HOT MELT ADHESIVE FOAM DISPENSING SYSTEM

TECHNICAL FIELD

This disclosure generally relates to hot melt adhesive foam dispensing systems, and more particularly to devices and methods for controlling the dispensing of hot melt adhesive foam onto a substrate from foam dispensing systems.

BACKGROUND

Hot melt thermoplastic adhesives are used in a number of applications such as packaging and product assembly. In conventional hot melt adhesive foam dispensing systems, a pump supplies an adhesive and gas solution to an adhesive dispenser, which can be referred to as a gun. The gun contains a valve at an outlet nozzle through which the solution is dispensed to atmospheric pressure. When the solution is dispensed, the gas is released from the solution to become entrapped in the adhesive to form a foam on a substrate to which the adhesive is applied.

During operation of conventional hot melt adhesive foam dispensing systems, it is desirable to maintain a consistent quality of hot melt adhesive foam applied to the substrate, such that the substrate with the applied foam meets particular product specifications. This can require increasing or decreasing the amount of gas mixed with the hot melt adhesive to produce the solution over time. However, various characteristics of the solution and system can change over time, which can affect the quality of the hot melt adhesive foam ultimately applied to the substrate. These characteristics, such as speed of the pump and viscosity and temperature of the solution, can be hard to simultaneously account for, which can lead to the production of hot melt adhesive foam having inferior quality. Additionally, detection devices that are particularly sensitive to viscosity and/or temperature changes in the solution can also be sensitive to changes in the gas content of the solution, which can lead to inaccurate characterization of certain aspects of the solution, and thus poor quality hot melt adhesive foam.

As a result, there is a need for a dispensing system that can characterize aspects of the hot melt adhesive and gas containing solution regardless of changes in the viscosity, temperature, and/or gas content of the solution in order to produce hot melt adhesive foam having consistent quality.

SUMMARY

An embodiment of the present disclosure is a dispensing system for dispensing hot melt adhesive foam onto a substrate. The dispensing system comprises a pump having a first input configured to receive a hot melt adhesive and a second input configured to receive a gas, where the pump is configured to mix the hot melt adhesive and the gas to produce a solution and pump the solution at a volumetric flow rate. The dispensing system also includes a valve configured to control an amount of the gas provided to the pump through the second input, a flow meter configured to measure the volumetric flow rate of the solution pumped by the pump, and a dispenser configured to receive the solution from the pump and dispense the solution to create the hot melt adhesive foam.

Another embodiment of the present disclosure is a method of dispensing hot melt adhesive foam onto a substrate. The method includes receiving a hot melt adhesive from a hot melt adhesive source, receiving a gas from a gas source, and mixing the hot melt adhesive and the gas to produce a solution. The method also includes pumping the solution from a pump to a dispenser at a volumetric flow rate, measuring the volumetric flow rate of the solution via a flow meter, and dispensing the solution to create the hot melt adhesive foam.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings. The drawings show illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown.

FIG. 1 illustrates a schematic diagram of a dispensing system according to an embodiment of the present disclosure;

FIG. 2 is top perspective view of a gear flow meter according to one example that may be used to implement the flow meter of the dispensing system shown in FIG. 1:

FIG. 3 is atop perspective view of the flow meter of FIG. 2 with the housing cover removed;

FIG. 4 is a top exploded perspective view of the flow meter of FIG. 2;

FIG. 5 is a bottom partially exploded perspective view of the flow meter of FIG. 2;

FIG. 6 is a perspective view of a bottom portion of the flow meter of FIG. 2;

FIG. 7 is a cross-sectional view of the housing cover of the flow meter of FIG. 2 taken along line 7-7 of FIG. 6;

FIG. 8 illustrates a perspective view of a gear flow meter according to another example that may be used to implement the flow meter of the dispensing system shown in FIG. 1;

FIG. 9 illustrates a plan view of the gear flow meter shown in FIG. 8:

FIG. 10 illustrates a bottom view of the gear flow meter shown in FIG. 8;

FIG. 11 illustrates a longitudinal cross-sectional view of the gear flow meter shown in FIG. 8; taken along line A-A in FIG. 9;

FIG. 12 illustrates a longitudinal cross-sectional view of the gear flow meter shown in FIG. 8; taken along line B-B in FIG. 9:

FIG. 13 illustrates an enlarged view of a portion of the gear flow meter shown in FIG. 12;

FIG. 14 illustrates a process flow diagram of a method of dispensing hot melt adhesive foam onto a substrate according to an embodiment of the present disclosure:

FIG. 15 illustrates a simplified flow diagram of a method of determining percent density reduction according to one example:

FIG. 16 illustrates a simplified flow diagram of a method of determining percent density reduction according to another example;

FIG. 17 illustrates a simplified flow diagram of a method of determining density of an adhesive or foam according to one example; and

FIG. 18 illustrates a simplified flow diagram of a method of determining density of an adhesive or foam according to another example.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

With initial reference to FIG. 1, a dispensing system 10 for dispensing hot melt adhesive foam onto a substrate in accordance with an embodiment of the present disclosure can include a pump 11. The pump 11 can be a gear pump, such as (without limitation) a two-stage pump having a first stage 12 and a second stage 13, or any other suitable pump. Each of the first and second stages 12, 13 can include oppositely rotating and meshed gear pairs. For example, the first stage 12 of the pump 11 can include a first gear 12a and a second gear 12b. Similarly, the second stage 13 of the pump 11 can include a first gear 13a and a second gear 13b. In one embodiment, the first gears 12a, 13a of each of the first and second stages 12, 13 define driven gears that are connected by a common drive shaft 14. In this embodiment, the second gears 12b, 13b of each of the first and second stages 12, 13 define idler gears that are connected by a common idler shaft 16. The pump 11 can include a first input 10a configured to receive a hot melt adhesive. Specifically, the hot melt adhesive can be provided to the pump 11 through the first input 10a from a hot melt adhesive source 17. The hot melt adhesive source 17 can be a conventional adhesive melter configured to store solid adhesive, melt the solid adhesive into hot melt adhesive, and selectively provide the pump 11 with the hot melt adhesive. However, the hot melt adhesive source 17 can be any conventional type of hot melt adhesive source as desired.

