extracting the needle at an incorrect speed, epoxy residue may be left on the inside walls of the connector body as a result of excess epoxy migrating to the outside of the needle and then transferring to the connector wall. Once cured, this material can break free of the connector wall and potentially contaminate the installation environment, and eventually lead to connection failure.

SUMMARY OF THE INVENTION

A method for dispensing epoxy comprising the step of degassing an epoxy. The method further comprises the step of associating the epoxy with an epoxy injector comprising a dispensing end. The method further comprises the step of a computer receiving data representative of a selected container to receive the epoxy. The method further comprises the step of a computer determining a dispensing rate and a dispensing amount, based on the received data. The method further comprises the step of a computer causing the epoxy injector to dispense the determined dispensing amount of epoxy, via the dispensing end, at the determined dispensing rate. The method further comprises the step of a computer causing a dispensing arm, supporting the dispensing end, to retract the dispensing end while the epoxy injector is dispensing the epoxy. The method further comprises the step of curing the dispensed epoxy.

A system for dispensing epoxy comprises a dispensing end. The system further comprises a support arm configured to support the dispensing end. The system further comprises at least one processor, at least one computer-readable tangible storage device, and program instructions stored on the at least one storage device for execution by the at least one processor. The program instructions comprise first program instructions configured to receive data representative of a selected container to receive epoxy. The program instructions further comprise second program instructions configured to determine a dispensing rate and a dispensing amount, based on the received data. The third program instructions further comprise third program instructions configured to cause the determined dispensing amount of epoxy to be dispensed, through the dispensing end, at the determined dispensing rate. The program instructions further comprise fourth program instructions configured to cause the support arm to retract the dispensing end while epoxy is being dispensed through the dispensing end.

A system for dispensing epoxy comprises an epoxy injector comprising a dispensing needle and a supporting arm configured to support the dispensing needle. The system further comprises a first programmable logic controller. The first programmable logic controller is configured to receive data representative of a selected container to receive the epoxy. The first programmable logic controller is further configured to determine a dispensing rate and a dispensing amount, based on the received data. The first programmable logic controller is further configured to cause the epoxy injector to dispense the determined dispensing amount of epoxy, via the dispensing needle, at the determined dispensing rate. The system further comprises a second programmable logic controller in data communication with the first programmable logic controller, and configured to cause the supporting arm to retract the dispensing needle while the first programmable logic controller is causing the epoxy injector to dispense the epoxy.

DETAILED DESCRIPTION

FIG. 1illustrates an embodiment of an example system100for dispensing epoxy. System100enables an operator to inject a defined and controlled amount of epoxy into a designated area without leaving residue in or around the area. For example, system100may be used to inject epoxy into a cavity of a fiber optic cable connector. Eliminating residue may eliminate possibility for contamination and thereby may help prevent a fiber optic cable connector from failing structurally.

It should be understood that, although the systems and methods described herein make reference to dispensing epoxy into a cavity of a fiber optic cable connector, the systems and methods may similarly be applies to dispensing epoxy into other suitable containers or objects comprising a cavity for receiving epoxy.

System100includes an epoxy dispenser (or injector)102configured to dispense an epoxy solution. Epoxy dispenser102can be an Engineered Fluid Dispenser (EFD) manufactured by Nordson, for example. Epoxy dispenser can also be another suitable device configured to dispense a defined amount of fluid at a defined rate, with the ability to compensate for changes in viscosity over time. Epoxy dispenser may include a user interface112configured to receive data from an operator. User interface may include suitable buttons, switches, dials, and so on.

Epoxy dispenser102includes a dispensing tube114for delivering pressurized air to an epoxy tube116in order to force epoxy to be dispensed from the epoxy tube116. Epoxy tube116has a dispensing syringe104(also referred to as a needle or a dispensing end), for directing dispensed epoxy from epoxy tube116to a specific area or location.FIG. 2illustrates an embodiment of an example dispensing syringe104positioned above an example fiber optic connector202. Dispensing syringe104is supported by a supporting arm204having a holding clamp206to securely hold dispensing syringe104. In the illustrated example, dispensing syringe104is configured to direct epoxy into a cavity of fiber optic connector202while retracting at a controlled rate from the connector.

Referring back toFIG. 1, system100includes a programmable logic controller (PLC)108, in data communication with epoxy dispenser102, and configured to control the speed at which needle is retracted from the connector. The amount of epoxy being dispensed is controlled by the PLC in epoxy dispenser102. PLC108is further configured to cause supporting arm204to retract dispensing syringe106while epoxy is being dispensed through the dispensing syringe106.

PLC108may be any suitable computing device capable of executing program instructions. It should be understood that, although PLC108is illustrated as a standalone device, PLC108may also be embedded within epoxy dispenser102. In one example, system100may include two PLCs. In such an example, a first PLC may be configured to control epoxy dispenser102to dispense a defined amount of epoxy at a defined rate, compensating for viscosity change over time, while a second PLC may be configured to control the retraction of supporting arm204. The first PLC may be embedded within epoxy dispenser102while the second PLC may remain a standalone device in data communication with the first PLC embedded in epoxy dispenser102.

System100further includes an activation pedal110configured to activate PLC108. In other words, PLC108may be configured to initiate an epoxy dispensing sequence when an operator pushes on the activation pedal110. It should be understood that activation pedal110may be any suitable form of button, switch, and so on, electrical or mechanical, capable of initiating PLC108.

