Patent Application
20160199861
The use of flowable materials, such as hot melt adhesives, thermoplastics, and resins, for example, is widespread in the manufacture and assembly of goods, such as textiles, packaging, and the like. Such flowable materials generally begin as raw materials in the form of solid pellets or highly viscous compounds, for example, which are heated into a flowable mass and deposited onto a targeted workpiece.
Various manufacturing equipment has been developed for depositing such material. However, much of this equipment is quite large and occupies a large footprint making them unsuitable for individual use within individual work spaces. In addition, the raw material is often melted directly within and transferred through the structure of the equipment making cleaning and maintenance a tedious operation, which can lead to significant downtime.
Certain handheld devices for dispensing flowable material currently exist, which are generally in the form of a gun. These devices generally store raw materials in hoppers or cartridges from which the flowable material is ejected upon the actuation of a trigger mechanism. However, these devices require at least one hand to operate and prolonged use can lead to muscle fatigue and/or repetitive motion injuries, such as carpal tunnel. Moreover, these devices may still require significant clean-up after use and often lack precise control over the deposition location and amount of material being deposited.
In one aspect of the disclosure, a system for dispensing a flowable material from a cartridge body includes a housing for receiving the cartridge body. Also included in the system is a nozzle, which is one of attachable to or integral with a dispensing end of the cartridge body and has an inner surface that defines a passageway for the flowable material and an outer surface. A flow control block is attachable to the housing and includes an inner surface that defines an in inlet passage and an outlet passage. The inlet passage is sized to receive at least a portion of the nozzle therein. The inner surface of the flow control block is configured to mate with the outer surface of the nozzle in a sealing relationship when at least a portion of the nozzle is disposed within the inlet passage.
Additionally, the housing may include an inner surface that defines a cavity for receipt of the cartridge body and a first end with a first cap attached thereto. The first cap may have an opening in communication with the cavity. The opening may be sized to allow passage of the at least a portion of the nozzle through the opening while prohibiting passage of the cartridge body. The flow control block may be attachable to the first end of the housing such that the inlet passage aligns with the opening of the first cap. The housing may include a second end that has a second cap attachable thereto. The second cap may be movable from a first position to a second position in which the second cap presses against the cartridge body when the cartridge body is at least partially disposed within the cavity of the housing. The second cap may be attached to the second end via a linkage system that includes a plurality of pivot locations. When the second cap is in the second position at least three of the plurality of pivot locations may substantially align in a linear alignment to lock the second cap into the second position.
Continuing with this aspect, the housing may include a locking ring at a first end thereof having an open position and a closed position. The flow control block may include a mounting adapter positionable within the locking ring. When the mounting adaptor is positioned with the locking ring, the locking ring and flow control block may be rotatable with respect to the housing while the locking ring is in the open position and prohibited from rotation with respect to the housing while the locking ring is in the closed position.
Further, the outer surface of the nozzle may include a first tapered region and the inner surface of the flow control block may include a second tapered region. The first and second tapered regions may be correspondingly tapered. Alternatively, the outer surface of the nozzle may define a first mating region that is normal to a longitudinal axis defined by the passageway of the nozzle, and the inner surface of the flow control block may include a second mating region that is normal to a longitudinal axis defined by the inlet passage. The first and second mating regions may be correspondingly sized so as to compress a gasket therebetween.
Moreover, the inlet passage may be orthogonal to the outlet passage. The inlet passage and outlet passage may also intersect at a corner. The inlet passage and nozzle may be sized such that when the nozzle is fully received within the inlet passage, an end of the nozzle is positioned substantially flush with the corner. The flow control block may also include a removable plug that when removed from the flow control block opens an access passage that communicates with both the inlet and outlet passages. The outlet passage may include a piston slidably disposed therein that is moveable from a first position to a second position such that in the first position, the inlet passage opens to the outlet passage, and in the second position, the inlet passage is sealed off from the outlet passage by the piston.
In another aspect of the disclosure, a system for dispensing a flowable material from a cartridge having a cartridge body includes a housing. The housing has first and a second ends and an inner surface defining a cavity therebetween sized to receive the cartridge body. The first end has a first cap attached thereto. The second end has a second cap attached thereto. The first cap has an opening extending therethrough and is in communication with the cavity. The system also includes a nozzle integral with or attachable to a dispensing end of the cartridge body and sized to at least partially extend through the opening of the first cap. Additionally, the system includes a flow control block that includes an inner surface that defines a passageway and is connectable to the first cap of the housing such that the opening of the first cap aligns with the passageway. The passageway has an inlet sized to receive a first portion of the nozzle therein.
Additionally the second cap may be hingedly attached to the housing and may be moveable from a first position to a second position in which the second cap applies a force to the cartridge when the cartridge is at least partially disposed within the cavity.
