U.S. patent application number 11/738768 was filed with the patent office on 2008-05-01 for product driven in-line glue dot applicator and method for using same.
This patent application is currently assigned to Glue Dots International, LLC. Invention is credited to Reid C. Moertl.
Application Number | 20080099510 11/738768 |
Document ID | / |
Family ID | 39092667 |
Filed Date | 2008-05-01 |
United States Patent
Application |
20080099510 |
Kind Code |
A1 |
Moertl; Reid C. |
May 1, 2008 |
Product Driven In-Line Glue Dot Applicator And Method For Using
Same
Abstract
A method and apparatus are provided, 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.
With the carrier release tape clamped against the workpiece,
relative linear movement between the carrier release tape and the
workpiece is 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 so that the one or more pressure-sensitive segments
are transferred from the flexible carrier tape to the
workpiece.
Inventors: |
Moertl; Reid C.;
(Germantown, WI) |
Correspondence
Address: |
REINHART BOERNER VAN DEUREN P.C.
2215 PERRYGREEN WAY
ROCKFORD
IL
61107
US
|
Assignee: |
Glue Dots International,
LLC
New Berlin
WI
|
Family ID: |
39092667 |
Appl. No.: |
11/738768 |
Filed: |
April 23, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11588695 |
Oct 27, 2006 |
|
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|
11738768 |
|
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Current U.S.
Class: |
222/168 ;
222/1 |
Current CPC
Class: |
B65H 37/002 20130101;
B65H 2701/19402 20130101 |
Class at
Publication: |
222/168 ;
222/1 |
International
Class: |
B65H 29/02 20060101
B65H029/02 |
Claims
1. A pressure-sensitive adhesive segment dispensing apparatus, for
selectively attaching the pressure-sensitive adhesive segments to a
workpiece surface, the dispensing apparatus comprising: a pivotable
arm, defining first and second ends of the arm and an arm axis
extending between the first and second ends of the arm, the arm
also defining a pivot axis disposed between the first and second
ends and extending substantially perpendicular to the arm axis, the
arm being adapted for pivotable movement about the pivot axis; an
actuator arrangement 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; a
supply spool mounting arrangement, rotatably attached to the arm
for rotation about a supply spool axis extending substantially
parallel to the pivot axis of the arm, and adapted for holding a
roll of flexible carrier release tape oriented to extend along a
longitudinal path running substantially parallel to the plane of
arm movement, with the flexible carrier release tape having 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; and an
adhesive dispensing roller rotatably mounted to the arm proximate
the first end of the arm for rotation about a dispensing roller
axis extending substantially parallel to the pivot axis; the
dispensing roller having 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 also being adapted for applying a clamping
force directed substantially perpendicularly to the longitudinal
path though the flexible carrier tape, and/or the
pressure-sensitive adhesive segments attached to the carrier tape,
such that the tape may be advanced by relative linear motion
between the arm and 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.
2. The dispensing apparatus of claim 1, further comprising 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.
3. The dispensing apparatus of claim 2, further comprising a
pre-dispensing roller and a post-dispensing roller, wherein, the
longitudinal path extends sequentially from a lower portion of the
supply spool, over the pre-dispensing roller, around a portion or
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.
4. The dispensing apparatus of claim 2, further comprising a drive
arrangement operatively connecting the supply spool mounting
arrangement to the take-up spool mounting arrangement in such a
manner that as the flexible carrier tape is pulled from the supply
spool 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 transmitted by the drive
arrangement to the take-up spool mounting arrangement for rotating
the take-up spool about the take-up spool axis.
5. The dispensing apparatus of claim 4, wherein, the drive
arrangement drives the take-up spool mounting arrangement at a
higher rotational speed than the supply spool mounting
arrangement.
6. The dispensing apparatus of claim 5, wherein the drive
arrangement is a belt and pulley arrangement having a drive pulley
and driven pulley connected by a drive belt, with the drive pulley
being larger than the driven pulley, the drive pulley being
operatively attached to the supply spool mounting arrangement and
the smaller pulley being operatively attached to the take-up spool
mounting arrangement, and the belt being capable of a limited
amount of slippage over one or both of the drive and driven
pulleys.
7. The dispensing apparatus of claim 1, wherein, the supply spool
drive arrangement includes first and second supply spool drive
arrangement side plates thereof, 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.
