Melting system including flow guide members

A melting unit melts a solid material into a molten material. The melt unit includes a reservoir, a hopper, and a melt grid disposed between the hopper and the reservoir. The melt grid heats the solid material into the molten material such that the molten material flows from the hopper to the reservoir. The melt unit includes a plurality of guide members, where the molten material flows through plurality of flow channels defined by the melt grid and along the plurality of guide members as the molten material flows from the hopper to the reservoir.

TECHNICAL FIELD

The present disclosure relates to a melting system including guide members over which molten material flows to reduce aeration of the material.

BACKGROUND

Conventional melting systems include a melt grid positioned below a hopper, a reservoir positioned below the melt grid, a pump coupled to a reservoir, and an applicator coupled to the pump. The melt grid exposes solid material stored in the hopper to an elevated temperature, which converts the solid material into a molten liquid. The melt grid is typically submerged in the molten liquid within the reservoir. The molten liquid is gravity fed to the reservoir where the pump transports the molten liquid to the applicator. The applicator deposits the molten liquid onto a substrate, such as a nonwoven or other material.

In some examples, the melt grid is located above the molten liquid pool that resides within the reservoir. As molten material, such as liquid adhesive, then flows from the melt grid to the reservoir pool, it can develop individual streams that extend from passages through the melt grid down to the surface of the reservoir pool. As these individual adhesive streams contact the reservoir pool, they can swirl and overlap, thus entraining pockets of air within the adhesive. This entrained air tends to remain trapped within the adhesive due to the viscous nature of hot melt adhesive. To ensure accurate adhesive pressure control and consistent performance of the melting system, it is desirable to prevent or remove air from the adhesive. Any air that becomes entrained in the adhesive can negatively impact the quality of patterns produced by the applicator. Specifically, upon dispensing the adhesive, entrained air can rapidly expand and cause adhesive splitting, gaps in adhesive patterns, or inaccurate adhesive pattern placement. This presents many problems, as accurate adhesive patterns are critical in nonwoven product and other applications.

Therefore, there is a need for a melting system that reduces the amount of air that becomes trapped in the adhesive.

SUMMARY

An embodiment of the invention is a melt unit including a reservoir for receiving molten material, a hopper for receiving solid material, and a melt grid disposed between the hopper and the reservoir, where the melt grid heats the solid material into the molten material. The melt grid includes a plurality of elongated melting rails that extend along a longitudinal direction, where each of the plurality of melting rails is spaced apart along a lateral direction that is perpendicular to the longitudinal direction, and a plurality of flow channels, where each of the plurality of flow channels extends between a respective two melting rails of the plurality of elongated melting rails. The melt grid also includes a plurality of guide members, where each of the plurality of guide members is positioned below the plurality of flow channels and the plurality of elongated melting rails along a vertical direction that is perpendicular to the lateral and longitudinal directions, such that the molten material flows through the plurality of flow channels and along respective flow surfaces of the plurality of guide members as the molten material flows from the hopper to the reservoir.

Another embodiment of the invention is a melt unit including a reservoir for receiving molten material, the reservoir including a base and a top opposite the base along a vertical direction. The top of the reservoir defines an outer wall that defines an inner surface, the reservoir further including a plurality of support bars attached to the inner surface of the outer wall and a plurality of guide members extending upward from the plurality of support bars along the vertical direction, where the plurality of guide members are spaced apart along a lateral direction that is perpendicular to the vertical direction and the plurality of support bars are spaced apart along a longitudinal direction that is perpendicular to the vertical and lateral directions. The melt unit also includes a hopper for receiving solid material and a melt grid disposed between the hopper and the reservoir, where the melt grid heats the solid material into the molten material. The melt grid includes a plurality of elongated melting rails that extend along the longitudinal direction and are spaced apart along the lateral direction, and a plurality of flow channels, where each of the plurality of flow channels extends between two melting rails of the plurality of elongated melting rails. The plurality of guide members are positioned such that the molten material flows through the plurality of flow channels and along the plurality of guide members as the molten material flows to the reservoir.

Another embodiment of the invention is a melt unit including a reservoir for receiving molten material, the reservoir including an outer wall that has an inner surface and a guide member that extends from a first part of the inner surface to a second part of the inner surface that is opposite the first part. The melt unit also includes a hopper for receiving solid material, and a melt grid disposed between the hopper and the reservoir, where the melt grid heats the solid material into the molten material. The melt grid includes a plurality of elongated melting rails that extend along a longitudinal direction and are spaced apart along a lateral direction that is perpendicular to the longitudinal direction and a plurality of flow channels, where each of the plurality of flow channels extends between two melting rails of the plurality of elongated melting rails. The melt grid further includes an opening that is in fluid communication with the reservoir and each of the plurality of flow channels. The guide member is positioned below the opening along a transverse direction that is perpendicular to the longitudinal and lateral directions and aligned with the opening along the transverse direction. Molten material flows through the plurality of flow channels, through the opening, and along the guide member as the molten material flows to the reservoir.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Described herein is a melting system10that includes a melt grid40,100for converting a solid material P, such as a solid polymer material, into a molten material M, such as a molten polymer material or adhesive. The melting system10includes guide members154,254,354,454, and/or500along which the molten material M flows as it moves from the melt grid40,100to a reservoir30. Certain terminology is used to describe the melting system10in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The words “inner” and “outer” refer to directions toward and away from, respectively, the geometric center of the description to describe the melting system10and related parts thereof. The words “forward” and “rearward” refer to directions in a longitudinal direction6and a direction opposite the longitudinal direction6along the melting system10and related parts thereof. The terminology includes the above-listed words, derivatives thereof, and words of similar import.

Unless otherwise specified herein, the terms “vertical,” “lateral,” and “longitudinal” are used to describe the orthogonal directional components of various components of the melting system10, as designated by the vertical direction2, lateral direction4, and longitudinal direction6. It should be appreciated that while the lateral and longitudinal directions4and6are illustrated as extending along a horizontal plane, and the vertical direction2is illustrated as extending along a vertical plane, the planes that encompass the various directions may differ during use.

