Patent Application
20080099132
This invention relates generally to pressure sensitive adhesives and their applications to desired surfaces, and more specifically to transferring pressure sensitive adhesive segments from a roll of flexible carrier release tape to a desired surface.
Pressure sensitive adhesives are widely used in a variety of industries. In many applications, it is convenient to apply pressure sensitive adhesive segments to a desired surface of a workpiece from a roll of flexible carrier release tape. The flexible carrier release tape typically has opposed first and second release surfaces which have different release properties. Adhesive segments are arrayed generally longitudinally along the first release surface of the carrier release tape. The second surface of the carrier release tape has a release property different from that of the first surface, so that the adhesive segments do not adhere to the second surface as strongly as they do to the first surface, and so that when the carrier release tape is wound into a roll, the first surface, and the adhesive segments applied thereto will be on the external surface of the roll of segment-laden carrier release tape. As the roll of carrier release tape is wound, therefore, the pressure sensitive adhesive segments will be wound between the first carrier release surface of the portion of the tape to which they are attached, and the second release surface of the successive layer of the roll of flexible carrier tape. Because the pressure sensitive adhesive does not adhere readily to the second release surface of the carrier tape, the tape may be readily unrolled, with the adhesive segments remaining attached to the first surface of the carrier tape, as the carrier tape with the adhesive segments attached to the first surface thereof are fed out for application to a desired surface of the workpiece.
Commonly assigned U.S. Patent Applications 2005/0178507 A1, 2005/0266198 A1, 2003/0118771 A1, and 2003/0116284 A1 describe a variety of apparatuses and methods for transferring pressure sensitive adhesive segments from a roll of flexible carrier release tape to a desired surface of a workpiece, through use of hand-held applicators.
These patent applications disclose and teach the construction and use of generally hand-held applicators, which in various embodiments thereof, feed the flexible carrier release tape with the adhesive segments attached thereto out through a manually or motorized drive mechanism.
Although the methods and apparatuses disclosed and taught by the Assignee's patent applications work well in a wide range of applications, there are circumstances in which it is desirable to have an applicator be mounted and operable in such a manner that it need not be held in the hand of an operator to accomplish application of the pressure sensitive adhesive segments to a workpiece.
Commonly assigned U.S. Patent Application No. 2003/0164220 A1 discloses and teaches the use of a stand and actuating arrangement for supporting a hand-held applicator in such a manner that adhesive segments may be applied to a workpiece by contact between an actuating arm of the actuator and the workpiece.
Although mounting of a hand-held applicator on a support stand, in the manner disclosed and taught by the '220 patent application works well in certain circumstances, there are circumstances in which such an arrangement cannot be effectively and efficiently utilized.
It is desirable, therefore, to provide an improved apparatus and method for transferring pressure-sensitive adhesive segments from a roll of flexible carrier release tape to the surface of a workpiece.
The invention provides an improved method and apparatus for transferring pressure sensitive adhesive segments from a rolled flexible carrier release tape to a workpiece, by directing the flexible carrier release tape to a dispensing member attached to a pivotable arm, and pivoting the arm in such a manner that the dispensing member clamps the flexible carrier release tape against the workpiece. Relative linear movement between the carrier release tape and the workpiece is then initiated, in such a manner that the relative motion unrolls the flexible carrier tape and moves one or more pressure sensitive adhesive segments into pressurized contact with the workpiece in such a manner that one or more pressure sensitive segments are transferred from the flexible carrier tape to the workpiece.
In some forms of the invention, a position of the flexible carrier is monitored as it is unrolled by the relative motion, and the pivoting arm is controlled in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired length of release tape has been unrolled. In other forms of the invention, a position of the flexible carrier tape is monitored as it is unrolled by the relative motion, and the pivoting arm is controlled in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired number of pressure sensitive adhesive segments have been brought into clamped contact with the workpiece.
In some forms of the invention, relative motion between the pivotable arm and the workpiece is generated by moving the workpiece linearly relative to the pivotable arm. In other forms of the invention, the relative motion is generated by moving the pivotable arm linearly relative to the workpiece.
