Patent Publication Number: US-7908997-B2

Title: Hybrid hot melt adhesive or other thermoplastic material dispensing system

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to hot melt adhesive or other thermoplastic material dispensing systems, and more particularly to a new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system wherein two or more different hot melt adhesive or other thermoplastic material depositions, comprising, for example, two or more different types of patterns, two or more different types of application techniques or processes, or two or more different types of cyclical operations, can effectively be simultaneously achieved at substantially two or more different locations relative to an underlying substrate by means of a metering station located at a first location and upon which is mounted a metering head comprising a plurality of metering head dispensing modules, and a pair or remote applicator heads, located at a second location, comprising a pair of applicator head dispensing modules. The depositions are therefore substantially independent of each other and do not interfere with each other which is important in connection with the manufacture or fabrication of particular products or articles of manufacture. 
     BACKGROUND OF THE INVENTION 
     In connection with the dispensing of hot melt adhesive or other thermoplastic materials for various different applications in conjunction with the fabrication of different products or articles upon various different production lines, or at various different locations or regions of a particular production line, two or more different hot melt adhesive or other thermoplastic material depositions, comprising, for example, two or more different types of patterns, two or more different types of application techniques or processes, or two or more different types of cyclical operations, sometimes need to be substantially simultaneously achieved at substantially two or more different locations relative to the underlying substrate. For example, in connection with the fabrication of particular articles of manufacture, it is sometimes necessary to apply or deposit the particular materials onto the underlying article substrate in accordance with different patterns, by means of different application techniques or processes, or by means of different cyclical operations. Yet further, it is desirable that the operating or application systems be relatively simple and cost-effective. For example, for example, the two or more different hot melt adhesive or other thermoplastic material depositions could of course be achieved by means of two or totally different or separate systems, however, that would not be very cost-effective. In a similar manner, or concomitantly, the physical or operative logistics would likewise be substantially problematic. 
     A need therefore exists in the art for a new and improved hot melt adhesive or other thermoplastic material dispensing system wherein two or more different hot melt adhesive or other thermoplastic material depositions, comprising, for example, two or more different types of deposition patterns, two or more different types of application techniques or processes, or two or more different types of cyclical operations, can in fact effectively be simultaneously achieved at substantially two or more different locations relative to an underlying substrate, and wherein further, the overall system is relatively simple and cost-effective. 
     SUMMARY OF THE INVENTION 
     The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system which comprises a hot melt adhesive or other thermoplastic material metering station which, in turn, comprises a metering head having a plurality of applicator modules fixedly mounted thereon for dispensing or depositing first portions of a hot melt adhesive or other thermoplastic material onto a first region of an underlying substrate in accordance with a first pattern and mode of operation. In addition, one or more hot melt adhesive or other thermoplastic material conveyance modules are also fixedly mounted upon the metering head so as to convey the hot melt adhesive or other thermoplastic material, through means of suitable hose connections, to one or more applicator heads, respectively having applicator modules fixedly mounted thereon, which are located remote from the hot melt adhesive or other thermoplastic metering station, so as to dispense or deposit second portions of the hot melt adhesive or other thermoplastic material onto a second region of the underlying substrate in accordance with a second pattern or mode of operation. In this manner, two or more different hot melt adhesive or other thermoplastic material depositions, comprising, for example, two or more different types of deposition patterns, two or more different types of application techniques or processes, or two or more different types of cyclical operations, can effectively be simultaneously achieved at substantially two or more different locations relative to the underlying substrate by means of the plurality of applicator modules mounted upon the metering head and the applicator modules mounted upon the remotely located applicator heads. In addition, it is to be appreciated that both sets of applicator modules are effectively supplied with hot melt adhesive or other thermoplastic material from the same metering station which renders the overall system cost-effective as well as relatively simple from an operational or logistical point of view. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various other features and attendant advantages of the present invention will be more fully appreciated from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein: 
         FIG. 1  is a perspective view of a new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system as constructed in accordance with the principles and teachings of the present invention and showing the cooperative parts thereof; and 
         FIG. 2  is a top plan view of the new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system as illustrated within  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, and more particularly to  FIGS. 1 and 2 , a new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system, constructed in accordance with the principles and teachings of the present invention, is disclosed and is generally indicated by the reference character  100 . More particularly, it is seen that the new and improved hybrid hot melt adhesive material or other thermoplastic material dispensing system  100  comprises a hot melt adhesive material or other thermoplastic metering station  102  which, in turn, comprises a metering head  103  and a drive gear manifold  104  upon which a plurality of rotary, gear-type metering pump assemblies  106  are mounted so as to individually output hot melt adhesive or other thermoplastic material toward the metering head  103 . While any number of rotary, gear-type metering pump assemblies  106  may be mounted upon the drive gear manifold  104 , eight rotary, gear-type metering pump assemblies  106  are illustrated, it being further appreciated that each one of the rotary, gear-type metering pump assemblies  106  effectively comprises a three-piece or three-plate sandwich construction within which the various gear members, comprising each one of the rotary, gear-type metering pump assemblies  106 , are disposed. Still further, a drive motor  108  is adapted to be operatively connected, through means of a gear box  110  and a coupling  32 , to a drive shaft, not illustrated, which is disposed within the drive gear manifold  104  and which is adapted to be operatively connected to each one of the plurality of rotary, gear-type metering pump assemblies  106 , and it is also seen that an electrical junction box  114 , for providing electrical power to the drive motor  108 , and a pair of pressure transducers  116  are operatively associated with the motor drive system. 