Further, the nozzle may include a second portion. The first portion may have a first cross-sectional dimension smaller than a second cross-sectional dimension of the second portion. The first portion of the nozzle may be tapered and the inner surface of flow control block may include a tapered region that is correspondingly tapered with the first portion such that the force applied by the second cap on the cartridge forms a seal between the first portion and tapered region. Also, a first transverse surface may be defined between first and second portions of the nozzle, and the inlet of the passageway may include first and second sections. The first section may be narrower than the second section, which defines a second transverse surface between the first and second sections. The first section may be sized to receive the first portion and the second section may be sized to receive the second portion such that a gasket positioned about the first portion is compressed between the first and second transverse surfaces when the force is applied on the cartridge by the second cap.
Continuing with this aspect, the second cap may include a cartridge contact surface having a gasket disposed thereon and a cannulated puncture screw extending therefrom. The second cap may be attached to the housing by a lever mechanism. The lever mechanism may include four members and four hinges. Each member may be connected to an adjacent member via one of the four hinges. The second cap may be pivotably attached to a support member via a mounting ball.
In a further aspect of the disclosure, a method for dispensing a flowable material from a cartridge includes loading the cartridge having a nozzle into a housing such that the nozzle extends through an opening at a front-end of the housing and into a flow control block having inlet and outlet passages. The method also includes applying force via an end cap of the housing to an end of the cartridge opposite the nozzle to sealingly mate the nozzle to an inner surface defining the inlet passage of the flow control block, and pressurizing the cartridge.
Additionally, the method may include actuating a piston disposed within the outlet passage from a first position in which the piston blocks the inlet passage from the outlet passage to a second position in which the inlet and outlet passages are in fluid communication.
the features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings in which:
As used herein, the terms “about,” “generally” and “substantially” are intended to mean that slight deviations from absolute are included within the scope of the term so modified.
Housing 20 defines a cavity for receipt of a cartridge containing flowable material. The cavity and housing 20 may be shaped to correspond with the shape of the cartridge, such as the cylindrical shape, as depicted, or some other shape, such as a prism. A mount 18 may be attached to housing 20, which allows system 10 to be attached to any number of surfaces, such as a table or a wall, for example. A first cap 80 or front cap is attached at one end of housing 20. A second cap 32 or rear cap is attached at the other end of housing 20.
A band heater 14 may be attached to an outer surface of housing 20. Housing 20 may be made from a conductive material, such as aluminum or steel, for example, which facilitates the transfer of heat through housing 20 to the cartridge from band heater 14. Insulation may be applied to the remainder of the outer surface of housing 20 to reduce heat loss and protect an operator from inadvertent contact. A temperature sensor 16a may be attached to the housing adjacent band heater 14. Temperature sensor 16a may also be connected to a control unit that regulates the temperature of the flowable material.
Mounting ball 34 is fitted into a spherical notch 31 in second cap 31. A retainer 35, also having a spherical notch, is attached to mounting ball 34. Retainer 35 can be adjusted to reduce or increase the amount second cap 32 can pivot about mounting ball 34.
Puncture element 37 is preferably cannulated and extends through second cap 32 from one end to another. An adapter 38 and pneumatic hose 12 is coupled to puncture element 37. Generally, the length of puncture element 37 is such that when a cartridge is sealed by gasket 33, puncture element 37 penetrates through an end of the cartridge at least enough to deliver gas to the inner chamber of the cartridge via pneumatic hose 12.
Hinge points 42a-d and linking members 44a-d are arranged in such a way that when second cap 32 is moved into the closed position, second cap 32 applies axial force to a cartridge within housing 20 and linkage system 40 locks second cap assembly 30 in place. In the particular embodiment depicted in
While a locking, four-bar mechanism is preferred, other mechanisms utilizing less than or more than four hinge points and linking members are possible. In one alternative embodiment, a linkage system (not shown) may include at least one hinge point that couples second cap assembly 30 to housing 20 and allows second cap assembly 30 to rotate between open and closed positions. Once in a closed position, a threaded element attached to second cap 32 may be threaded into an aperture attached to housing 20 to lock cap 32 in the closed position.
Nozzle 70 is generally cylindrical and includes a passageway 78 extending therethrough and a first portion 72 and second portion 74. First portion 72 has a smaller diameter than second portion 76. The difference in diameters forms a transverse surface 76 or shoulder. An O-ring 79 or gasket is fitted about first section 72 and abuts transverse surface 76.
A flow control block 90 is attachable to housing 20 via first cap 80. Flow control block 90 may be provided as a component of an extruder, such as extruder 50 shown in
Flow control block 90 includes an inner surface that defines an inlet passage 92 and an outlet passage 94. As depicted, inlet passage 92 and outlet passage 94 intersect at about a perpendicular angle. However, other angles are envisioned such as a 60, 45, 30 or 0 degree angle, for example. Inlet passage 92 extends beyond the intersection with outlet passage 94 where a removable plug 96 is coupled to flow control block 90. Removable plug 96 is preferably threaded into flow control block 90 and can be removed to gain access to inlet and outlet passages 92 and 94 to remove obstructions or for other reasons. Outlet passage 94 extends beyond the intersection with inlet passage 92, which provides a channel for piston 52.