An apparatus for transferring pressure sensitive adhesive segments from a rolled flexible carrier release tape to a workpiece, according to the invention, may include a pivotable arm, pivotably mounted for selective movement from a first to a second angular position, and a dispensing member attached to the pivotable arm. The dispensing member is operatively connected to the rolled flexible carrier tape in such a manner that when the arm is pivoted to the first angular position, the dispensing member clamps the flexible carrier release tape against the workpiece, such that relative linear motion between the carrier release tape and the workpiece unrolls the flexible carrier tape and moves one or more pressure sensitive adhesive segments into pressurized contact with the workpiece, in such a manner that one or more pressure sensitive segments are transferred from the flexible carrier tape to the workpiece. An apparatus, according to the invention, may further include an instrumentality for generating relative linear motion between the arm and the workpiece. The instrumentality may generate the relative motion by moving the workpiece linearly relative to the pivotable arm. In other forms of an apparatus, the instrumentality may generate the relative motion by moving the pivotable arm linearly relative to the workpiece.
An apparatus, according to the invention, may include a position sensing and control arrangement, for monitoring a position of the flexible carrier as it is unrolled by the relative motion, and for pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired length of the release tape has been unrolled. In other forms of the invention, a position sensing and control arrangement, according to the invention, may pivot the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired number of pressure sensitive adhesive segments have been brought into clamped contact with the workpiece.
In one form of a pressured sensitive adhesive segment dispensing apparatus, for selectively attaching the pressure-sensitive adhesive segments to a workpiece surface, the dispensing apparatus may include a pivotable arm, an actuator arrangement, a supply spool mounting arrangement, and an adhesive dispensing roller.
The pivotable arm may define first and second ends of the arm, and an arm axis extending between the first and second ends of the arm. The arm may also define a pivot axis disposed between the first and second ends, and extending substantially perpendicular to the arm axis, with the arm being adapted for pivotable movement about the pivot axis.
The actuator arrangement is operatively connected to the arm for causing the arm to pivot about the pivot axis substantially along a plane of arm movement extending orthogonally to the pivot axis, from an apply position of the arm to a retracted position of the arm.
The supply spool mounting arrangement is rotatably attached to the arm for rotation about a supply spool axis extending substantially parallel to the pivot axis of the arm. The supply spool mounting arrangement is adapted for holding a roll of flexible carrier release tape in such a manner that the flexible carrier release tape is oriented to extend along a longitudinal path running substantially parallel to the plane of arm movement. The flexible carrier release tape has a transverse width, opposed first and second release surfaces, and a plurality of pressure-sensitive adhesive segments arrayed non-contiguously in a longitudinally spaced-apart progression along the first release surface of the carrier release tape.
The adhesive dispensing roller is rotatably mounted to the arm proximate the first end of the arm for rotation about a dispensing roll axis extending substantially parallel to the pivot axis. The dispensing roller has a peripheral surface thereof adapted for bearing against the second release surface of the flexible carrier tape, for guiding the flexible carrier tape along a portion of the longitudinally extending path of the tape. The peripheral surface of the dispensing roller is also adapted for applying a clamping force, directed substantially perpendicularly to the longitudinal path through the flexible carrier tape, and/or the pressure-sensitive adhesive segments attached to the carrier tape, in such a manner that the tape may be advanced by relative motion between the arm and the workpiece for positioning the pressure-sensitive adhesive segments between the dispensing roller and the workpiece surface, when the arm is disposed in the apply position.
In some forms of the invention, a dispensing apparatus, according to the invention also includes a take-up spool mounting arrangement, rotatably attached to the arm for rotation about a take-up spool axis extending substantially parallel to the pivot axis of the arm, and adapted for forming and holding a roll of the flexible carrier release tape received along the longitudinal path.
The dispensing apparatus may also include a drive arrangement operatively connecting the supply spool mounting arrangement to the take-up spool mounting arrangement, in such a manner as the flexible carrier tape pulled from the supply reel along the longitudinally directed path, and the supply spool is thereby rotated about the supply spool axis. Rotation of the supply spool mounting arrangement is transferred by the drive arrangement to the take-up spool mounting arrangement for rotating the take-up spool about the take-up spool axis.