     An inlet port  118 , is adapted to be fluidically connected by means of a suitable supply hose, not illustrated, to a remotely located adhesive supply unit (ASU), also not illustrated, whereby a supply of the hot melt adhesive or other thermoplastic material is able to be supplied to the hot melt adhesive or other thermoplastic material metering station  102  of the hot melt adhesive or other thermoplastic material dispensing system  100 , and it is seen that the inlet port  118  is mounted upon a filter block  120  within which there is disposed a pair of filter assemblies  122 , 124 . The filter block  120  is mounted upon the drive gear manifold  104 , and it is also seen that a plurality of pressure monitoring devices or mechanisms  126  are disposed atop the drive gear manifold  104 . A plurality of first hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128 , such as, for example, six metering head dispensing or applicator modules, are mounted upon a side wall surface portion  130  of the metering head  103  so as to effectively define a horizontal transverse array of the metering head dispensing or applicator modules  128 , and a plurality of second hot melt adhesive or other thermoplastic material conveyance modules  132 , 134  such as, for example, two conveyance modules, are also adapted to be mounted upon the side wall surface portion  130  of the metering head  103  so as to be disposed upon opposite sides of the horizontal array of the first hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128 . All of the first hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128 , as well as the pair of second hot melt adhesive or other thermoplastic material conveyance modules  132 , 134 , are adapted to be respectively fluidically connected to each one of the plurality of rotary, gear-type metering pump assemblies  106  through means of suitable fluid passageways, not illustrated, which are defined within the drive gear manifold  104  such that each one of the first hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128 , as well as each one of the pair of second hot melt adhesive or other thermoplastic material conveyance modules  132 , 134 , is adapted to receive a metered supply of hot melt adhesive or other thermoplastic material from a respective one of the plurality of rotary, gear-type metering pump assemblies  106 . 
     Continuing further, in accordance with the principles and teachings of the present invention, it is seen that the plurality of first hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  respectively comprise or have dispensing nozzle assemblies  135  operatively associated therewith wherein the dispensing nozzle assemblies  135  are adapted to dispense and deposit first predetermined metered amounts of the hot melt adhesive or other thermoplastic material onto an underlying substrate  136  in accordance with first predetermined techniques or processes so as to in fact deposit the first predetermined metered amounts of the hot melt adhesive or other thermoplastic material onto first predetermined, relatively central regions of the underlying substrate  136  in accordance with first predetermined patterns  138 . It is to be noted that the deposition techniques or processes can be any one of a variety of non-contact spray-type techniques or processes, such as, for example, uniform fiber deposition, spiral spray, melt-blown, or curtain coat techniques or processes, or alternatively, the deposition techniques or processes can be any one of a variety of contact techniques or processes, such as, for example, standard slot die coating, bead coating, or rotary pattern coating. 
     Continuing still yet further, however, it is seen that unlike the plurality of first hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  having the aforenoted dispensing nozzles  135  operatively associated therewith, the pair of second hot melt adhesive or other thermoplastic material conveyance modules  132 , 134  do not have dispensing nozzle assemblies operatively associated therewith. To the contrary, each one of the pair of second hot melt adhesive or other thermoplastic material conveyance modules  132 , 134  is adapted to be fluidically connected to a first end portion of a hot melt adhesive or other thermoplastic material conveyance hose assembly  140 , 142 , while a second, oppositely disposed end portion of each one of the hot melt adhesive or other thermoplastic material conveyance hose assemblies  140 , 142  is respectively fluidically connected to a hot melt adhesive or other thermoplastic material applicator head  144 , 146  through means of a hot melt adhesive or other thermoplastic material manifold  148 , 150  and a filter block  152 , 154 . 