Referring toFIGS.1and2, an embodiment of the present disclosure includes a melting system10configured to melt and deliver a liquid, such as a molten polymer material P, which may be a thermoplastic material, downstream to dispensing equipment (not shown). The dispensing equipment can be used to apply the molten material onto a substrate. The substrate can be a nonwoven material used in hygiene or other applications such as paper and paperboard packaging or other product assembly applications involving adhesives. Alternatively, the substrate can include any materials where the application of a polymer material, such as an adhesive, is needed. The solid material P can be a pressure sensitive adhesive. However, it should be appreciated that melting system10can be adapted to process other polymer materials.

As shown inFIGS.1and2, the melting system10generally includes a base frame12mounted on wheels (not numbered), a control unit14supported by one side of the base frame12, and at least one melt unit. In accordance with the illustrated embodiment, the melt unit20is supported by the side of the base frame12opposite the control unit14. The control unit14includes a cabinet that houses controllers, displays, user interfaces, etc., that an operator can use to control operation of the melting system10. The control unit14is connected to the melt unit20via wired connectors16. Though shown as including a single melt unit, the melting system10can include two or more melt units. The inventive principles as described herein can be scaled up or down in size depending on application requirements, such as for nonwoven or packaging applications.

Continuing withFIGS.1and2, the melt unit20is supported by the base frame12and the underlying surface and extends upward along a vertical direction2. The melt unit20and control unit14, and thus the base frame12, define the overall “footprint” of the melting system10. As illustrated, the footprint is substantially rectilinear and extends along a lateral direction4and a longitudinal direction6that are perpendicular to each other. The lateral and longitudinal directions4and6are also perpendicular to the vertical direction2.

Continuing withFIGS.1-3, the melt unit20includes a pump assembly24above the base frame12, a reservoir30coupled to the pump assembly24, one or more sensors29positioned in the reservoir30, a melt grid40above the reservoir30, and the hopper60mounted above the melt grid40. The melt unit20also includes a thermal isolation region50disposed between the reservoir30and the hopper60. The melting system10includes a control system700that controls operations of the melt unit20, as shown inFIG.21. The control system700includes a controller702coupled to the one or more sensors29and the melt grid40. The control system700is used to control flow of molten material from the melt grid40and into the reservoir30as explained below.

Referring toFIGS.1-3, the thermal isolation region50creates a barrier between the molten material M, which is typically a polymer material, in the reservoir30and the solid material P in the hopper60. The thermal isolation region50helps maintain the temperature in the hopper60below the melting temperature of the solid material P. For example, the thermal isolation region50helps maintains the solid material P in the hopper60at a first temperature that is lower than a second temperature of the molten material M in the reservoir30by creating a thermal barrier that minimizes heat transfer from the reservoir30to the hopper60through the melt grid40. As shown inFIG.3, the thermal isolation region50comprises the gap G between the melt grid40and the molten material M in reservoir30. The thermal isolation region50can be any space or structure that creates a thermal barrier to minimize or even eliminate thermal migration from the molten material in the reservoir to the solid material P in the hopper. For instance, the thermal isolation region50may be an upper portion of the reservoir30, as shown inFIG.3. In another embodiment, the thermal isolation region50may comprise a separate component positioned between the reservoir30and the melt grid40. In some instances, there may be a thermal isolation region50and/or separate component positioned between the hopper60and the melt grid40(not shown).

Turning toFIGS.3and4, the reservoir30captures the molten material M exiting the melt grid40. The reservoir30includes a base32, a top34opposite the base32along a vertical direction2, and an outer wall36. The outer wall36includes four sides: first side37a(not shown), second side37b, third side37cand fourth side37d. The outer wall36defines an inner surface35along which the sensor29is positioned. The base32has an inner surface33, a portion of which can be angled with respect to the vertical direction2. The inner surface33guides molten material M into a portal (not numbered) that feeds into the pump assembly24below the reservoir30. The amount of molten material M that accumulates in the reservoir30is based, in part, on a) the throughput of solid material P through the melt grid40, b) the output of molten material M from the reservoir30, and c) the height of the outer wall36.

In accordance with the illustrated embodiment, the thermal isolation region50is disposed below the melt grid40. As shown inFIGS.3and4, the outer wall36has a height that is sufficient to facilitate formation of an air gap G between the melt grid40and a pool of molten material M that accumulates at the base32of the reservoir30during operation. As shown, the thermal isolation region50comprises, at least in part, the air gap G aligned with an upper portion52of the reservoir30. In this regard, it can be said the thermal isolation region50includes the upper portion52of the reservoir30. The upper portion52of the outer wall36extends from the top34of the reservoir30to an axis A that extends through the outer wall36of the reservoir30. The axis A is shown at a location above the base32of the reservoir30. The extent of the gap G is selected to separate the bottom of the melt grid40from the heated, molten material M in the reservoir30. The separation creates a thermal barrier that can inhibit or minimize heat transfer from the molten material M to the melt grid40.

Continuing withFIGS.3and4, the melt grid40heats the solid material P in the hopper60into the molten material M. The melt grid40includes a bottom42and a top44spaced from the bottom42along the vertical direction2. The bottom42of the melt grid40is mounted to the top34of the reservoir30. The hopper60is coupled to the top44of the melt grid40. The melt grid40has an outer wall46that includes four sides47a,47b,47cand47d(only47band47dare shownFIG.4). The melt grid40may also include a plurality of parallel and spaced apart melting rails48. The melting rails48extend across the melt grid40along the longitudinal direction6(into the sheet inFIG.3). The melting rails48define passages49that extend between adjacent melting rails48. The melting rails48can have different orientations as needed. In some instances, cross-bars (not shown) may connect adjacent melting rails. Each melting rail48includes one or more heater elements that elevate the temperature of the melting rails48to the desired temperature for processing the solid material P. The heating elements are connected to the controller702via the wired connector16. In addition, the melt grid40may include guide members43coupled to the bottom the melt grid40. The guide members43guide the molten material M as it exits from between the melting rails48into the molten material M. The guide members43may reduce formation of air bubbles as the molten material M falls from the bottom42of the melt grid40into the reservoir30, as will be described below in further detail.