8. The dispensing apparatus of claim 7, wherein: the flexible
carrier tape includes first and second longitudinally extending
edges thereof spaced apart by the transverse width; and the first
supply spool drive arrangement side plate further comprises an
inner surface thereof adapted for frictionally engaging one of the
first and 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.
9. The dispensing apparatus of claim 7, wherein, the second supply
spool drive plate is 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.
10. The dispensing apparatus of claim 9, wherein the second side
plate is fabricated from a substantially opaque material having an
opening therein through which the supply spool can be viewed.
11. The dispensing apparatus of claim 1, further comprising: a
pre-dispensing guide roller 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 having a peripheral surface thereof adapted
for bearing against the first release surface of the flexible
carrier tape 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.
12. The dispensing apparatus of claim 11, wherein, the peripheral
surface of the pre-dispensing roller has a resistant to adhesion
thereto of the pressure-sensitive adhesive segments.
13. The dispensing apparatus of claim 12, wherein, the peripheral
surface of the pre-dispensing roller includes 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.
14. The dispensing apparatus of claim 12, wherein, the peripheral
surface of the pre-dispensing roller comprises a material having
low adhesion to the pressure-sensitive adhesive segments attached
to the first release surface.
15. The dispensing apparatus of claim 14, wherein, the peripheral
surface of the pre-dispensing roller includes 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.
16. The dispensing apparatus of claim 1, further comprising: a
post-dispensing guide roller rotatably mounted to the arm along the
longitudinal path, for receiving the flexible carrier tape from the
adhesive dispensing roller, and for rotation about a
post-dispensing roller axis extending substantially parallel to the
pivot axis; the post-dispensing roller having 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.
17. The dispensing apparatus of claim 1, further including a
position sensor, for monitoring a position of the flexible carrier
tape along the longitudinally oriented path.
18. The dispensing apparatus of claim 17, wherein, the sensor is
located between dispensing roller and the post-dispensing
roller.
19. The dispensing apparatus of claim 17, wherein, the flexible
carrier tape further comprises registration indicators detectable
by the position sensor.
20. The dispensing apparatus of claim 18, wherein, the registration
indicators are optically detectable, and the position sensor
comprises an optical sensor adapted for detecting the registration
indicators.
21. The dispensing apparatus of claim 1, further comprising an arm
support member, having the arm pivotably connected thereto along
the pivot axis.
22. The dispensing apparatus of claim 20, wherein, the actuator
arrangement is operatively connected between the arm and the arm
support member, for pivoting the arm with respect to the arm
support member.
23. The dispensing apparatus of claim 21, wherein, 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.
24. The dispensing arrangement of claim 21, wherein the workpiece
is stationary, and the arm support member is movable linearly
relative to the workpiece for transferring one or more adhesive
segments from the flexible carrier tape to the workpiece.
25. A method for transferring pressure sensitive adhesive segments
from a rolled flexible carrier release tape to a workpiece, the
method comprising: 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 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 the
one or more pressure-sensitive segments are transferred from the
flexible carrier tape to the workpiece.
26. The method of claim 24, further comprising, monitoring a
position of the flexible carrier as it is unrolled by the relative
motion, and 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.
27. The method of claim 24, further comprising, monitoring a
position of the flexible carrier as it is unrolled by the relative
motion, and pivoting 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.
28. The method of claim 24, wherein, the relative motion is
generated by moving the workpiece linearly relative to the
pivotable arm.
29. The method of claim 24, wherein, the relative motion is
generated by moving the pivotable arm linearly relative to the
workpiece.
30. An apparatus for transferring pressure sensitive adhesive
segments from a rolled flexible carrier release tape to a
workpiece, the apparatus comprising: 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 also being 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 the one or more pressure
sensitive segments are transferred from the flexible carrier tape
to the workpiece.
31. The apparatus of claim 29, further comprising, an
instrumentality for generating relative linear motion between the
arm and the workpiece.
32. The apparatus of claim 30, wherein, the instrumentality
generates the relative motion by moving the workpiece linearly
relative to the pivotable arm.
33. The apparatus of claim 30, wherein, the instrumentality
generates the relative motion by moving the pivotable arm linearly
relative to the workpiece.
34. The apparatus of claim 29, further comprising, a position
sensing and control arrangement for monitoring a position of the
flexible carrier tape as it is unrolled by the relative motion, and
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.
35. The apparatus of claim 29, further comprising, a position
sensing and control arrangement for monitoring a position of the
flexible carrier as it is unrolled by the relative motion, and
pivoting 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.