     The hot melt adhesive or other thermoplastic material applicator heads  144 , 146  respectively have hot melt adhesive or other thermoplastic material dispensing or applicator modules  156 , 158  fixedly mounted thereon, and respectively comprise or have dispensing nozzle assemblies  160 , 162  operatively associated therewith wherein the dispensing nozzle assemblies  160 , 162  are adapted to dispense and deposit second predetermined metered amounts of the hot melt adhesive or other thermoplastic material onto the underlying substrate  136  in accordance with second predetermined techniques or processes so as to in fact deposit the second predetermined metered amounts of the hot melt adhesive or other thermoplastic material onto second predetermined regions of the underlying substrate  136 , upon lateral sides or outside of the first relatively centralized regions  138  of the underlying substrate  136 , in accordance with second predetermined patterns  164 , 166 . As was the case with the deposition techniques or processes characteristic of the dispensing nozzle assemblies  135 , the deposition techniques or processes characteristic of the dispensing nozzle assemblies  160 , 162  can be any one of a variety of non-contact spray-type techniques or processes, such as, for example, uniform fiber deposition, spiral spray, melt-blown, or curtain coat techniques or processes, or alternatively, the deposition techniques or processes can be any one of a variety of contact techniques or processes, such as, for example, standard slot die coating, bead coating, or rotary pattern coating. 
     It is to be noted further that a first supply air coupling, not visible, is provided upon each one of the applicator heads  144 , 146  so as to respectively supply air into each applicator head  144 , 146  for mixture with the incoming hot melt adhesive or other thermoplastic material being supplied to each one of the applicator heads  144 , 146  by means of its respective hose assembly  140 , 142 , and first electrical connectors for electrical connections to supply air pre-heater mechanisms, also not illustrated, are disclosed at  168 ,  170 . In addition, second electrical connectors, for electrical connections to hot melt adhesive or other thermoplastic material pre-heater mechanisms, also not illustrated, are disclosed at  172 , 174 , and second and third sets of air couplings  176 , 178  and  180 , 182  are provided for conducting control air into the hot melt adhesive or other thermoplastic material manifolds  148 , 150  in order to control the disposition of the hot melt adhesive or other thermoplastic material dispensing control valve mechanisms, not illustrated but respectively disposed within the hot melt adhesive or other thermoplastic material manifolds  148 , 150 , for controlling the dispensing of the hot melt adhesive or other thermoplastic material to the output or dispensing nozzle assemblies  160 ,  162 . 
     Having described substantially all of the structural components comprising the new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system  100  of the present invention, as constructed and operatively interengaged with each other in accordance with the principles and teachings of the present invention, the practical and operational significance and advantages of the new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system  100  of the present invention will now be discussed. More particularly, for example, it is to be appreciated that in accordance with the principles and teachings of the present invention, two different types of hot melt adhesive or other thermoplastic material depositions onto the underlying substrate  136  can be achieved at or upon two different locations or regions of the underlying substrate  136  by means of, for example, the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135 , and the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  which are located at positions or locations remote from, and upstream of, the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135  as considered in the direction of movement of the underlying substrate  136  along the substrate flow path SFP. 
     As has been noted hereinbefore, the deposition processes or techniques of either one of the sets of dispensing nozzle assemblies  135 , or of the dispensing nozzle assemblies  160 ,  162  can be any one of the variety of non-contact spray-type techniques or processes, such as, for example, uniform fiber deposition, spiral spray, melt-blown, or curtain coat techniques or processes, or alternatively, the deposition techniques or processes can be any one of a variety of contact techniques or processes, such as, for example, standard slot die coating, bead coating, or rotary pattern coating. It is therefore to be appreciated that two or more different hot melt adhesive or other thermoplastic material depositions, comprising, for example, two or more different types of deposition patterns, two or more different types of application techniques or processes, or two or more different types of cyclical operations, can effectively be simultaneously and independently achieved at substantially two or more different locations relative to the underlying substrate  136  by means of the plurality of applicator modules  128  and their dispensing nozzle assemblies  135  mounted upon the metering head  103 , and the applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  mounted upon the remotely located applicator heads  144 , 146 . 
     In addition, it is to be appreciated that while the aforenoted substrate deposition results comprising, for example, the two or more different hot melt adhesive or other thermoplastic material depositions encompassing the two or more different types of deposition patterns, the two or more different types of application techniques or processes, or the two or more different types of cyclic operations, could effectively be otherwise simultaneously and independently achieved at the substantially two or more different locations relative to the underlying substrate  136  by, for example, a first set of metering head applicator modules and metering head dispensing nozzle assemblies similar to the plurality of metering head applicator modules  128  and the metering head dispensing nozzle assemblies  135  mounted upon the metering head  103 , and a second set of remotely located metering head applicator modules and metering head dispensing nozzle assemblies in lieu of the applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  mounted upon the remotely located applicator heads  144 , 146 , such a system would be extremely costly and logistically problematic in view of the fact that separate metering stations, similar to metering station  102 , would have to be disposed or positioned at each location at which one would want to achieve a particular independent deposition pattern, application technique or process, or cyclical operation. Accordingly, multiple motor drives, multiple sets of rotary, gear-type metering pump assemblies, multiple metering heads, and the like, would be required. 