The melt grid40is designed for efficient heating to the desired operating temperature from a cooled state. In one example, the melt grid40has a mass selected to provide a watt density of 8-10 w/in3. Such a melt grid may take about 20 minutes to reach its desired operating temperature. In another example, the melt grid40has a mass selected to increase watt density and utilizes thin film heaters. In this example, the melt grid40has a watt density of 60-70 w/in3. Such a melt grid40will take about 3-6 minutes to reach its desired operating temperature. In contrast, conventional melt grids use heavy castings and cartridge heaters and have a watt density of 4-5 w/in3. As a result, conventional melt grids will take thirty or more minutes to reach the desired operating temperature. Accordingly, the melt grids as described herein may be considered low mass melt grids and have a watt density that is greater than 6-8 w/in3and could be as high as 60-70 w/in3. Such low mass melt grids heat up and cool down faster compared to the conventional melt grids. Faster heat-up and cooling increases operational efficiency by reducing the amount of time the melt unit is not generating molten material but is waiting for the system to reach its desired operational temperatures.

Referring toFIGS.3-4, the hopper60is configured to hold solid material P. As illustrated, the hopper60has a lower end62and an upper end64opposite the lower end62along the vertical direction2. The hopper60also includes a wall66that extends from the lower end62to the upper end64. The upper end64includes an upper cover68that closes the upper end64of the hopper60. The upper cover68can include an access door23that may be removable from the upper cover68, or connected but movable relative to the upper cover68, such as by a hinge (not shown). The access door23covers an opening25that extends through the upper cover68, through which an operator of the melting system10can replenish the supply of polymer material P within the hopper60. The wall66of the hopper60extends around an entirety of the hopper60such that the wall66and the upper cover68define an internal chamber65that holds the solid material P. The lower end62of the hopper60is substantially open to the melt grid40. As shown inFIGS.3-4, the lower end62is open to the melting rails48and passages49of the melt grid40.

In accordance with the illustrated embodiment, the wall66includes a plurality of sides72a-72d. As best shown inFIGS.2and4, the wall66includes a first side72a, a second side72bthat intersects the first side72a, a third side72cthat intersects the second side72band is opposite the first side72a, and a fourth side72dthat intersects the first side72a(FIG.2) and the third side72c. The fourth side72dis opposite the second side72b. The first side72acan be considered the front side or front of the hopper60and the third side72ccan be considered the back or backside of the hopper60. A “side” of the hopper60can also be referred to as a side wall in certain embodiments. As shown, the upper cover68intersects all four sides72a-72d. The four sides72a-72dare arranged to form a rectilinear cross-sectional shaped hopper. Although a rectilinear cross-sectional shaped hopper60is illustrated, the hopper60can have other cross-sectional shapes. For example, in accordance with an alternative embodiment, the hopper60has a tubular shape. In such an embodiment, the hopper60includes a wall66that forms a tubular shaped body. In such an embodiment, the hopper60includes a single curved wall.

The hopper60has been described and shown as disposed on top of the melt grid40that is separated from the molten material in the reservoir30by the thermal isolation region50(or the air gap G). The thermal isolation region50inhibits heat transfer from the molten material M to the solid material P stored in the hopper60. However, the hopper60as described herein can be used in melting systems with different types of melt grids and reservoir configurations than what is shown and described above. Rather, the hopper60can be used in any type of melting system where molten material M and the solid material P stored in the hopper60are thermally isolated with respect to each other. In other words, embodiments of the present disclosure include a melting system that includes a hopper that is thermally isolated from the reservoir30that contains molten material M.

Referring toFIG.3, in operation, the hopper60holds a supply of solid material P on top of the melt grid40. The melt grid40has heating elements that expose the solid material P positioned above the melt grid40to a temperature sufficient to form a molten material M. The molten material M flows through the melt grid40and is deposited into the reservoir30, and flows through one or more passageways to the pump assembly24. The control system700implements a closed-loop control mechanism to maintain an adequate level of molten material M in the reservoir30. The controller702receives a signal from the melt grid40with data concerning the melt grid temperature. As polymer flows into the reservoir30, the sensor29determines the level of molten material M in the reservoir30. The sensor29transmits a signal to the controller702. The controller702determines if the level of molten material M is at or higher than a threshold level. If the level of molten material M is at or higher than the threshold level, the controller702causes the temperature of the melt grid40to decrease by a determined amount. The lower melt grid temperature decreases the rate of molten material M flowing into the reservoir30. This results in the level of molten material M in the reservoir30decreasing as molten material M is pumped to the applicator (not shown). The sensor29detects when the level of molten material M falls below the threshold level and transmits the signal to the controller702. The controller702causes the temperature of the melt grid40to increase, thereby increasing the amount of molten material M flowing into the reservoir30. The feedback loop between sensor data and temperature adjustment based on the sensor data controls the level of molten material M in the reservoir30to maintain an air gap G below the melt grid40. During the control process described above, the pump assembly24, however, is used to continuously pump the molten material M from the reservoir30through hoses (not shown) to an applicator (not shown), which ejects the molten material M onto the desired substrate. As molten material M is ejected, the supply of solid material P in the hopper60is depleted.

Referring toFIGS.5-8, one embodiment of a melt grid100and other components that can be used in the melting system10will be discussed. Melt grid100, like melt grid40, is configured to turn the solid material P in the hopper60into a molten material M. Melt grid100defines a bottom102, a top104opposite the bottom102along the vertical direction2, and an outer wall106that extends between the top104and the bottom102. The bottom102of the melt grid100is mounted to the top34of the reservoir30, while the top104of the melt grid100is coupled to the hopper60. The melt grid100may define a substantially rectangular shape, and thus the outer wall106can define four outer sides107a-107d, specifically, the outer wall106can include a first outer side107a, a second outer side107b, a third outer side107cthat is opposite the first outer side107aalong the longitudinal direction6, and a fourth outer side107dthat is opposite the second outer side107balong the lateral direction4. The second and fourth outer sides107band107dextend from the first to the third outer sides107aand107c. The melt grid100also defines an inner wall110opposite the outer wall106, where the inner wall includes four inner sides112a-112d. Specifically, the inner wall110includes a first inner side112a, a second inner side112b, a third inner side112copposite the first inner side112aalong the longitudinal direction6, and a fourth inner side112dopposite the second inner side112balong the lateral direction4. The second and fourth inner sides112band112dcan extend from the first inner side112ato the third inner side112c. The inner wall110, in particular the first and third inner sides112aand112c, can attach to and support one or more guide members, such as guide member154, as will be discussed further below.