36. A pressure-sensitive adhesive segment dispensing apparatus, for
selectively attaching the pressure-sensitive adhesive segments to a
workpiece surface, the dispensing apparatus comprising: a pivotable
arm, defining first and second ends of the arm and an arm axis
extending between the first and second ends of the arm, the arm
also defining a pivot axis disposed between the first and second
ends and extending substantially perpendicular to the arm axis, the
arm being adapted for pivotable movement about the pivot axis; an
actuator arrangement 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; a
supply spool mounting arrangement, rotatably attached to the arm
for rotation about a supply spool axis extending substantially
parallel to the pivot axis of the arm, and adapted for holding a
roll of flexible carrier release tape oriented to extend along a
longitudinal path running substantially parallel to the plane of
arm movement, with the flexible carrier release tape having 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; an adhesive
dispensing roller rotatably mounted to the arm proximate the first
end of the arm for rotation about a dispensing roller axis
extending substantially parallel to the pivot axis; the dispensing
roller having 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 also being adapted for applying a clamping
force directed substantially perpendicularly to the longitudinal
path though the flexible carrier tape, and/or the
pressure-sensitive adhesive segments attached to the carrier tape,
such that the tape may be advanced by relative linear motion
between the arm and 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; 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; a drive arrangement
operatively connecting the supply spool mounting arrangement to the
take-up spool mounting arrangement in such a manner that as the
flexible carrier tape is pulled from the supply spool 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 transmitted by the drive arrangement to the
take-up spool mounting arrangement for rotating the take-up spool
about the take-up spool axis; the drive arrangement being
configured for driving the take-up spool mounting arrangement at a
higher rotational speed than the supply spool mounting arrangement;
the drive arrangement including a belt and pulley arrangement
having a drive pulley and driven pulley connected by a drive belt,
with the drive pulley being larger than the driven pulley, the
drive pulley being operatively attached to the supply spool
mounting arrangement and the smaller pulley being operatively
attached to the take-up spool mounting arrangement, and the belt
being capable of a limited amount of slippage over one or both of
the drive and driven pulley; a pre-dispensing guide roller
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 having a peripheral
surface thereof adapted for bearing against the first release
surface of the flexible carrier tape 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 peripheral surface of the
pre-dispensing roller including a material that is resistant to
adhesion thereto of the pressure-sensitive adhesive segment; the
peripheral surface of the pre-dispensing roller includes 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; and a post-dispensing guide
roller rotatably mounted to the arm along the longitudinal path,
for receiving the flexible carrier tape from the adhesive
dispensing roller, and for rotation about a post-dispensing roller
axis extending substantially parallel to the pivot axis; the
post-dispensing roller having 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; the longitudinal path
extending sequentially from a lower portion of the supply spool,
over the pre-dispensing roller, around a portion or 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.
37. The apparatus of claim 36, further comprising, a position
sensing and control arrangement for monitoring a position of the
flexible carrier tape as it is unrolled by the relative motion, and
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.
38. The apparatus of claim 36, further comprising, a position
sensing and control arrangement for monitoring a position of the
flexible carrier as it is unrolled by the relative motion, and
pivoting 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.
39. The dispensing apparatus of claim 36, further comprising an arm
support member, having the arm pivotably connected thereto along
the pivot axis, with the actuator arrangement being operatively
connected between the arm and the arm support member, for pivoting
the arm with respect to the arm support member.
40. The dispensing apparatus of claim 36, wherein: the supply spool
drive arrangement includes first and second supply spool drive
arrangement side plates thereof, 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 flexible carrier tape includes first and
second longitudinally extending edges thereof spaced apart by the
transverse width; and the first supply spool drive arrangement side
plate further comprises a cushioned inner surface thereof adapted
for frictionally engaging one of the first and 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.
41. The dispensing apparatus of claim 2, further comprising a drive
arrangement operatively connecting the supply spool mounting
arrangement to the take-up spool mounting arrangement in such a
manner that as the flexible carrier tape is pulled from the supply
spool along the longitudinally directed path, and the supply spool
is thereby rotated about the supply spool axis, the drive
arrangement rotates the take-up spool about the take-up spool
axis.
42. The dispensing apparatus of claim 41, wherein, the drive
arrangement comprises, a motor operatively connected to the take-up
spool mounting arrangement for rotating the take-up spool as the
flexible carrier tape is pulled from the supply spool.