     To the contrary, however, in accordance with the new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system  100  as constructed in accordance with the principles and teachings of the present invention, only the one metering station  102  is necessary for the supply of the hot melt adhesive or other thermoplastic material to both of the aforenoted first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135 , and the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  which are located at positions or locations remote from, and upstream of, the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135  as considered in the direction of movement of the underlying substrate  136  along the substrate flow path SFP. Accordingly, the overall hybrid system is effectively rendered quite cost-effective as well as relatively simple from an operational or logistical point of view. 
     Furthermore, it is also to be noted that as a result of locating the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  at positions or locations which are remote from and upstream of the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135 , as considered in the direction of movement of the underlying substrate  136  along the substrate flow path SFP, the particular deposition patterns, for example, dispensed from the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  will not interfere with the particular deposition patterns, for example, which are dispensed from the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135 . In addition, the re-verse also holds true, that is, the particular deposition patterns dispensed from the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135  will not interfere with the particular deposition patterns which are dispensed from the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162 . 
     Still further, it is to be noted that, in accordance with the particular structural requirements or characteristics of particular products or articles of manufacture, the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135  may necessarily be activated or run in accordance with different modes of operation than the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 ,  162 . For example, the first set of hot melt adhesive or other thermoplastic material metering head dispensing or applicator modules  128  and their dispensing nozzle assemblies  135  may be activated or run substantially continuously throughout the production or fabrication of a particular product or article of manufacture, whereas the second set of hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  may be run substantially intermittently. In conjunction with such production line operations, it is noted that the hose assemblies  140 , 142  may be flexible or rigid, heated or non-heated, depending upon the particular material being conveyed for dispensing and deposition, and may have length dimensions anywhere within a range, for example, of 50 mm to 25 meters. It is to be lastly appreciated that by incorporating the hose assemblies  140 , 142  into the aforenoted hybrid system  100 , the hose assemblies  140 , 142  will effectively serve as fluid accumulators whereby the hot melt adhesive or other thermoplastic material, being outputted by means of the particular ones of the rotary, gear-type metering pump assemblies  106  fluidically connected to the hot melt adhesive or other thermoplastic material conveyance modules  132 , 134 , will always be available to the hot melt adhesive or other thermoplastic material applicator head dispensing or applicator modules  156 , 158  and their dispensing nozzle assemblies  160 , 162  in the desired amounts and at requisite supply pressures. 
     Thus, it may be seen that in accordance with the teachings and principles of the present invention, there has been provided a new and improved hybrid hot melt adhesive or other thermoplastic material dispensing system which comprises a hot melt adhesive or other thermoplastic material metering station which, in turn, comprises a metering head having a plurality of applicator modules fixedly mounted thereon for dispensing or depositing a first hot melt adhesive or other thermoplastic material onto a first region of an underlying substrate in accordance with a first pattern and mode of operation. In addition, one or more hot melt adhesive or other thermoplastic material conveyance modules are also fixedly mounted upon the metering head so as to convey the hot melt adhesive or other thermoplastic material, through means of suitable hose connections, to one or more applicator heads, respectively having applicator modules fixedly mounted thereon, which are located remote from the hot melt adhesive or other thermoplastic metering station, so as to dispense or deposit a second hot melt adhesive or other thermoplastic material onto a second region of the underlying substrate in accordance with a second pattern or mode of operation. In this manner, two or more different hot melt adhesive or other thermoplastic material depositions, comprising, for example, two or more different types of deposition patterns, two or more different types of application techniques or processes, or two or more different types of cyclical operations, can effectively be simultaneously achieved at substantially two or more different locations relative to the underlying substrate by means of the plurality of applicator modules mounted upon the metering head and the applicator modules mounted upon the remotely located applicator heads. It is also to be appreciated that both sets of applicator modules are effectively supplied with hot melt adhesive or other thermoplastic material from the same metering station which renders the overall system cost-effective as well as relatively simple from an operational or logistical point of view. 
     Obviously, many variations and modifications of the present invention are possible in light of the above teachings. It is noted, for example, that while the disclosure has been directed toward the deposition of hot melt adhesive or other thermoplastic materials, the disclosed hybrid dispensing system can likewise be utilized to dispense other fluids, comprising, for example, non-thermoplastic materials. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.