Like the melt grid40, the melt grid100includes a plurality of melting rails128. Though nine melting rails128are depicted, the melt grid100can include more or less melting rails as desired based upon the particular designs of various melting systems10and the requirements of different melting operations. As depicted, each of the melting rails128extends from the first inner side112ato the third inner side112calong the longitudinal direction6, with each of the melting rails128being spaced apart along the lateral direction4. However, it is also contemplated that the melting rails128can extend from the second inner side112bto the fourth inner side112dalong the lateral direction4, with each of the melting rails128being spaced apart along the longitudinal direction6. In either embodiment, the melting rails128can extend substantially parallel to each other. Additionally, each of the melting rails128can extend from the bottom102of the melt grid100toward the top104along the vertical direction2.

The melt grid100further defines at least one passage that extends through the outer wall106, the inner wall110, and the melting rails128. In the depicted embodiment, the melt grid100defines at least four passages: a first passage120, a second passage122, a third passage124, and a fourth passage126. The first through fourth passages120,122,124, and126can each be configured to allow a heating element, a heating liquid, or a cooling liquid to pass through the melting rails128to increase temperature control over the melt grid100, and likewise the solid material P and the molten material M. Specifically, heating elements can be used to elevate the temperature for processing the solid material P. The heating elements are connected to the controller702via the wire connector16. As shown, the first through fourth passages120,122,124, and126extend from the first outer side107ato the third outer side107cthrough each of the melting rails128. However, in embodiments where the melting rails128extend from the second inner side112bto the fourth inner side112d, the first through fourth passages120,122,124, and126will extend from the second outer side107bto the fourth outer side107d. Though the second passage122is depicted as defining a smaller cross section than the first, third, and fourth passages120,124, and126, each can be differently sized based upon the particular heating or cooling liquid or element that will pass through, as well as the relative dimensions of the other passages. Also, though the melt grid100is shown as including four passages120,122,124, and126, the melt grid100can include more or less passages as desired.

Continuing withFIGS.7-8, the structure of the melting rails128will be further described with reference to a single exemplary melting rail128. The melting rail128defines a top corner129that defines the uppermost portion of the melting rail128along the vertical direction2. The melting rail128further defines a first surface128aand a second surface128bopposite the first surface128aalong the lateral direction4, where the first and second surfaces128aand128bmeet at the top corner129and extend away from the top corner129along the vertical and lateral directions2and4. The first and second surfaces128aand128bare configured to contact and transfer heat to the solid material P to transition the solid material P into the molten material M. The first and second surfaces128aand128bcan define an angle θ at the top corner129of the melting rail128, such that the first and second surfaces128aand128bare angularly offset by the angle θ. The angle θ as depicted is about 30 degrees. As a result, the melting rail128defines a substantially triangular cross-section when viewed along a plane defined by the vertical and lateral directions2and4. However, the angle θ can be more or less than 30 degrees as desired. For example, the angle θ can be from about 10 degrees to about 50 degrees.

Opposite the top corner129, the melting rail128can define a rail bottom recess138that extends upward into the melting rail128along the vertical direction2. The rail bottom recess138allows for the conservation of material when constructing the melt grid100by preventing the melting rail128from being completely solid, as well as allowing for increased efficiency in heating the melting rail128, as less material in the melting rail128needs to be heated during the course of operating the melting system10. The melting rail128can define a first inner rail surface134a, a second inner rail surface134b, and a third inner rail surface134cthat partially define the rail bottom recess138. The first and second inner rail surfaces134aand134bcan extend from the first inner side112ato the third inner side112cof the melt grid100along the longitudinal direction6, such that the first inner rail surface134ais spaced from the second inner rail surface134balong the lateral direction4. The third inner rail surface134ccan extend from the first inner rail surface134ato the second inner rail surface134balong the lateral direction, as well as from the first inner side112ato the third inner side112cof the melt grid100along the longitudinal direction6. As a result, the third inner rail surface134cmay be oriented substantially transverse to the first and second inner rail surfaces134aand134b.

Continuing withFIGS.7-8, the melting rails128are spaced apart from each other as well as from the second and fourth inner sides112band112dalong the lateral direction4, such that flow passages142are defined between the adjacent melting rails128, as well as between a melting rail128and the second inner side112b, and between another melting rail128and the fourth inner side112d. The flow passages142provide a pathway for adhesive to flow through the melt grid100along the vertical direction2. As a result, the flow passages142allow any solid material P from the hopper60that has been heated sufficiently and transitioned into the molten material M to flow from above the melt grid100to the reservoir30.

Additionally, each of the melting rails128can define a first support pad146aand a second support pad146bopposite the first support pad146aalong the lateral direction4. The first support pad146acan extend from the first surface128aof a melting rail128along the lateral direction4, while the second support pad146bcan extend from the second surface128bof the melting rail128along the lateral direction4. The first support pad146acan define a flow passage150athat extends through the support pad146a, while the second support pad146bcan define a flow passage150bthat extends through the support pad146b. Each of the flow passages150aand150bcan be open to a flow passage142. Though only one first support pad146aand one support pad146bis shown in the cross-sections of the melt grid100depicted inFIGS.7-8, each of the melting rails128can define a plurality of support pads146aand flow passages150aspaced apart along longitudinal direction6, as well as a plurality of support pads146band flow passages150bspaced apart along the longitudinal direction6. As shown, the support pads146aof one melting rail128may face the support pads146bof an adjacent melting rail128. The support pads146aand146band the corresponding flow passages150aand150bcan help provide an increased surface area for supporting the un-molten and semi-molten material as it flows from above the melt grid100toward the reservoir30, which can help increase the flow rate of molten material M through the melt grid100and prevent the backup of molten material M above the melt grid100.

The melting system10can further include at least one guide member attached to the melt grid100to prevent air bubbles from becoming entrapped in the melted material M as it flows from the melt grid100to the reservoir30, as will be discussed further below. As shown inFIGS.5-9B, one embodiment of such a guide member is guide member154. Though the melting system10can include a plurality of guide members154, only one guide member154will be discussed below for brevity. The guide member154defines a first wall158and a second wall160opposite the first wall158. The first wall158defines an inner surface158aand an outer surface158bopposite the inner surface158a, while the second wall160defines an inner surface160aand an outer surface160bopposite the inner surface160a, such that the inner surface158aof the first wall158faces the inner surface160aof the second wall160. To attach the guide member154to the melt grid100, the outer surfaces158band160bof the first and second walls158and160can engage the inner wall110of the melt grid100. Specifically, in the embodiments shown, the first wall158of the guide member154engages the third inner side112cof the inner wall110, and the second wall160of the guide member154engages the first inner side112aof the inner wall110. As a result, each of the guide members154will be spaced apart along the lateral direction4. However, in other embodiments where the melting rails128are differently oriented, it is contemplated that the guide member154can attach to different portions of the inner wall110as desired. The guide member154may be attached to the melt grid100through a variety of means, such as through fasteners, welding, adhesive, integral molding, etc. As a result, the guide member154may be releasably attachable to the melt grid100, or may be permanently attached to the melt grid100.