Once received through the first input 10a, the hot melt adhesive can be fed at atmospheric pressure into a low pressure inlet 18 of the first stage 12 of the pump 11. The first stage 12 can also include an outlet 19, such that the first stage 12 can deliver the hot melt adhesive to the outlet 19 at a metered rate. After exiting the outlet 19 of the first stage 12, the hot melt adhesive can be introduced into an inlet 21 of the second stage 13 of the pump 11 flowing at the metered rate. In addition to the hot melt adhesive, gas can be provided from a gas source 22 into a second input 10b of the pump 11. Specifically, the gas can flow from the gas source 22, through a gas line 23, through the second input 10b, and into the inlet 21 of the second stage 13. The gas may be, for example, nitrogen, air, or carbon dioxide, though other gasses are contemplated. The dispensing system 10 can also include a gas valve 24 in fluid communication with the gas line 23 between the gas source 22 and the second input 10b. The gas valve 24 can be configured to control an amount of gas provided to the pump 11 through the second input 10b. The operation of the gas valve 24 will be described in more detail hereinafter.

After being received through the inlet 21 of the second stage 13, the gas from the gas source 22 and the hot melt adhesive from the outlet 19 of the first stage 12 are mixed in the second stage 13 of the pump 11. The pump 11 is configured to mix the hot melt adhesive and the gas under such pressure that the gas goes into solution with the molten adhesive. The pump 11 can then pump the solution at a volumetric flow rate from an outlet 26 of the second stage 13 of the pump 11. After exiting the outlet 26, a temperature sensor 56 in fluid communication with the solution can be configured to detect a temperature of the solution. In the depicted embodiment, the temperature sensor 56 can be positioned adjacent the outlet 26 of the second stage 13, though other positions are contemplated. Additionally, a heat exchanger 57 can be positioned adjacent the outlet 26, where the heat exchanger can be configured to selectively decrease the temperature of the solution exiting the outlet 26. The solution can then flow through a filter 27 to a flow meter 100. As such, the filter 27 can be fluidly disposed between the pump 11 and the flow meter 100. The filter 27 can be configured to separate any hardened particles of the hot melt adhesive that may have solidified while passing through the pump 11 or were never melted by the hot melt adhesive source 17. The flow meter 100 can be configured to measure the volumetric flow rate of the solution pumped by the pump 11, as will be described further below. Thus, the flow meter 100 can be implemented as a volumetric flow meter. In some examples, the flow meter 100 can be implemented as a gear flow meter; however, it will be understood that other suitable flow meters may be employed. After flowing through the flow meter 100, the solution can be provided to a dispenser 28, which can comprise a valved adhesive dispensing gun. The dispenser 28 can be configured to receive the solution from the pump 11 and dispense the solution onto a substrate so as to create a hot melt adhesive foam, as the gas previously comprising the solution will be released from the solution and become entrapped in the adhesive.

During normal operation of the system, the solution that flows from the outlet 26 of the second stage 13 of the pump 11 is fluidly coupled to the first input 10a of the pump 11. For example, the dispensing system 10 can include a first recirculation channel 35 and a second recirculation channel 29 configured to selectively direct the solution from the dispenser 28 to the pump 11. The dispenser 28 can include a dispenser valve 32 that is configured to be transitioned between an open position, in which the dispenser 28 dispenses at least a portion of the solution, and a closed position, in which the dispenser 28 dispenses none of the solution, to dispense the solution onto a substrate to form the hot melt adhesive foam. When the dispenser valve 32 is in an open position, and thus the dispenser 28 is dispensing the solution, a portion, such as for example 75%, of the solution is recirculated through the first and second recirculation channels 35, 29. Likewise, the remaining 25% of the flow of solution from the pump 11 can be dispensed by the dispenser 28. Though one particular split of the solution is described, this is exemplary only and the solution can be split in different percentages as desired. For example, any percentage from 1% to 100% of the solution can be dispensed from the dispenser 28 when the dispenser valve 32 is in the open position. When the dispenser valve 32 is closed, all of the solution flowing from the outlet 26 of the second stage 13 of the pump 11 can be recirculated through the second recirculation channel 29.

The dispensing system 10 can include a translucent panel 43 connected to the dispenser 28. The translucent panel 43 can comprise a window that allows an operator of the dispensing system 10 to view the solution, and particularly the gas bubbles within the solution, as the solution flows into the first recirculation channel 35. As objectively measuring quality of the hot melt adhesive foam applied to the substrate can be difficult using various measuring devices, the translucent panel 43 allows the operator to easily monitor solution quality and make adjustments to the operation of the dispensing system 10 accordingly. The operator can also monitor the quality of the hot melt adhesive foam being dispensed from the dispenser 28 and make adjustments to the operation of the dispensing system 10 accordingly.

As the amount of solution flowing through the first and second recirculation channels 35, 29 can vary as described above during operation of the dispensing system 10, the pressure of the solution within the dispenser 28 can be affected by the pressure of the material flowing through the first and second recirculation channels 35, 29. As such, the dispensing system 10 can contain devices for controlling the pressure of the solution flowing through the first and second recirculation channels 35, 29. In one embodiment, the dispensing system 10 can include a pressure regulator 31 in fluid communication with the first and second recirculation channels 35, 29, where the pressure regulator 31 is configured to control the pressure of solution flowing through the first recirculation channel 35. Though the pressure regulator 31 is depicted as connected to the first recirculation channel 35, in other embodiments the pressure regulator 31 can be connected to the second recirculation channel 29. The pressure regulator 31 can be controlled by a transducer 52, such as an electro-pneumatic (E/P) transducer that is configured to selectively actuate the pressure regulator. However, any conventional device for controlling operation of a pressure regulator 31 can alternatively be utilized.