In some forms of the invention, the drive arrangement drives the take-up spool at a higher rotational speed than the dispensing spool, in such a manner that tension is continually maintained in the flexible carrier tape along the longitudinal path. In some forms of the invention, the drive arrangement may be a belt and pulley arrangement, having a drive pulley and a driven pulley connected by a drive belt, with the drive pulley being larger then the driven pulley. The drive pulley is operatively attached to the supply spool mounting arrangement, and the smaller pulley is operatively attached to the take-up spool mounting arrangement. The belt is operatively attached between the drive and driven pulleys in such a manner that the belt is capable of a limited amount of slippage over one or both of the drive and driven pulleys, in such a manner that continual tension is maintained along the longitudinal path of the flexible carrier tape, throughout the process of unwinding the flexible carrier tape from the supply spool and winding it onto the take-up spool.
A supply spool drive arrangement, according to the invention, may include first and second supply spool drive arrangement side plates, adapted for operatively clamping the supply spool therebetween, with the second drive spool side plate being selectively removable for installation and removal of the supply spool. The first supply spool drive arrangement side plate may further include an inner surface thereof, adapted for frictionally engaging one of a first or second longitudinally extending edges of the flexible carrier tape, when the supply spool is clamped between the first and second supply spool drive arrangement side plates, to thereby substantially preclude slippage of an outer layer of the roll of flexible carrier tape with respect to an inner layer of the flexible carrier tape, as the tape is pulled from the supply spool along the longitudinally oriented path.
A second supply spool drive plate, according to the invention, may be constructed in a manner allowing the supply spool to be viewed through the second side plate, to thereby allow viewing of the amount of flexible carrier tape remaining on the supply spool. Where the second side plate is fabricated from a substantially opaque material, it may include an opening therein through which the supply spool can be viewed.
An apparatus, according to the invention, may also include a pre-dispensing guide roller, which is rotatably mounted to the arm along the longitudinal path between the supply spool and the adhesive dispensing roller, for rotation about a pre-dispensing roller axis extending substantially parallel to the pivot axis. The pre-dispensing roller includes a peripheral surface thereof, adapted for bearing against the first release surface of the flexible carrier tape, and/or the pressure-sensitive adhesive segments attached to the first release surface, for guiding the flexible carrier tape along a portion of the longitudinally extending path of the tape between the supply spool and the adhesive dispensing roller. The pre-dispensing roller may have a peripheral surface thereof which is resistant to adhesion thereto of the pressure-sensitive adhesive segments. The peripheral surface of the pre-dispensing roller may include grooves or other surface treatments therein, for reducing contact of the peripheral surface of the pre-dispensing roller with the first release surface of the flexible carrier tape, or the pressure-sensitive adhesive segments attached to the first release surface. The peripheral surface of a pre-dispensing roller, according to the invention, may include a material having a low adhesion to the pressure-sensitive adhesive segments attached to the first release surface. The peripheral surface of a pre-dispensing roller including a material having a low adhesion to the pressure-sensitive adhesive segments may also include grooves therein for reducing contact of the peripheral surface of the pre-dispensing roller with the first release surface of the flexible carrier tape or the pressure-sensitive adhesive segments attached to the first release surface.
Some forms of the invention may also include a post-dispensing guide roller rotatably mounted to the arm along the longitudinal path, for receiving the flexible carrier tape from the dispensing roller, and further operatively mounted for rotation about a post-dispensing roller axis extending substantially parallel to the pivot axis. The post-dispensing roller includes a peripheral surface thereof adapted for bearing against the second release surface of the flexible carrier tape, for guiding the flexible carrier tape along a portion of the longitudinally extending path. In forms of the invention including both a pre-dispensing roller, and a post-dispensing roller, the longitudinally extending path may extend sequentially from a lower portion of the supply spool, over the pre-dispensing roller, about a portion of the periphery of the dispensing roller, around a portion of the periphery of the post-dispensing roller, and back over an upper portion of the supply spool, to the take-up spool.