The guide member154also includes a curved guide wall166that extends from the first wall158to the second wall160. In the depicted embodiment, the curved guide wall166defines a semi-circular shape, though other shapes are also contemplated. The curved guide wall166defines an inner wall166aand an outer wall166bthat is opposite the inner wall166a. Additionally, the guide member154can include a first guide wall162and a second guide wall164that each extend form the curved guide wall166along the vertical direction2. In the depicted embodiment, the first and second guide walls162and164are spaced apart along the lateral direction4, while the first and second walls158and160are spaced apart along the longitudinal direction6. The first guide wall162defines an inner wall162aand an outer wall162bopposite the inner wall162a, while the second guide wall164defines an inner wall164aand an outer wall164bopposite the inner wall164a. The inner wall162aof the first guide wall162can substantially face the inner wall164aof the second guide wall164. The inner wall162aof the first guide wall162, the inner wall166aof the curved guide wall166, and the inner wall164aof the second guide wall164can define a continuous surface, while the outer wall162bof the first guide wall162, the outer wall166bof the curved guide wall166, and the outer wall164bof the second guide wall164can define another continuous surface.

When attached to the melt grid100, the guide member154can be positioned such that the outer curved wall166bof the curved guide wall166is directly under a flow passage142defined between two adjacent melting rails128along the vertical direction2. In particular, the apex of the curved guide wall166can be aligned with the center of the flow passage142. As a result, a gap G1is defined between the lower ends of the two adjacent melting rails128and the curved guide wall166of the guide member154. In operation, as the melt grid100melts the solid material P into the molten material M, the resulting molten material M flows through the flow passage142defined between two adjacent melting rails128, as well as through the flow passage150adefined by the first support pad146aand the second flow passage150bdefined by the second support pad146b. Without the presence of the guide member154, molten material M would otherwise flow downward from the flow passage142and through the thermal isolation region50uninhibited, until the molten material M contacts a pool of molten material M contained by the reservoir30. With the guide member154, molten material M contacts the outer wall166bof the curved guide all166after it flows through the flow passage142, and further flows along the outer wall162bof the first guide wall162and/or the outer wall164bof the second guide wall164and to the pool of molten material M in the reservoir30.

Continuing withFIGS.10A-10B, a guide member254according to another embodiment of the present disclosure is shown. Though a plurality of guide members254can be included in the melting system10, only one guide member254will be discussed for brevity. The guide member254includes an attachment wall258, a lateral wall262that extends from the attachment wall258, and a guide wall264that extends from the lateral wall262. The attachment wall258and the guide wall264can extend substantially along the vertical direction2, though other orientations for these walls are contemplated. Also, the attachment wall258is spaced from the guide wall264along the lateral and vertical directions2and4. The lateral wall262is depicted as meeting the guide wall264at a substantially curved intersection. However, this intersection can define a sharp angle if desired. The lateral wall262can be angularly offset with respect to the lateral direction4, such that the lateral wall is offset from a plane defined by the lateral and longitudinal directions4and6by an angle α1. As depicted, the angle is about 25 degrees. However, the angle can be from about 0 degrees to about 90 degrees. The guide wall264can define a plurality of tabs266, which can be spaced apart along the lateral direction2. In the depicted embodiment, the tabs266are substantially triangular in shape. However, the tabs266can be alternatively configured, such that the tabs266are rectangular, circular, etc. A gap268is defined between each adjacent pair of tabs266, and extends into the guide wall264from the end of the guide wall264.

The attachment wall258can include an inner surface258aand an outer surface258bopposite the inner surface258a. The attachment wall258can function as the part of the guide member254that secures the guide member254to a portion of the melt grid100, such as one of the melting rails128. In particular, the inner or outer surfaces258aor258bof the attachment wall258can be secured to the first or second inner rail surface134aor134b, though other securing locations are contemplated. As with the guide member154, the guide member254may be attached to the melt grid100through a variety of means, such as through fasteners, welding, adhesive, integral molding, etc. As a result, the guide member254may be releasably attachable to the melt grid100, or may be permanently attached to the melt grid100.

The lateral wall262can define a top surface262aand a bottom surface262bopposite the top surface262a, and the guide wall264can define an inner surface264aand an outer surface264bopposite the inner surface264a. As a result, the inner surface258aof the attachment wall258, the top surface262aof the lateral wall262, and the inner surface264aof the guide wall264can define a continuous surface, while the outer surface258bof the attachment wall258, the bottom surface262bof the lateral wall262, and the outer surface264bof the guide wall264can define another continuous surface. When the guide member254(or a plurality of guide members254) is attached to the melt grid100, the top surface262aof the lateral wall262is positioned below the flow passage142along the vertical direction2. In operation, molten material M flowing through the flow passages142contacts the top surface262aof the lateral wall262. From there, the molten material M flows along the top surface262a, along the inner surface264aof the guide wall264, along the tabs266, and into the reservoir30.

Continuing withFIGS.11A-11B, a guide member354according to another embodiment of the present disclosure is shown. The guide member354is similar to the guide member254, but with notable differences that will be detailed below. Though a plurality of guide members354can be included in the melting system10, only one guide member354will be discussed for brevity. The guide member354includes an attachment wall358, a lateral wall362that extends from the attachment wall358, and a guide wall364that extends from the lateral wall362. The attachment wall358and the guide wall364can extend substantially along the vertical direction2, though other orientations for these walls are contemplated. Also, the attachment wall358is spaced form the guide wall364along the lateral and vertical directions2and4. The lateral wall362is depicted as meeting the guide wall364at a substantially curved intersection. However, the intersection can define a sharp angle if desired. The lateral wall362can be angularly offset with respect to the lateral direction4, such that the lateral wall362is offset from a plane defined by the lateral and longitudinal directions4and6by an angle α2. As depicted, the angle α2is about 25 degrees. However, the angle α2can be from about 0 degrees to about 90 degrees. Unlike the guide wall264of the guide member254, the guide wall364defines a substantially solid, rectangular shape devoid of the tabs266or gaps268included in the guide wall264.