The dispensing system 10 can also include a pressure sensor 44 in fluid communication with the first recirculation channel 35, where the pressure sensor 44 is configured to measure the pressure of the solution flowing through the first recirculation channel 35 upstream from the pressure regulator 31. The pressure sensor 44 can be a pressure transducer, though other conventional pressure-measuring devices can be utilized. Both the transducer 52 and the pressure sensor 44 can be in signal communication with a controller 48, where the controller 48 is configured to receive signals from the pressure sensor 44 that are indicative of the pressure of the solution flowing through the first recirculation channel 35. The controller 48 can utilize this signal to control the transducer 52, and thus the pressure regulator 31, so as to instruct the transducer 52 to actuate the pressure regulator 31 based on the pressure measured by the pressure sensors 44. As a result, the dispensing system 10 can maintain a substantially consistent pressure of the solution at the dispenser 28. In one embodiment, the controller 48 is a PID controller. However, the controller 48 can alternatively be a proportional controller, or any other type of controller capable of controlling the transducer 52 based upon signals received from the pressure sensor 44. Further, the controller 48 can be configured to receive a user input from an operator of the dispensing system 10 so as to set the desired pressure of the solution flowing through the first recirculation channel 35.

During operation of the dispensing system 10, the solution can become blocked within various components of the system. For example, the solution can become blocked as the solution flows through the outlet 26 of the second stage 13 of the pump 11, such as in the filter 27 or the dispenser 28. Such blockages can result in a pressure buildup at the outlet 26, thus negatively affecting operation of the dispensing system 10. To prevent this, the dispensing system 10 can include a pressure relief path 34 that is in communication with the outlet 26 of the second stage 13 of the pump 11 and extends to the second recirculation channel 29. A pressure relief valve 33 can be connected to the pressure relief path 34 and can be configured to open upon the pressure of fluid flowing from the outlet 26 reaching a predetermined threshold. When the pressure of the solution reaches the predetermined threshold, opening of the pressure relief valve 33 allows the solution to escape to the second recirculation channel 29 and flow to the first input 10a of the pump 11. Accordingly, the pressure relief valve 33 and pressure relief path 34 can prevent excessively pressurized solution from building up at the outlet 26 of the second stage 13 of the pump 11.

To control the various components of the dispensing system 10, the dispensing system 10 can include a controller 37. In one embodiment, the controller 37 can comprise a PID controller. In another embodiment, the controller 37 can comprise a proportional controller. However, it is contemplated that the controller 37 can comprise any suitable computing device configured to host a software application for monitoring and controlling various operations of the dispensing system 10 as described herein. It will be understood that the controller 37 can include any appropriate computing device, examples of which include a processor, a desktop computing device, a server computing device, or a portable computing device, such as a laptop, tablet, or smart phone. Specifically, the controller 37 can include a memory 40 and a human-machine interface (HMI) device 41. The memory 40 can be volatile (such as some types of RAM), non-volatile (such as ROM, flash memory, etc.), or a combination thereof. The controller 37 can include additional storage (e.g., removable storage and/or non-removable storage) including, but not limited to, tape, flash memory, smart cards, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, universal serial bus (USB) compatible memory, or any other medium which can be used to store information and which can be accessed by the controller 37. The HMI device 41 can include inputs that provide the ability to control the controller 37, via, for example, buttons, soft keys, a mouse, voice actuated controls, a touch screen, movement of the controller 37, visual cues (e.g., moving a hand in front of a camera on the controller 37), or the like. The HMI device 41 can provide outputs, via a graphical user interface, including visual information, such as the visual indication of the current pressure values of the gas, hot melt adhesive, and/or the solution, as well as acceptable ranges for these parameters via a display. Other outputs can include audio information (e.g., via speaker), mechanically (e.g., via a vibrating mechanism), or a combination thereof. In various configurations, the HMI device 41 can include a display, a touch screen, a keyboard, a mouse, a motion detector, a speaker, a microphone, a camera, or any combination thereof. The HMI device 41 can further include any suitable device for inputting biometric information, such as, for example, fingerprint information, retinal information, voice information, and/or facial characteristic information, for instance, so as to require specific biometric information for accessing the controller 37.

The controller 37 can be in signal communication with various components of the dispensing system 10 so as to receive signals from and/or provide instructions to each component. The controller 37 can be in signal communication with the flow meter 100 through signal connection 38a, the gas valve 24 through signal connection 38b, the pump 11 through signal connection 38c, and the temperature sensor 56 through signal connection 38d. Each of the signal connections 38a-38d can comprise wired and/or wireless connections.

Now referring to FIGS. 2-7, a gear flow meter 80 that can be used to implement the flow meter 100 of FIG. 1 will be described in further detail. It will be understood that the dispensing system 10 can include alternatively configured flow meters as desired. The flow meter 80 comprises a housing body 82 having a flow inlet passage 84 and a flow outlet passage 85. The flow inlet passage 84 is configured to receive the solution from upstream components such as the pump 11. The flow outlet passage 85 is configured to discharge the solution to downstream components such as to the dispenser 28. The housing body 82 of the flow meter 80 can be removably connected to a body (not shown) of the dispensing system 10 such as a housing via fasteners 87a, such as screws or bolts. The flow meter 80 further includes a housing cover 83 that is removably connected to the housing body 82 by a plurality of fasteners 87b, such as screws or bolts.