43. The dispensing apparatus of claim 42, wherein: the drive
arrangement further comprises, a clutch operatively connecting the
motor to the take-up spool mounting arrangement in such a manner
that the clutch applies a torque to the take-up spool mounting
arrangement for urging the take-up spool mounting arrangement to
rotate the take-up spool for winding the flexible carrier tape onto
the take-up spool; and the clutch is configured to slip when the
flexible carrier tape is not being pulled from the supply
spool.
44. The dispensing apparatus of claim 43, wherein, the drive
arrangement drives the take-up spool mounting arrangement at a
higher rotational speed than the supply spool mounting
arrangement.
45. The dispensing apparatus of claim 43, further comprising, a
braking arrangement operatively connected for resisting rotation of
the supply-spool mounting arrangement, when the flexible carrier
tape is not being pulled from the supply spool along the
longitudinally directed path.
46. The dispensing apparatus of claim 44, wherein, the braking
arrangement is configured for resisting rotation of the
supply-spool when the arm is not in the retracted position.
47. The dispensing apparatus of claim 45, wherein, the braking
arrangement includes a brake actuator which is activated and
deactivated in correspondence to movement of the arm between the
retracted and apply positions of the arm.
48. The dispensing apparatus of claim 46, wherein, the braking
apparatus further comprises a brake shoe having a braking surface
and operatively connected to the arm and the brake actuator for
movement by the brake actuator from an engaged position, whereat
the braking surface bears against a portion of the supply-spool
mounting arrangement, for resisting rotation of the supply spool,
and a disengaged position, whereat the braking surface does not
bear against the supply-spool mounting arrangement.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation-in-part of
co-pending U.S. patent application Ser. No. 11/588,695, filed Oct.
27, 2006, the disclosure and teachings of which are incorporated
herein in their entireties, by reference.
FIELD OF THE INVENTION
[0002] 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.
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
BRIEF SUMMARY OF THE INVENTION
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] 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.
[0023] In some forms of the invention, various types of drive
arrangements, other than a belt and pulley drive, may be used for
operatively connecting the supply spool mounting arrangement to the
take-up spool mounting arrangement, in such a manner that, as the
flexible carrier tape is pulled from the supply spool along the
longitudinally directed path, and the supply spool is thereby
rotated about the supply spool axis, the drive arrangement rotates
the take-up spool about the take-up spool axis. In some forms of
the invention, such a drive arrangement may include a motor
operatively connected to the take-up spool mounting arrangement for
rotating the take-up spool as the flexible carrier tape is pulled
from the supply spool.
[0024] In a drive arrangement having a motor, according to the
invention, a clutch may operatively connect the motor to the
take-up spool mounting arrangement in such a manner that the clutch
applies a continuous torque to the take-up spool mounting
arrangement, for urging the take-up spool mounting arrangement to
rotate the take-up spool for winding the flexible carrier tape onto
the take-up spool. The clutch may be configured to slip when the
flexible carrier tape is not being pulled from the supply spool, to
thereby maintain a tension on the flexible carrier tape wound about
the take-up spool, so that it does not unwind from the take-up
spool. In some forms of the invention, it may be desirable to have
the motor drive the take-up spool mounting arrangement at a higher
rotational speed than the rotational speed achieved by the supply
spool mounting arrangement when the pressure sensitive adhesive
segments are being dispensed onto the surface of the workpiece.
[0025] Some forms of the invention may also include a braking
arrangement, operatively connected for resisting rotation of the
supply-spool mounting arrangement when the flexible carrier tape is
not being pulled from the supply spool along the longitudinally
directed path. The braking arrangement may be configured for
resisting rotation of the supply spool when the arm is not in the
retract position. A braking arrangement, according to the
invention, may include a brake actuator which is activated and
deactivated in correspondence to movement of the arm between the
retracted and apply positions of the arm. A braking arrangement,
according to the invention, may include a brake shoe, having a
braking surface, and operatively connected to the arm and brake
actuator for movement by the brake actuator from an engaged
position of the braking apparatus, whereat the braking surface
bears against a portion of the supply-spool mounting arrangement
for resisting rotation of the supply spool, and a disengaged
position of the braking apparatus, whereat the braking surface does
not bear against the supply-spool mounting arrangement.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] 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:
[0034] FIG. 1 is a perspective illustration, from a first view
angle, of an exemplary embodiment of a dispensing apparatus, in
accordance with the invention;
[0035] FIG. 2 is a perspective illustration, from a second viewing
angle, of the exemplary embodiment of the dispensing apparatus
shown in FIG. 1;
[0036] FIG. 3 is a partially schematic orthographic illustration of
a first application of the exemplary dispensing apparatus of FIGS.