In one example, system100further includes an epoxy degasser (not shown) configured to degas and remove bubbles from the epoxy before the epoxy is dispensed by epoxy dispenser102. The epoxy degasser includes a centrifuge as well as a vacuum degasser. The combination may enable an operator to remove a greater number of bubbles from the epoxy, which increases the process capability (consistent shot size) of the epoxy dispenser and may prevent structural failure of the fiber optic connector.

In one example, system100further includes an epoxy curing device (not shown) configured to cure the epoxy after injection into a fiber optic cable connector. The epoxy curing device is configured to cure the epoxy at two different temperatures. In one example, system100includes two epoxy curing devices (not shown), each configured to cure the epoxy at a different temperature. Curing the epoxy at a lower temperature before raising the curing temperature may allow for bubbles remaining in the epoxy after degassing to freeze and remain entrapped at a smaller size. This may further prevent a fiber optic cable connector from failing structurally.

FIG. 3illustrates a block diagram of an example programmable logic controller (PLC)108ofFIG. 1. PLC108includes a data interface logic302configured to receive information about a selected container or connector. Data interface logic302may receive data from user interface112. Data interface logic302may also be configured to communicate with a data store in order to retrieve additional information corresponding to the received data about a selected connector.

PLC108further includes determination logic304configured to determine a dispensing rate and a dispensing amount based on received data about a connector selected to receive the epoxy. For example, data interface logic302may receive information indicating that a selected fiber optic connector or container has a particular shape or size cavity. Determination logic304may then perform a calculation or instruct interface logic302to access a data store to determine the dispensing rate or a dispensing amount based on the selected connector or based on the shape or size of the selected fiber optic connector cavity.

PLC108further includes dispensing logic306configured to control epoxy dispenser102to dispense the determined amount of epoxy at the determine rate. In one example, dispense logic306is configured to maintain a constant dispense rate. In one example, dispense logic306is configured to adjusting the dispense rate at certain time intervals to account for changes in the viscosity of the epoxy during the time intervals. Thus, dispense logic306is able to control epoxy dispenser to deliver epoxy to a target area at a constant rate over time, even though the viscosity of the epoxy may change over time. In one example, dispense logic306is configured to adjust and therefore maintain a constant dispense rate by controlling the air pressure of epoxy dispenser102.

PLC108further includes retraction logic308configured to cause supporting arm204retract dispensing syringe104while the epoxy dispenser102is dispensing the epoxy. In one example, retraction logic308is further configured to instruct determination logic304to determine a variable retraction rate based on a shape of a cavity of a selected connector, and to cause supporting arm204to retract the dispensing syringe at the determined variable retraction rate or speed.

FIG. 4is a flow chart illustrating an example method for preparing, dispensing, and curing epoxy. At step402, an operator degasses an epoxy solution. In one example, an operator first degasses the epoxy using a centrifuge for a first length of time and then degasses the epoxy using a vacuum for a second length of time.

At step404, the operator associates the epoxy solution with epoxy dispenser102. For example, the operator may place epoxy tube116into holding clamp206of supporting arm204.

At step406, PLC108receives data representative of a selected connector. At step408, PLC108determines a dispensing rate and a dispensing amount based on the received data. At step410, PLC108causes epoxy dispenser102to dispense the determined dispensing amount of epoxy, via dispensing syringe104, at the determined dispensing rate. At step412, PLC108causes supporting arm204to retract dispensing syringe104while epoxy dispenser102is dispensing the epoxy.

At step412, an operator cures the dispensed epoxy. In one example, an operator cures the epoxy in two stages by heating the dispensed epoxy at first temperature for a first predetermined amount of time, and heating the dispensed epoxy at a second temperature for a second predetermined amount of time.

FIG. 5is a block diagram of an example computer system500for implementing an example controller of a system for dispensing epoxy. Computer system500is intended to represent various forms of digital computers, including laptops, desktops, handheld computers, tablet computers, servers, and other similar types of computing devices such as a programmable logic controller. Computer system500includes a processor502, memory504, a storage device506, and a communication port522, connected by an interface508via a bus510.

Processor502processes instructions, via memory504, for execution within computer system500, including data interface logic302, determination logic304, dispensing logic306, and retracting logic308stored on storage device506. In an example embodiment, multiple processors along with multiple memories may be used. In an example embodiment, multiple computer systems500may be connected, with each device providing portions of the necessary operations.

Memory504may be volatile memory or non-volatile memory. Memory504may be a computer-readable medium, such as a magnetic disk or optical disk. Storage device506may be a computer-readable medium, such as floppy disk devices, a hard disk device, and optical disk device, a tape device, a flash memory, or other similar solid state memory device, or an array of devices, including devices in a storage area network of other configurations. A computer program product can be tangibly embodied in a computer readable medium such as memory504or storage device506. The computer program product may contain data interface logic302, determination logic304, dispensing logic306, and retracting logic308.

Computer system500can be coupled to one or more input and output devices such as a display514, a scanner518, a printer516, and a mouse520.

Some portions of the detailed descriptions are presented in terms of algorithms and symbolic representations of operations on data bits within a memory. These algorithmic descriptions and representations are the means used by those skilled in the art to convey the substance of their work to others. An algorithm is here, and generally, conceived to be a sequence of operations that produce a result. The operations may include physical manipulations of physical quantities. Usually, though not necessarily, the physical quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a logic and the like.