The flow meter 80 comprises a pair of rotatable gears 86 and at least one sensor 88, such as a magnetic pick-up sensor, configured to measure an amount of the liquid adhesive flowing through the flow meter. A pair of sensors 88a, 88b are shown in the implementation of the flow meter 80 depicted in the figures. In particular, the pair of sensors 88a, 88b are configured to measure rotation of the rotatable drive gears 86 to determine an amount of the adhesive flowing out of the flow outlet 85 passage.

The housing body 82 comprises an elastomeric seal 89, such as an elongated or oval shaped O-ring, to maintain a watertight seal with the cover to prevent fluid leakage from the flow meter. The gears 86 are contained within a hollow central recess 82a of the housing body 82 so that they are free to rotate about an axis of rotation. In particular, the gears are secured between the housing body 82 and the housing cover 83 so as to be rotatable. In one implementation, the gears 86 are a substantially linear series of intermeshing, flow-metering spur gears that are each configured to rotate about respective pins 81 provided in corresponding bushings 81a in the housing body 82. The gears 86 are positioned so that they are substantially coplanar, and so that each gear is parallel to and spaced from at least one neighboring gear. Further, the gears 86 are positioned so that an axis of rotation of each of the gears is positioned along a common central line. The gears 86 are also positioned so that the teeth of each gear intermesh with the teeth of the neighboring gear.

The flow inlet passage 84 provides a conduit to the inlet side of the intermeshing pair of gears 86. Similarly, flow outlet passage 85 provides a conduit from the discharge side of the intermeshing pair of gears 86. The gears 86 are in fluid communication with a flow inlet passage 84 that directs the solution into the recess 82a toward the inlet side of the intermeshing pair of gears. As a result, the solution drives the gears 86 in tandem so that each of the gears rotate in an opposite direction relative to each other. For example, one of the gears rotates in a counterclockwise direction while its immediately neighboring gear rotates in a clockwise direction. Employing counter-rotating gears 86 creates a positive displacement for precise metering of liquid hot melt adhesive.

As a result of this rotation of the gears 86, after the solution is directed to the inlet side of the intermeshing portion of the gears via the flow inlet passage 84, the solution is divided in half by the two gears. This occurs because, as the gears rotate, solution flows into the spaces between the teeth of each of the oppositely rotating intermeshing pair of gears. Thus, two solution streams are respectively carried in opposite directions around the perimeter of the central recess 82a by the teeth of each oppositely rotating gear, such that the two solution streams converge near the flow outlet passage 85. Accordingly, the volume of solution flowing between the gears 86 and the perimeter wall of the central recess 82a represents the volume of solution per pulse. As the respective gear teeth of each neighboring gear comes into mesh with each other, the solution is displaced from the spaces between the gear teeth of each gear, which forces the solution into and through the flow outlet passage 85 that is adjacent the intermeshing pair of gears. Thus, during this process, the solution moving through the flow meter 80 exerts rotational forces on the gears 86, causing them to rotate at a particular rate. The sensors 88a. 88b are configured to measure this speed of rotation of the gears 86 in order to determine the flow rate of solution moving through the flow meter 80. The gear-tooth flow meter 80 is configured to provide a resolution of, for example, approximately 25 mg.

As shown in FIGS. 3 and 4, the gears 86 are bounded within the recess 82a by a flat inner surface of the housing cover 83. Each gear may further be bounded by a respective hardened support shaft 83a provided in the housing cover 83. A thin membrane 83b is provided underneath each sensor 88a, 88b on the flat inner surface of the housing cover 83, such that the thin membrane 83b is located between the sensors 88a, 88b and the gears 86.

Turning now to FIGS. 8 to 13, a gear flow meter 102 is shown according to another embodiment that can implement the flow meter 100 of FIG. 1. The gear flow meter 102 can comprise a multipart housing 108 that includes an upper housing portion 112 and a lower housing portion 116 connected to the upper housing portion 112. The gear flow meter 102 can also include a gear chamber 120 disposed between the upper housing portion 112 and the lower housing portion 116. One or more connections 124 can be included on the top side of upper housing portion 112 for receiving and connecting a probe 154 that includes a fiber optic 104. Additionally, one of the connections 124 can be configured to connect with the signal connection 38a that connects the gear flow meter 102 to the controller 37.

The upper housing portion 112, lower housing portion 116, and gear chamber 120 can be connected to each other by screw connections 142. Connections 124 for probe 154 and fiber optic 104 on the top side of upper housing portion 112 can be fixed by means of screws 146. The lower housing portion 116 can have a plurality of fluid inlets 134 and fluid outlets 138. Fluid passing through gear flow meter 102, via the fluid channels located in upper and lower housing portions 112, 116, can be received from the pump 11 through the fluid inlets 134 and directed out of the gear flow meter 102 through the fluid outlets 138.

Rotating axles 130, which can be disposed adjacent to fluid inlets 134 and fluid outlets 138, extend through parts of housing 108. The gear chamber 120 of the gear flow meter 102 can be sealed against the upper housing portion 112 and the lower housing portion 116 by sealing elements 150 to prevent the solution from exiting the housing 108. The axles 130 can be configured to rotate and can each carry a gear 128 driven by the fluid entering through the fluid inlets 134 located adjacent to gears 128. The gears 128 can be configured to transport the solution in the direction of rotation of the gears 128 to the fluid outlets 138, from which the solution continues to flow to the dispenser 28. The fluid can be transported through cavities formed between engaging gears 128 and the wall of the gear chamber 120 that surrounds the gears 128. The depicted embodiment shows the positioning of probe 154. In this embodiment, probe 154 is located substantially parallel to the rotating axles 130 and offset from sectional plane A-A.