1 and 2, wherein, relative linear motion between a pivotable arm of
the dispensing apparatus and one or more workpieces is provided by
moving the workpieces linearly with respect to the arm of the
dispensing apparatus;
[0037] FIG. 4 is a partially schematic illustration of an
application of the exemplary embodiment of the dispensing apparatus
of FIGS. 1 and 2, in an application where relative motion between
the arm of the dispensing apparatus and one or more workpieces is
generated by holding the workpieces stationary and moving the arm
linearly along a linear guide rail arrangement;
[0038] FIGS. 5 and 6 are orthographic side views of the exemplary
embodiment of the dispensing apparatus of FIGS. 1 and 2,
respectively illustrating the dispensing apparatus in a first, or
apply, angular position of the arm, and a second, retracted angular
position of the arm;
[0039] FIG. 7 is a partially cut-away orthographic view of a
portion of the exemplary embodiment of the dispensing apparatus of
FIGS. 1 and 2, illustrating construction and operational details of
the dispensing apparatus;
[0040] FIG. 8 is a perspective illustration, from a view angle
similar to the view angle of FIG. 1, having some of the components
in the foreground removed and others shown in dashed lines, in
order to illustrate construction and functional details of a drive
arrangement of the exemplary embodiment of the dispensing apparatus
of FIGS. 1 and 2;
[0041] FIG. 9 is a partially exploded perspective view of a supply
spool mounting arrangement of the exemplary embodiment of the
dispensing apparatus of FIGS. 1 and 2; and
[0042] FIG. 10 is a partially exploded perspective illustration of
a take-up spool mounting arrangement of the exemplary embodiment of
the dispensing apparatus of FIGS. 1 and 2.
[0043] FIG. 11 is a perspective illustration of a second exemplary
embodiment of a dispensing apparatus, in accordance with the
invention.
[0044] 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.
DETAILED DESCRIPTION OF THE INVENTION
[0045] FIGS. 1 and 2 illustrate a first exemplary embodiment of a
pressure-sensitive adhesive segment dispensing apparatus 100,
according to the invention, for selectively attaching the
pressure-adhesive segments 102 to a surface of a workpiece 104, in
the manner described in greater detail below, and as illustrated in
FIGS. 3 and 4.
[0046] As best seen in FIG. 2, the dispensing apparatus 100
includes an arm 106 pivotably mounted to an arm support member 108
for pivotable movement about an arm pivot axis 110. An actuator
arrangement, including a pneumatic cylinder 112 operatively
connects the arm 106 to the arm support member 108, in such a
manner that the arm 106 may be pivoted about the pivot axis 110
from a first (apply) angular position of the pivot arm 106, as
shown in FIG. 5, to a second (retracted) angular position of the
pivot arm 106, as shown in FIG. 6. In other embodiments of the
invention, other types of actuators, i.e. hydraulic, electric,
mechanical, etc., could be used instead of a pneumatic
cylinder.
[0047] As further illustrated in FIG. 2, the arm 106 has first and
second ends 114, 116 thereof, and defines an arm axis 118 extending
between the first and second ends 114, 116 of the arm 106. From the
description given thus far, and examination of the referenced
drawing FIGS., it will be appreciated that the operative
arrangement and construction of the arm 106, the arm support member
108, and the actuator arrangement 112 cause the arm 106 to pivot
about the pivot axis 110 and travel substantially angularly along a
plane of arm movement extending orthogonally to the pivot axis 110,
from the apply position shown in FIG. 5, to the retracted position
of the arm shown in FIG. 6.
[0048] As shown in FIGS. 1, 2, and 7, a supply spool mounting
arrangement 120 is rotatably attached to the arm 106, for rotation
about a supply spool axis 122, which extends substantially parallel
to the pivot axis 110 of the arm 106. The supply spool mounting
arrangement 120 is adapted, in a manner to be described in more
detail below, for holding a roll 124 of flexible carrier release
tape 126 oriented to extend along a longitudinal path, as
illustrated by arrows 128, in FIG. 1, with the longitudinal path
128 running substantially parallel to the plane of movement of the
arm 106. The flexible carrier release tape 126 has a transverse
width 130 extending between first and second longitudinal edges
132, 134 of the carrier tape 126. The flexible carrier tape 126
further includes opposed first and second release surfaces 136,
138, and a plurality of pressure-sensitive adhesive segments 102
arrayed non-contiguously in a longitudinally spaced-apart
progression along the first release surface 136 of the carrier
release tape 126.