Some forms of the invention may include a position sensor, for monitoring a position of the flexible carrier tape along the longitudinally oriented path. In forms of the invention including a post-dispensing roller, the sensor may be located between the dispensing roller and the post-dispensing roller. A flexible carrier tape, for use in practicing the invention, may include registration indicators detectable by the position sensor. Where the registration indicators are optically detectable, the position sensor may include an optical sensor adapted for detecting the registration indicators.
The invention may further include an arm support member, having the arm pivotably connected thereto along the pivot axis. The actuator arrangement, according to the invention, may be operatively connected between the arm and the arm support member, for pivoting the arm with respect to the arm support member. In some forms of the invention, having an arm support member, the arm support member is stationary and the workpiece is movable linearly relative to the arm support member, for transferring one or more adhesive segments from the flexible carrier tape to the workpiece. In other forms of the invention, the workpiece may be held stationary with the arm support member being movable linearly relative to the workpiece, for transferring one or more adhesive segments from the flexible carrier tape to the workpiece.
Other aspects, objects, and advantages of the invention will be apparent from the following detailed description and accompanying drawings, illustrating exemplary embodiments of the invention.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
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The dispensing roller 140 has a peripheral surface 144 thereof, adapted for bearing against the second release surface 138 of the flexible carrier tape 126, for guiding the flexible carrier tape along a portion of the longitudinally extending path 128 of the tape 126. The peripheral surface 144 of the dispensing roller 140 is also adapted for applying a clamping force directed substantially perpendicularly to the longitudinal path 128, through the flexible carrier tape 126, and/or the pressure-sensitive adhesive segments 102 attached to the carrier tape 126, such that the tape 126 may be advanced by relative linear motion between the arm 106 and the workpiece 104 for positioning the pressure-sensitive adhesive segments 102 between the dispensing roller 140 and the surface of the workpiece 104, when the arm 106 is disposed in the apply position, as shown in
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The second side plate 162, of the supply spool mounting arrangement 120, in the exemplary embodiment 100, is formed from a relatively strong, opaque material, such as steel. Because the second side plate 162 is opaque, in the exemplary embodiment, an opening, in the form of a slot 176 is provided in the second side plate 162, so that the amount of flexible carrier tape 126 remaining within the supply spool mounting arrangement 120 can be monitored by looking through the slot 176. In other embodiments of the invention, where the second side plate 162 is not fabricated from a material that is completely opaque, other provisions may be utilized in lieu of providing the opening 176, such as having the side plate 162 formed from a transparent material, or having the second side plate 162 include a transparent area.
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In the exemplary embodiment 100, the position sensor 202 is an optical sensor, for sensing registration marks 204, in the form of marking bars extending across the transverse width 130 of the carrier tape 126 between adjacent adhesive segments 102, in the exemplary embodiment, in such a manner that, by counting passage and/or monitoring the location of successive registration marks 204, the position sensor 202 and controller 200 can ascertain the number of pressure-sensitive adhesive segments 102 which have been brought into clamped contact with the workpiece 104. The position sensor 202 and controller 200, may also utilize a timer or clock function, or any other appropriate parameter in addition to, or in lieu of optically sensing the registration marks 204, for monitoring and controlling operation of the dispensing apparatus 100.
It is contemplated, that in other embodiments of the invention, other types of conveyance arrangements may be utilized for generating the relative motion between the arm 106 and the workpiece 104. For example, in other embodiments of the invention, a dispensing apparatus, according to the invention, may be attached to some form of moveable boom of a numerically controllable machine or mechanism.
From the foregoing description of exemplary embodiments, together with the referenced drawing figures, those having skill in the art will recognize that the exemplary embodiments described herein provide an improved method and apparatus for transferring pressure-sensitive adhesive segments from a rolled flexible carrier release tape to a workpiece, by first, directing the flexible carrier tape to a dispensing member attached to a pivotable arm, and pivoting the arm in such a manner that the dispensing member clamps the flexible carrier release tape against the workpiece, and then initiating relative linear motion between the carrier release tape and the workpiece, whereby the relative motion unrolls the flexible carrier tape and moves one or more pressure-sensitive adhesive segments into pressurized contact with the workpiece in such a manner that one or more pressure-sensitive segments are transferred from the flexible carrier tape to the workpiece.
All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventor for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