At least one probe 154 can be inserted into upper housing portion 112 as part of a measuring unit, where said measuring unit can be configured to perform contactless optical detection of the rotational speed of one of gears 128. The probe 154 can be inserted light-sealingly and fluid-sealingly into a correspondingly shaped recess 162 in the housing 108 of the gear flow meter 102. In order to fasten the probe 154, the probe 154 can comprise a shape 166 having a circumferential flange 158 that is partially overlapped by the screw heads of the screws 146. The probe 154 is connected via a fiber optic 104 to a light source that is designed to produce light, where the light source is part of the measuring unit. The probe 154 of the measuring unit is adapted to emit light onto a portion of one of the gears 128, from which the light is reflected. The probe 154 can be spaced apart from the rotating axle 130 of the gear 128, such that the portion of the gear 128 onto which the probe 154 emits light is between the tip diameter and the root diameter of the gear 128. The probe 154 can be adapted to receive light reflected off the portion of the gear 128 onto which the probe 154 emits light. In order to analyze the light received from probe 154, the measuring unit includes a signal transducer which is adapted to detect light received by probe 154 and returned via fiber optic 104 to the signal transducer, in order to produce electrical signals corresponding to the intensity of the reflected light that are representative of the rotational speed of gear 128. The gear flow meter 102 can then transmit a signal to the controller 37 that is indicative of the rotational speed of the gear 128, from which the controller 37 can determine the volumetric flow rate of the solution.

Returning to FIG. 1, the controller 37 can control and utilize information received from the various components of the dispensing system 10 so as to maintain a consistent quality of hot melt adhesive foam applied to the substrate. During operation, the operator of the dispensing system 10 may want to change the speed of the pump 11. Alternatively, the viscosity and/or temperature of the solution flowing to the dispenser 28 can change over time. Additionally, due to interactions between the pump 11 and the solution, as well as other factors, the temperature profile of the solution can be inconsistent throughout the dispensing system 10, which can cause detecting the actual temperature of the solution to be difficult. Each of these factors individually and in combination can have an effect on the quality of the hot melt adhesive foam created on the substrate. As a result, measuring the volumetric flow rate of the solution using the flow meter 100 is particularly advantageous as opposed to alternative pressure-based sensing devices, as the flow meter 100 can be used to characterize the solution in a manner that is not sensitive to temperature and/or viscosity changes in the solution.

In particular, the volumetric flow rate of the solution as measured by the flow meter 100 can be utilized to determine the efficiency of the pump 11. The efficiency of the pump 11 can be utilized as a target parameter to be maintained throughout operation of the dispensing system 10, as the efficiency can be relatively unaffected by the speed of the pump 11, as well as the viscosity and temperature of the solution, all of which may be adjusted or change throughout the operation of the dispensing system 10. As such, after determining the efficiency of the pump 11 when the hot melt adhesive foam quality is optimal, the controller 37 can adjust aspects of the dispensing system 10 to maintain this desired efficiency level throughout a particular dispensing operation.

In one embodiment, the controller 37 is configured to receive a signal from the flow meter 100 that is indicative of the volumetric flow rate of the solution pumped by the pump 11. Using this signal, the controller 37 can determine the efficiency of the pump 11 based on the volumetric flow rate. The controller can be configured to determine the efficiency of the pump 11 to be equal to or proportional to Equation (1):

$\begin{matrix} \frac{AFR}{RPM * DPR} & (1) \end{matrix}$

where:

- AFR is the actual volumetric flow rate measured by the flow meter 100;
- RPM is the revolutions per minute (RPM) at which the pump 11 is operating; and
- DPR is the volumetric displacement per revolution of the pump 11.
  
  While the AFR can be measured by the flow meter 100, the RPM of the pump 11 can be received by the controller 37 through the signal connection 38c that connects the pump 11 with the controller 37, or can be input into the controller 37 by the operator of the dispensing system 10 in order to control the pump 11. Additionally, the DPR can be a known variable that corresponds to the particular pump 11 utilized within the dispensing system 10, and can similarly be received by the controller 37 from the pump 11 through the signal connection 38c or can be input into the controller 37 by the operator. The RPM of the pump 11 multiplied by the DPR of the pump 11 can also be referred to as the theoretical volumetric flow rate of the pump 11. As such, the efficiency of the pump 11 can be calculated to be equal to or proportional to Equation (1) by dividing the actual volumetric flow rate by the theoretical volumetric flow rate.

In operation, the operator of the dispensing system 10 can adjust the speed of the pump 11 until the dispensing system 10 produces hot melt adhesive foam that is optimal for a particular dispensing operation. At this point, the controller 37 can calculate the efficiency of the pump 11. This efficiency can be referred to as a predetermined setpoint for the efficiency of the pump 11, as it represents the efficiency that the pump 11 must maintain in order to maintain the hot melt adhesive foam at the desired quality. Over time, however, the efficiency of the pump 11 may increase or decrease based upon many factors within the dispensing system 10. As such, the controller 37 must be able to take corrective action in order to maintain efficiency of the pump 11 at the predetermined setpoint.