The attachment wall358can include an inner surface358aand an outer surface358bopposite the inner surface358a. The attachment wall358can function as the part of the guide member354that attaches the guide member354to a portion of the melt grid100, such as one of the melting rails128. In particular, the inner or outer surfaces358aor358bof the attachment wall358can be secured to the first or second inner rail surface134aor134b, though other securing locations are contemplated. As with the guide member154, the guide member354may be attached to the melt grid100through a variety of means, such as through fasteners, welding, adhesive, integral molding, etc. As a result, the guide member354may be releasably attachable to the melt grid100, or may be permanently attached to the melt grid100.

The lateral wall362can define a top surface362aand a bottom surface362bopposite the top surface362a, and the guide wall364can define an inner surface364aand an outer surface364bopposite the inner surface364a. As a result, the inner surface364aof the attachment wall358, the top surface362aof the lateral wall362, and the inner surface364aof the guide wall364can define a continuous surface, while the outer surface358bof the attachment wall358, the bottom surface362bof the lateral wall362, and the outer surface364bof the guide wall364can define another continuous surface. When the guide member354(or a plurality of guide members354) is attached to the melt grid100, the top surface362aof the lateral wall362is positioned below the flow passage142along the vertical direction2. In operation, molten material M flowing through the flow passages142contacts the top surface362aof the lateral wall362. From there, the molten material M flows along the top surface362a, along the inner surface364aof the guide wall364, and into the reservoir30.

Now referring toFIG.12, the guide member can comprise a plurality of guide rods454. Though a plurality of guide rods454can be included in the melting system10, only one guide rod454will be discussed for brevity. The guide rod454includes an attachment section458, a lateral section462that extends from the attachment section458, and a guide section464that extends from the lateral section462. The attachment section458and the guide section464can extend substantially along the vertical direction2, although other orientations for these sections are contemplated. Also, the attachment section458and the guide section464are spaced apart along the lateral and vertical directions4and2. The lateral section462is depicted as meeting the guide section464at a substantially curved intersection. However, this intersection can define a sharp angle if desired. The lateral section462can be angularly offset with respect to the lateral direction4, such that the lateral section462is offset from a plane defined by the lateral and longitudinal directions4and6by an angle α3. As depicted, the angle α3is about 45 degrees. However, the angle can be from about 0 degrees to about 90 degrees.

The attachment section458can define one or more recesses, such as first and second recesses456aand456b. The first and second recesses456aand456bcan be configured to engage with a corresponding structure (not shown) on the melt grid100to attach the guide rod454to a portion of the melt grid100, such as one of the melting rails128. Though two recesses are shown, the attachment section458can include more or less recesses as desired. The lateral section462can define an outer surface463, and the guide section464can define an outer surface465. The outer surface463of the lateral section462and the outer surface465of the guide section464can define a substantially continuous surface. The body of the guide rod454can be substantially circular, such that the outer surface463of the lateral section462and the outer surface465of the guide section464are also substantially circular. However, other shapes of the body of the guide rod454are contemplated, such as triangular, rectangular, etc. When the guide rod454(or a group of guide rods454) is attached to the melt grid100, the lateral section462is positioned below the flow passage142along the vertical direction2. A group of guide rails454can be attached to a melt grid100such that multiple guide rods454are positioned below a single flow passage142, such that the guide rails are spaced apart along the longitudinal direction6. In operation, molten material M flowing through the flow passage142contacts the outer surface463of the lateral section462. From there, the molten material M flows along the outer surface463of the lateral section462, along the outer surface465of the guide section464, and into the reservoir30.

Continuing withFIGS.13-16, another embodiment of a guide member will be discussed. InFIGS.5-12, the various guide members154,254,354, and454attached to a portion of the melt grid100and extended downward from the melt grid100, such that at least a portion of the guide members are positioned below the flow passages142. In contrast, guide member500is attached to the reservoir30and extends upward toward the melt grid100, as will be described further below. Though a plurality of guide members500can be including in the melting system10, only one guide member500will be discussed below for brevity.

Each guide member500can define a first surface501aand a second surface501bopposite the first surface501a, such that the guide member500defines a substantially triangular cross section. The first and second surfaces501aand501bintersect at a top corner502, which can define the portion of the guide member500that is closest to the melt grid100. As shown, the top corner502can be positioned directly below a passage49so that molten material M contacts the top corner502after it flows out of the passage49. The first and second surfaces501aand501bcan be angularly offset, such that an angle θ2is defined between the first and second surfaces501aand501b. As depicted, the angle θ2can be about 15 degrees. However, the angle θ2can alternatively be from about 5 degrees to about 75 degrees, as desired. Though nine guide members500are depicted as being included in the melting system10, more or less guide members500can be include as desired.

The melting system10can include a plurality of guide members500that are spaced apart along the lateral direction4, such that each guide member500is positioned below a respective flow passage49of the melt grid40along the vertical direction2. Though the guide members500can be differently oriented, they will generally correspond to the orientation of the melting rails48, and thus the flow passages49. The guide members500can be both positioned below the melting grid100along the vertical direction, as well as above the inner surface33of the base32of the reservoir30. To support the guide members500, the melting system10can include one or more support bars504. Each support bar504can extend from one side of the inner surface35of the wall39to the other side, and each guide member500can extend from the support bars504along the vertical direction2. Though the support bars504are show as extending along the lateral direction4and spaced apart along the longitudinal direction6, the support bars504can extend along other directions as desired. The support bars504can be alternatively attached to other parts of the reservoir30, such as the inner surface33of the base32. Also, though four support bars504are shown as included in the melting system10, more or less support bars504can be included as desired. For example, the melting system10can include only one support bar, two support bars, or more than four support bars. In other embodiments, no support bars may be required, and the guide members500can be supported through direct attachment to the inner surface33of the base of the reservoir. In operation, molten material M flows through the flow passage142of the melt grid100, and contacts the top corner502of the guide members500, which can be aligned with the flow passages142along the lateral direction4. Then, the molten material M flows along the first and second surface501aand501bof the guide members500, and subsequently flows off the guide members500and into the reservoir30.