The inner surface of flow control block 90 at inlet passage 92 includes surface features that correspond with the structure of nozzle 70. In the embodiment depicted in
Generally, first portion 72 of nozzle 70 has a length such that the end face 77 of first portion 72 lies substantially flush with a corner 99 formed by the intersection of inlet and outlet passage 92 and 94. This allows for substantially all of the flowable material to flow directly into outlet passage 94, which facilitates an easier clean-up and helps reduce opportunities for obstructions. In addition, since the flowable material is deposited from cartridge 60 directly into flow control block 90, which is attachable to housing 20, flow control block 90 could be easily removed and replaced without having to go through an extensive cleaning process.
While it has been described that nozzle 70 and inlet passage 92 have features with diameters, other shapes, such as a prism, are envisioned. In such a case, the cross-sectional dimension of first section 93 would be smaller than second section 95, and a cross-sectional dimension of first portion 72 of the nozzle would be smaller than a cross-sectional dimension of second portion 74.
Flow control block 90 also preferably includes a mounting adapter 98. This mounting adapter 98 is optional and is attachable to or integral with the remainder of the mounting block structure. This adapter 98 includes also includes an extension of inlet passage 92 and an inner surface that may also include additional features corresponding with nozzle 70. Mounting adapter 98 has a generally cylindrical outer surface and fits within locking ring 82 of first cap 80 (best shown in
In addition, as shown in
Generally, in a method of operation, nozzle 70 is attached to cartridge 60. Cartridge 60 and nozzle 70 are then loaded into the cavity of housing 20 such that nozzle 70 at least partially passes through opening 86 of first cap 80 and into flow control block 90. Handle 46 is actuated to operate linkage system 40 and move second cap assembly 30 into the closed position. While handle 46 is actuated, puncture element 37 punctures diaphragm plate. When the locking position is reached, pivot points 42a-c align in a substantially linear arrangement, gasket 33 seals against rim 67, and second cap 32 applies axial force to cartridge 60 helping portions 72 and 74 of nozzle 70 interface with the inner surface of inlet passage 92 of flow control block 90 to form a sealing relationship.
More specifically, in the method of operation, flow control block 90 is connected to housing 20 by inserting mounting adapter 98 into locking ring 82 while locking ring 82 is in an open configuration. Flow control block 90 is rotated to the desired orientation, and locking ring 82 is tightened to a closed configuration.
Cartridge 60 is obtained, and nozzle 70 is attached to dispensing end 64 of cartridge 60. Of course, in some embodiments where nozzle 70 is integral with cartridge body 62, this step can be skipped. With linkage system 40 and second cap assembly 30 in the open position, cartridge 60 is inserted into the cavity of housing 20. Nozzle 70 partially passes through opening 86 in first cap 80, first portion 72 of nozzle enters into first section 93 of flow control block 90, second portion 74 enters into second section 95 of flow control block 90, and gasket 33 contacts both transverse surfaces 76 and 97.
Thereafter, the linkage system 40 is actuated via handle 46, which moves second cap assembly 30. Penetration element 37 contacts diaphragm plate 68 of cartridge 60, which then provides some resistance to the operator. Additional force may be applied, which pierces diaphragm 68. When gasket 33 contacts rim 67, second cap 32 may pivot about mounting ball 34 until gasket 33 is fully aligned with rim 66. Force is continuously applied to handle 46 until the first, second, and third pivot points 42a-c are aligned, as shown in
Gas is pumped through puncture element 37 to pressurize the internal contents of cartridge 60. Housing 20 enhances the cartridge's structural integrity during this process. In addition, linkage system 40 resists additional loads applied by the dispensing and pressurization. Depending on the material being dispensed, band heater 14 may transfer heat to the material within cartridge 60 to enhance flowabilty.
Piston 52 of extruder 50 may be pneumatically or electrically controlled and may be automated such that material dispenses for a precise duration at precise intervals. Alternatively, an operator may have a foot pedal to actuate piston 52, which allows the operator to utilize both hands to control a workpiece during operation. The piston's operation may be calibrated to dispense a precise amount of flowable material giving the operator repeatable results.
When the material is dispensed, it exits nozzle 70 and enters directly into outlet passage 94 of flow control block 90 and then dispensed to the outside. In the event a different extruder or flow control block is desired, flow control block 90 can be quickly removed by opening locking ring 82. Additionally, adjustments may be made by the operator to the orientation of flow control block 90 with respect to housing 20. Once cartridge 60 is empty, linkage system 40 is actuated to open second cap assembly 80 and a new cartridge is inserted thereafter with minimal downtime.
Flow control block 190 is similar to flow control block 90 with the difference being that the inner surface of inlet passage 192 is specifically configured to correspond with first and second portions 172, 174 of nozzle 170. Thus, first portion 172 and first section 193 are correspondingly tapered to provide a taper-lock when fully engaged. This taper-lock provides a sealing relationship to prohibit the flowable material from leaking through this tapered interface during operation. In such a relationship, an O-ring may not be needed.
The method of using these alternative embodiments is substantially similar with the difference being the interaction between flow control block 190 and nozzle 170 is slightly modified due to their alternative geometries.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