One method of affecting the efficiency of the pump is to adjust the gas content of the solution. When the gas content of the solution increases, the efficiency of the pump 11 decreases because the pressure regulator 31 may be configured to control the pressure within the second recirculation channel 29 to be substantially equal to the atmospheric pressure. As a result, a substantial amount of the gas comprising the solution will become unmixed from the solution after passing through the pressure regulator 31 and consequently form bubbles within the solution, where the bubbles can reduce the efficiency of the pump 11. As a result, the more gas the solution contains, the lower the efficiency of the pump 11 can be. Likewise, when the gas content of the solution decreases, the efficiency of the pump 11 increases. In one embodiment, the gas valve 24 can be selectively opened and closed to allow amounts of gas to flow to the pump 11. The gas valve 24 can be opened for discrete intervals over a set period of time, where the set period of time can be referred to as the duty cycle of the gas valve 24. The duty cycle can be from about 10-100 milliseconds, though other duty cycles are contemplated. The controller 37 can control the percentage of the duty cycle that the gas valve 24 is open and closed so as to adjust the amount of gas provided to the pump 11, and thus adjust the efficiency of the pump 11. In another embodiment, the gas valve 24 can be configured to be transitioned between more positions than simply open and closed. For example, it is contemplated that the gas valve 24 can allow any percent between 0% and 100% of the gas flow received from the gas source 22 through to the second input lob of the pump 11. As a result, the gas content of the solution can be controlled by controlling the percentage that the gas valve 24 is opened,

After the predetermined setpoint has been set, the controller 37 can be configured to instruct the gas valve 24 to decrease an amount of gas provided to the pump when the efficiency is below the predetermined setpoint. This decrease can be performed according to a proportional-integral-derivative (PID) control algorithm. Alternatively, this decrease can be performed according to a proportional control algorithm. The amount of gas provided can be decreased until the efficiency is equal to, or just below (such as within a predetermined amount below), the predetermined setpoint. When the gas content of the solution decreases, the efficiency of the pump 11 can increase.

Likewise, the controller 37 can be configured to instruct the gas valve 24 to increase the amount of gas provided to the pump 11 when the efficiency is above the predetermined setpoint. As with the decrease in gas content, this increase can be performed according to a PID control algorithm. Alternatively, this increase can be performed according to a proportional control algorithm. The amount of gas provided can be increased until the efficiency is equal to, or just below (such as within a predetermined amount below), the predetermined setpoint. When the gas content of the solution increases, the efficiency of the pump 11 can decrease. Each of these above-described changes to the percentage of the duty cycle that the gas valve 24 is open and closed may not occur only when the efficiency of the pump 11 deviates from the exact predetermined setpoint. For example, the controller 37 may only instruct the gas valve 24 to increase or decrease the percentage of the duty cycle that the gas valve 24 is open and closed when the efficiency of the pump 11 as calculated by the controller 37 deviates from the predetermined setpoint by a certain percentage, where the percentage can be determined by the controller 37 based upon the particular dispensing operation being performed or input into the controller 37 by the operator of the dispensing system 10 via the HMI device 41.

During a dispensing operation, it may become necessary to change the predetermined setpoint so as to adjust the efficiency of the pump 11, and thus adjust the characteristics of the hot melt adhesive foam produced by the dispensing system 10. To do this, the operator of the dispensing system 10 can provide at least one user input to the HMI device 41 that adjusts the predetermined setpoint. The controller 37 can then instruct the gas valve 24 as described above so as to change the gas content of the solution and cause the pump 11 to operate at the desired efficiency.

The at least one user input may include, for example, foam density (e.g., lb/cu ft or kg/L), percent density reduction (% DR), solid volume fraction (e.g., solid volume/total volume), or gas volume fraction (e.g., gas volume/total volume). Methods of determining percent density reduction (% DR) are discussed below in relation to FIGS. 15-18. Percent density reduction has been shown to have a relatively linear relationship with efficiency up to a maximum density reduction (e.g., 60%-80%), where the adhesive won't retain any more gas. Thus, in the linear region, an increase in percent density reduction generally results in a corresponding decrease in efficiency, while a decrease in percent density reduction generally results in a corresponding increase in efficiency. This relationship is generally true for different adhesives, although the slope and intercept of the linear relation may vary based on the composition of the adhesive. Thus, once the user input is received, the controller 37 can determine the predetermined setpoint based on the user input and adjust the amount of the gas provided to the pump so as to maintain the efficiency of the pump at the predetermined setpoint. In one example, the controller 37 can determine the predetermined setpoint from a table or curve of predetermined setpoints stored in memory, where each predetermined setpoint corresponds to a user input. It will be understood that the user can determine the user inputs above by direct measurement and calculation, or the user inputs can be selected from a set of predetermined values. The predetermined values, such as the efficiency, density, percent density reduction, solid volume fraction, gas volume fraction, and curves of any of these values relative to efficiency can be stored, for example, in a database, a library, or in another suitable location.

In addition to, or alternatively to, the user inputs discussed above, the operator of the dispensing system 10 can provide the HMI device 41 with a user input that adjusts the speed of the pump 11. However, change in the speed of the pump 11 may not directly affect the efficiency of the pump 11. Despite this, in such situations the controller 37 can be configured to instruct the gas valve 24 to adjust the amount of gas provided to the pump 11 so as to maintain the efficiency of the pump 11 at the predetermined setpoint.

Now referring to FIG. 14, a method of dispensing the hot melt adhesive foam onto a substrate will be described. The method 200 can include step 202, which includes receiving the hot melt adhesive from the hot melt adhesive source 17. Method 200 can also include step 206, which includes receiving the gas from the gas source 22. In practice, steps 202 and 206 can begin simultaneously, or in any desired order. Once the pump 11 receives the hot melt adhesive and the gas, step 210 can be performed. In step 210, the hot melt adhesive and the gas can be mixed to produce a solution. The mixing can be performed by the pump 11 at a desired speed that can be set by the operator of the dispensing system 10 via the HMI device 41 of the controller 37. After mixing the hot melt adhesive and the gas to form the solution, step 214 can be performed, which includes pumping the solution from the pump 11 to the dispenser 28 at a volumetric flow rate. While the solution is being pumped by the pump 11, step 218 can be performed, which includes measuring the volumetric flow rate of the solution via the gear flow meter 100. The gear flow meter 100 can transmit a signal that is indicative of the volumetric flow rate to the controller 37 through the signal connection 38a.