Continuing withFIGS.17-20, another embodiment of a melting system will be discussed. The melting system10′ can include a melt grid600, an isolation chamber630, and a reservoir650that includes a guide member658. Similar to the guide member500, the guide member658extends upward toward the melt grid600, as will be discussed below. The melt grid600defines a bottom602, a top604opposite the bottom602along the vertical direction2, and an outer wall606that extends between the top604and the bottom602. The bottom602of the melt grid600is mounted to the top631bof the isolation chamber630, while the top604of the melt grid600is coupled to the lower end62of the hopper60. The melt grid600may define a substantially rectangular shape, and thus the outer wall606can define four outer sides607a-607d. Specifically, the outer wall606can include a first outer side607a, a second outer side607b, a third outer side607cthat is opposite the first outer side607aalong the longitudinal direction6, and a fourth outer side607dthat is opposite the second outer side607balong the lateral direction4. The second and fourth outer sides607band607dextend from the first to the third outer sides607aand607c. The melt grid600also defines an inner wall610opposite the outer wall606, where the inner wall610includes four inner sides612a-612f. Specifically, the inner wall610includes a first inner side612a, a second inner side612b, a third inner side612copposite the first inner side612aalong the longitudinal direction6, and a fourth inner side612dopposite the second inner side612balong the lateral direction4. The second and fourth inner sides612band612dcan extend from the first inner side612ato the third inner side612c. The inner wall610can also include a first bottom surface612eand a second bottom surface612fopposite the first bottom surface612ealong the lateral direction4. The first bottom surface612eextends between the first, second, and third inner sides612a-612c, while the second bottom surface612fextends between the first, third, and fourth inner sides612,612c, and612d. Both the first and second bottom surfaces612eand612fcan extend towards each other along the lateral direction4and downwardly along the vertical direction2, such that the first and second bottom surface612eand612fdirect a flow of adhesive towards an opening624formed between the first and second bottom surfaces612eand612fat the center of the melt grid600, as will be discussed further below.

Like the melt grids40and100, the melt grid600includes a plurality of melting rails618. Though the depicted melt grid600includes nine melting rails, the melt grid600can include more or less melting rails as desired based upon the particular designs of various melting systems10′ and the requirements of different melting operations. As depicted, each of the melting rails618extends from the second inner side612bto the fourth inner side612dalong the lateral direction4, with each of the melting rails618being spaced apart along the longitudinal direction6. However, it is also contemplated that the melting rails618can extend from the first inner side612ato the third inner side612calong the longitudinal direction6, with each of the melting rails618being spaced apart along the lateral direction4. In either embodiment, the melting rails618can extend substantially parallel to each other. Additionally, each of the melting rails618can extend from the bottom602of the melt grid600, in particular the first and second bottom surfaces612eand612f, toward the top604along the vertical direction2.

Each of the melting rails618defines a top corner that defines an uppermost portion of the melting rail618along the vertical direction2. The melting rail618further defines a first surface618aand a second surface (not shown) opposite the first surface618aalong the longitudinal direction6, where the first surface618aand the second surface meet at the top corner and extend away from the top corner along the longitudinal and vertical directions6and2. The melting rails618are spaced apart from each other such that flow passages615are defined between adjacent pairs of melting rails618. The melting rails618also define a plurality of recesses622that are spaced apart along the lateral direction4and are in communication with the flow passages615. The first surface618aand the second surface are configured to contact and transfer heat to the solid material P to transition the solid material P into the molten material M. When transitioned from the solid material P to the molten material M, the molten material M flows through the flow passage615and the recesses622and to the first and second bottom surfaces612eand612f. From there, the molten material M flows along the first and second bottom surfaces612eand612fto the center of the melt grid600and through the opening624formed between the first and second bottom surfaces612eand612f.

Continuing withFIGS.17-20, the isolation chamber630is disposed between the melt grid600and the reservoir650. In particular, the isolation chamber630defines a top631bthat is attached to the bottom602of the melt grid600, and a bottom631aopposite the top631balong the vertical direction2that is attached to the top651bof the reservoir650. The isolation chamber630has an outer wall632that can define four outer sides632a-632d: a first outer side632a, a second outer side632b, a third outer side632cthat is opposite the first outer side632aalong the longitudinal direction6, and a fourth outer side632dthat is opposite the second outer side632calong the lateral direction4. The second and fourth outer sides632band632dextend from the first to the third outer sides632aand632c.

The isolation chamber630further includes two discrete sections separated by a channel646. The first section630ahas an inner surface634that defines a first inner surface634a, a second inner surface634b, a third inner surface634cthat is opposite the first inner surface634aalong the lateral direction4, and a fourth inner surface634dthat is opposite the second inner surface634balong the vertical direction2. Collectively, the inner surfaces634a-634dbound a chamber636defined by the first section630a. The chamber636has a height G2measured from the fourth inner surface634dto the second inner surface634balong the vertical direction2. The height G2varies along the lateral direction4due to the inclination of the second inner surface634b, which results from the inclination of the second bottom surface612fof the melt grid600. The chamber636provides an air-insulated buffer between the melt grid600and the reservoir650, such that heat emanating from the molten material M in the reservoir650does not affect the solid material P disposed above the melting rails618of the melt grid600. Instead, the molten material M heats the air in the chamber636, which can escape the isolation chamber630through vents638that extend through the outer wall632. Though the vents638of the first section630aare shown as substantially cylindrically-shaped and arranged in a certain configuration, the vents638can be any configuration or design as desired. The vents638can also extend through any portion of the outer wall632as desired.

Similarly, the isolation chamber630includes a second section630bspaced from the first section630aalong the lateral direction4. The second section630bhas an inner surface640that defines a first inner surface640a, a second inner surface640b, a third inner surface640cthat is opposite the first inner surface640a, and a fourth inner surface640dthat is opposite the second inner surface640balong the vertical direction2. Collectively, the inner surfaces640a-640dbound a chamber642defined by the second section630b. The chamber642has a height G3measured form the fourth inner surface640dto the second inner surface640balong the vertical direction2. The height G3varies along the lateral direction4due to the inclination of the second inner surface640b, which results from the inclination of the first bottom surface612eof the melt grid600. Like the chamber636, the chamber642provides an air-insulated buffer between the melt grid600and the reservoir650, such that heat emanating from the molten material M in the reservoir650does not affect the solid material P disposed above the melting rails618of the melt grid600. Instead, the molten material M heats the air, which can escape the isolation chamber630through vents638that extend through the outer wall632, particularly the fourth outer side632dand the first inner surface640a. Though the vents638of the second section630bare shown as substantially cylindrically-shaped and arranged in a certain configuration, the vents638can be any configuration or design as desired.