Once the volumetric flow rate of the solution is measured in step 218, in step 222 the efficiency of the pump 11 can be determined by the controller 37. In one embodiment, the efficiency of the pump 11 can be determined according to Equation (1), as described above, using the volumetric flow rate of the solution as measured by the gear flow meter 100. Once the efficiency of the pump 11 is determined, the controller 37 can determine whether the efficiency is above or below a predetermined setpoint in step 226. The predetermined setpoint can be recalled by the controller 37 from the memory 40 based upon a particular dispensing operation to be performed, speed of the pump 11, etc. Additionally, the operator of the dispensing system 10 can provide a user input to the HMI device 41 that sets the predetermined setpoint. The predetermined setpoint can comprise a discrete value, or a percentage deviation from a discrete value, where the particular percentage can be determined by the controller 37 or selected by the operator through the HMI device 41.

If the controller 37 determines that the efficiency of the pump 11 is above the predetermined setpoint, step 230 is performed. In step 230, the controller 37 can instruct the gas valve 24 to increase the percentage of the duty cycle that the gas valve 24 is open, thus increasing the amount of gas provided to the pump 11. As such, the gas content of the solution produced by the pump 11 will increase, and the efficiency of the pump 11 will likewise decrease. Alternatively, if the controller 37 determines that the efficiency of the pump 11 is below the predetermined setpoint, step 234 is performed. In step 234, the controller 37 can instruct the gas valve 24 to decrease the percentage of the duty cycle that the gas valve 24 is open, thus decreasing the amount of gas provided to the pump 11. As such, the gas content of the solution produced by the pump 11 will decrease, and the efficiency of the pump 11 will likewise increase.

After passing through the gear flow meter 100, the solution can be dispensed to create the hot melt adhesive foam on the substrate in step 238. Throughout operation of the dispensing system 10, the operator can make adjustments to the system, and the controller 37 can adjust various aspects of the dispensing system 10 accordingly. For example, in step 242 the operator can adjust the predetermined setpoint for the efficiency of the pump 11. This step can be performed by providing an input to the HMI device 41 of the controller 37. In one embodiment, the predetermined setpoint for the efficiency of the pump 11 can be changed by the operator to increase the quality of the hot melt adhesive foam applied to the substrate. In response to changing the predetermined setpoint, in step 246 the controller 247 can provide instructions to the gas valve 24 to adjust the amount of gas provided to the pump 11 so as to maintain the efficiency of the pump 11 at the new predetermined setpoint. Additionally, the operator of the dispensing system 10 can adjust the rotational speed of the pump 11. Like adjusting the predetermined setpoint, this step can be performed by providing an input to the HMI device 41 of the controller 37. The speed of the pump 11 can be increased or decreased so as to change the rate at which hot melt adhesive foam is applied to the substrate. In response to changing the speed of the pump in step 250, in step 254 the controller 37 can provide instructions to the gas valve 24 to adjust the amount of gas provided to the pump 11 so as to maintain the efficiency of the pump 11 at the new rotational speed of the pump 11.

After step 254, the method 200 can continue by returning to step 218 and again measuring the volumetric flow rate of the solution via gear flow meter 100. As a result, steps 218, 222, 226, 230, and 234 can be repeated so as to ensure that the efficiency of the pump 11, and thus the quality of the hot melt adhesive foam, remains consistent. These steps can be repeated continuously or intermittently throughout the course of operating the dispensing system 10 automatically or upon initiation by the operator of the dispensing system 10. As steps 242, 246, 250, and 254 can be optional or performed as desired by the operator, step 218 can be performed immediately after step 238 to create a continuous feedback loop. Additionally, any of steps 242, 246, 250, 254 can be performed in isolation and without the occurrence of any of the other ones of steps 242, 246, 250, and 254.

With reference to FIG. 15, one method 300 of determining at least one percent-density-reduction (% DR) value is shown according to one example. The at least one percent-density-reduction value can be calculated based on a density of the adhesive (without gas) and a density of the foam. The method 300 can comprise a step 302 of determining a density value of the adhesive without gas being added. Thus, the density value determined in step 302 can be determined based on adhesive dispensed from the dispenser 28 with the gas valve 24 in the closed position. The density of the adhesive can be determined using any suitable method, including the one or both of the methods discussed below in relation to FIGS. 17 and 18.

The method 300 can include a step 304 of adjusting the gas valve 24 such that the gas valve 24 discharges gas at a desired gas level. In one example, the desired gas level can be determined by increasing the gas until the gas reaches a gas level in which the foam quality deteriorates, and the desired gas level can be selected to be just below the gas level in which the foam quality deteriorates.

The method 300 can include a step 306 of determining a density value of the foam discharged from the dispensing system 10 at the desired gas level. The density of the foam can be determined using any suitable method, including the one or both of the methods discussed below in relation to FIGS. 17 and 18. The method can include a step 308 of calculating the percent-density-reduction value of the foam. The percent-density-reduction value can be calculated to be equal to or proportional to:

$\begin{matrix} \frac{D_{A} - D_{F}}{D_{A}} \times 100 & (2) \end{matrix}$

where:

D_Ais the adhesive density; and

D_Fis the foam density.

Once determined, the user can enter the percent-density-reduction (% DR) value using the HMI device 41. Additionally, or alternatively, the user can input one or both of the adhesive density (from step 302) and the foam density at the desired gas level (from step 306) to the HMI device 41, and the controller 37 can calculate the percent-density-reduction value.

Referring to FIG. 16, one method 400 of determining at least two percent-density-reduction (% DR) values (also referred to as first and second percent-density-reduction values) is shown according to one example. The first and second percent-density-reduction values can define an upper limit and a lower limit, respectively, of a range of percent-density-reduction values from which the dispensing system 10 can determine a range of efficiencies to operate the dispensing system 10. Each percent-density-reduction value can be calculated based on a density of the adhesive (without gas) and a density of the foam.

The method 400 can comprise a step 402 of determining a density value of the adhesive without gas being added. As in step 302 discussed above, the density value determined in step 402 can be determined based on adhesive dispensed from the dispenser 28 with the gas valve 24 in the closed position. The density of the adhesive can be determined using any suitable method, including the one or both of the methods discussed below in relation to FIGS. 17 and 18.

To determine the first percent-density-reduction value, the method 400 can include a step 404 of adjusting the gas valve 24 such that the gas valve 24 discharges gas at a first predetermined gas level. The first predetermined gas level can be determined to be a gas level results causes foam to be dispensed from the dispensing system 10 at a first density level. In one example, the first predetermined gas level can be just below the desired gas level discussed above in relation to FIG. 15. The method 400 can include a step 406 of determining a first density value of the foam discharged from the dispensing system 10, where the first density value is determined at the first predetermined gas level. The first density value of the foam can be determined using any suitable method, including the one or both of the methods discussed below in relation to FIGS. 17 and 18. The method can include a step 408 of calculating the first percent-density-reduction of the foam. The first percent-density-reduction value can be calculated to be equal to or proportional to Equation (2) above using the adhesive density determined in step 402 and the foam density determined in step 406. Once determined, the user can enter the first percent-density-reduction value to the HMI device 41. Additionally, or alternatively, the user can input one or both of the adhesive density (from step 402) and the first foam density value at the first gas level (from step 406) to the HMI device 41, and the controller 37 can calculate the first percent-density-reduction value.

To determine the second percent-density-reduction value, the method 400 can include a step 410 of adjusting the gas valve 24 such that the gas valve 24 discharges gas at a second predetermined gas level. The first predetermined gas level can be determined to be a gas level results causes foam to be dispensed from the dispensing system 10 at a second density level, greater than the first density level. In one example, the second predetermined gas level can be determined in a manner similar to step 304 above by increasing the gas until the gas reaches a gas level in which the foam quality deteriorates, and selecting the desired gas level to be just below the gas level in which the foam quality deteriorates.

The method 400 can include a step 412 of determining a second density value of the foam discharged from the dispensing system 10, where the second density value is determined at the second predetermined gas level. The second density value of the foam can be determined using any suitable method, including the one or both of the methods discussed below in relation to FIGS. 17 and 18. The method can include a step 414 of calculating the second percent-density-reduction of the foam. The second percent-density-reduction can be calculated to be equal to or proportional to Equation (2) above using the adhesive density determined in step 402 and the second foam density determined in step 412. Once determined, the user can enter the second percent-density-reduction to the HMI device 41. Additionally, or alternatively, the user can input one or both of the adhesive density (from step 402) and the second foam density at the second gas level (from step 412) to the HMI device 41, and the controller 37 can calculate the second percent-density-reduction value.

Turning now to FIG. 17, a method 500 of determining a density value of the adhesive without gas and/or foam is shown according to one example. The method comprises a step 502 of placing a cup on a scale, and taring the scale to display a weight of zero. The method comprises a step 504 of filling the cup with water or other liquid to a desired level and recording the weight of the water. Note that for liquids other than water, Equation (2) above may need to be multiplied by a factor corresponding to the particular liquid. The method comprises a step 506 of emptying the water from the cup. The method comprises a step 510 of dispensing adhesive or foam from the dispensing system 10 into the cup to the desired level and recording the weight of the cup with adhesive or foam. For adhesive, the gas valve 24 is closed. For foam, the gas valve 24 is adjusted to a desired or predetermined gas level as discussed above in relation to FIGS. 15 and 16.

The method comprises a step 512 of calculating the density value. The density value can be calculated by dividing the weight of the cup and adhesive (from step 510) by the weight of the water (from step 504). In some examples, the method can comprise a step 514 of determining whether to determine one or more additional density values. If additional density values are desired, then steps 502 to 512 can be repeated. If additional density values are not desired, then the method can terminate, or an average of the density values determined in step 512 can be calculated. Averaging a plurality of density values can reduce potential errors that may arise in one or just a few density values.

Turning now to FIG. 18, a method 600 of determining a density value of the adhesive without gas and/or foam is shown according to one example. The method comprises a step 602 filling a cup with water to a desired level. The method comprises a step 604 of placing the cup on a scale and taring the scale to display a weight of zero. The method comprises a step 606 of removing a bead sample of the adhesive or foam from a substrate. The method comprises a step 608 of placing the bead sample of the adhesive or foam on the scale with the cup and recording the weight of the bead. The method comprises a step 610 of submerging the bead sample into the cup of water and recording the weight of the submerged bead. In one example, the bead can be impaled with a small wire and then submerged. If additional density values are desired, then steps 602 to 612 can be repeated. If additional density values are not desired, then the method can terminate, or an average of the density values determined in step 612 can be calculated. Averaging a plurality of density values can reduce potential errors that may arise in one or just a few density values.

It will be understood that various steps of methods 200, 300, 400, 500, and 600 can be performed in an order other than that described. For example, in method 400, the first and second percent-density-reduction values can both be calculated in step 414. As a further example, the cup in method 500 can be filled with water before being placed on the scale. As another example, step 516 of method 500 and/or step 61 can calculate the average as each new density value is determined, rather than calculating the average after all density values have been determined. As yet another example, the cup in method 600 can be placed on the scale before being filled with water.

While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts, and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features, and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts, and features that are fully described herein without being expressly identified as such or as part of a specific invention, the scope of the inventions instead being set forth in the appended claims or the claims of related or continuing applications. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated. 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.

HOT MELT ADHESIVE FOAM DISPENSING SYSTEM

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