The channel646, which receives the flow of molten material M flowing through the opening624, can be centrally disposed in the isolation chamber630such that the first and second sections630aand630bare equally sized. The channel646extends from the top631bof the isolation chamber630to the bottom631aalong the vertical direction2. The first section630acan include a first inner wall644athat partially defines the channel646, while the second section630bcan include a second inner wall644bopposite the first inner wall644aacross the channel646that also partially defines the channel646.

Continuing withFIGS.17-20, the reservoir650includes a bottom651aand a top651bopposite the bottom651aalong the vertical direction2, the top651bbeing connected to the bottom631aof the isolation chamber630. The reservoir650also includes an outer wall652that includes a plurality of sides: a first side652a, a second side652b, a third side652cthat is opposite the first side652aalong the longitudinal direction6, and a fourth side652dthat is opposite the second side652balong the lateral direction4. The reservoir650defines a cavity666bounded by the outer wall652, which provides additional thermal insulation between the molten material M in the reservoir650and the melt grid600. The outer wall652defines an inner surface654along which a level sensor656is positioned. The level sensor656is used to determine the level of molten material M within the reservoir650, and provides this reading to the controller702through an electrical connection. The inner surface654includes a first inner surface654a, a second inner surface654b, a third inner surface654cthat is opposite the first inner surface654aalong the longitudinal direction6, a fourth inner surface654dthat is opposite the second inner surface654balong the lateral direction4, and a bottom surface654ethat extends between each of the surfaces654a-654d. The reservoir650also includes a guide member658for heating the molten material M within the reservoir650and guiding the molten material M as it flows from the channel646. Though the guide member658is depicted as extending from the first inner surface654ato the third inner surface654calong the longitudinal direction6, the guide member658can also extend from the second inner surface654bto the fourth inner surface654dalong the lateral direction4. The guide member658can define a plurality of passages, such as first and second passages653aand653bthat extend through the guide member658from the first side652ato the third side652c. Each of the first and second passages653aand653bcan each be configured to allow a heating element, a heating liquid, or a cooling liquid to pass through the guide member658to increase temperature control over the reservoir650, and likewise the molten material M.

The guide member658includes a first surface658a, a second surface658bthat is opposite the first surface658aalong the lateral direction4, and a third surface658clocated at the upper end of the guide member658that extends from the first surface658ato the second surface658b. The guide member658is positioned such that the third surface658cis aligned with, and optionally located within, the channel646. The first and second surface658aand658bcan be angled relative to each other by an angle θ3, such that the cross-sectional shape of the guide member658is substantially triangular. As depicted, the angle θ3is about 40 degrees. However, it is contemplated that the angle θ3can be from about 5 degrees to about 75 degrees. Though depicted as a flat surface with curved edges, it is contemplated that the third surface658cdefines other shapes and configurations. For example, the third surface658ccan be curved, have sharp edges, or define a sharp point between the first and second surfaces658aand658b. The guide member658can also be spaced from the bottom surface658ealong the vertical direction2.

The reservoir650can include a plurality of fins660that extend upwards from the bottom surface658ealong the vertical direction2. As depicted, each of the fins660defines a slender, triangular cross section. However, in other embodiments the fins660can be substantially rectangular, or define other shapes as desired. The fins660extend along the lateral direction4, and can extend substantially parallel to each other. The fins660are spaced apart from each other, such that passages662are defined between each respective pair of adjacent fins660. The bottom surface654ecan have an outlet664that allows molten material M that has accumulated within the reservoir650to be transported to an applicator. The bottom surface654ecan be tapered, such that the bottom surface654enaturally guides molten material M to the outlet664. The outlet664is depicted as positioned laterally off-center within the reservoir650, though embodiments in which the outlet664is centered within the reservoir650are contemplated. The fins660can be positioned on opposite sides of the outlet664along the lateral direction4, such that none of the fins660align with the outlet664along the longitudinal direction6.

As stated above, when transitioned from the solid material P to the molten material M, the molten material M flows through the flow passages615and the recesses622and to the first and second bottom surfaces612eand612fFrom there, the molten material M flows along the first and second bottom surfaces612eand612fto the center of the melt grid600and through the opening624formed between the first and second bottom surfaces612eand612fAfter flowing through the opening624, the molten material M passes through the channel646and contacts the third surface658cof the guide member658. From there, the molten material M flows down the guide member658along the first and second surfaces658aand658b, and either onto the fins660or into the passages662. After flowing along the fins660and/or the passages662, the molten material M is guided by the bottom surface654eto the outlet664, from which the molten material M is pumped to an applicator.

As noted above, in previous embodiments of melt grids that do not include guide members, streams of adhesive can swirl or fold upon reaching the reservoir, which can trap air in the adhesive. The inclusion of the guide members154,254,354,454, and/or500, as well as the guide member658and fins660, can help prevent aeration of the adhesive from occurring. Upon flowing through the flow passages142, the hot melt adhesive almost immediately engages the guide members154,254,354,454, and/or500, which function to steadily guide the streams of adhesive to the reservoir below. This gradual transition along the guide members154,254,354,454, and/or500prevents the longer free-fall of adhesive from the melt grid to the reservoir that can occur in melting systems that do not include guide members, which can help prevent the adhesive from swirling or folding and thus entrapping pockets of air. Similarly, the guide member658and fins660help prevent aeration of adhesive, as hot melt adhesive is steadily guided from the channel646to the bottom surface654eby the guide member658and fins660, as opposed to the molten material M free-falling from the channel646to a pool of adhesive below. As a result, preventing adhesive aeration can help ensure adhesive pattern quality from the applicator is preserved.

The guide member658is a purpose heated zone, which reduces the viscosity of the molten and semi-molten material as it flows across the heated surfaces, allowing the fluid film to thin out and disperse across the full face of the guide member658. This lower viscosity and film thinning phenomenon causes an elongation and popping of air bubbles that may be present, which supplements the primary aeration prevention realized thru the elimination of the swirling streams that entrap air as discussed above.

While the invention is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method can be implemented in a particular order as desired.