[0049] As shown in FIG. 1, an adhesive dispensing roller 140 is
rotatably mounted to the arm 106 proximate to the first end 114 of
the arm 106, for rotation about a dispensing roller axis 142, which
extends substantially parallel to the pivot axis 122.
[0050] 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 FIG. 5.
[0051] As shown in FIG. 1, the exemplary embodiment of the
dispensing apparatus 100 further includes a take-up spool mounting
arrangement 146, rotatably attached to the arm 106 for rotation
about a take-up spool axis 148 extending substantially parallel to
the pivot axis 110 of the arm 106. The take-up spool mounting
arrangement 146 is adapted for forming and holding a roll 150 of
the flexible carrier release tape 126, received along the
longitudinal path 128.
[0052] As best seen in FIG. 8, the dispensing apparatus 100 further
includes a drive arrangement 152 operatively connecting the supply
spool mounting arrangement 120 to the take-up spool mounting
arrangement 146, in such a manner that as the flexible carrier tape
126 is pulled from the supply spool, i.e. the roll 124 of carrier
tape 126, along the longitudinally directed path 128, thereby
resulting in the supply spool 122 being rotated about the supply
spool axis 122, rotation of the supply spool mounting arrangement
120 is transmitted by the drive arrangement 152 to the take-up
spool mounting arrangement 146, for rotating the take-up spool 150
about the take-up spool axis 148.
[0053] Specifically, the drive arrangement 152, in the exemplary
embodiment, is a belt and pulley arrangement, having a drive pulley
154 and a driven pulley 156 connected by a drive belt 158. The
drive pulley 152 is attached to the supply spool mounting
arrangement 120, for rotation therewith about the supply spool axis
122, and the driven pulley 154 is connected to the take-up spool
mounting arrangement 146, for rotation therewith about the take-up
spool axis 148.
[0054] As illustrated in FIG. 8, the drive pulley 154 is larger in
diameter than the driven pulley 156, in the exemplary embodiment
100, so that the take-up spool mounting arrangement 146 is driven
at higher rotational speed than the take-up spool mounting
arrangement 146. By virtue of this arrangement, tension is
continually maintained on the flexible carrier tape 126, along the
longitudinally extending path 128. The drive belt 158, and the
drive and driven pulleys 154, 156, are cooperatively configured
such that the drive belt 158 is capable of a limited amount of
slippage over one or both of the drive or driven pulleys 154, 156,
so that tension is continually maintained in the flexible carrier
tape 126 as the carrier tape 126 is transferred from the supply
spool 124 to the take-up spool 150, to thereby compensate for the
change in relative outer diameters of the roll of carrier tape 124
and the roll 124 of carrier tape 126 remaining in the supply spool
mounting arrangement 120 and the outer diameter of the roll 150 of
the carrier tape 126 being wound up by the take-up spool mounting
arrangement 146.
[0055] As shown in FIG. 9, the supply spool mounting arrangement
120, of the exemplary embodiment 100 includes first and second
supply spool drive arrangement side plates 160, 162 thereof,
adapted for operatively clamping a supply spool, in the form of the
roll 124 of carrier tape 126 between the first and second side
plates 160, 162. The second side plate 162 is removable, by
unscrewing a wing nut 164 from a threaded member 166, in the
exemplary embodiment, for installation and removal of the roll 124
of carrier tape 126.
[0056] As further illustrated in FIG. 9, a hub 168 protrudes from
the first side plate 160, to engage a hollow central core (not
shown) upon which the carrier tape 126 is wound to form the roll
124 of carrier tape 126. In the exemplary embodiment, the first
supply spool drive arrangement side plate 160 further includes a
layer of felt material 170, attached to the first side plate 160 to
thereby form a cushioned inner surface of the first side plate 160,
which is adapted for frictionally engaging one of the first or
second longitudinally extending edges 132, 134 of the flexible
carrier tape 126. By virtue of this arrangement, when the roll 124
of carrier tape 126 is clamped between the first and second side
plates 160, 162 of the supply spool drive arrangement 120, slippage
of an outer layer 172 (see FIG. 7) of the roll 124, with respect to
an inner layer 174 of the roll 124 of flexible carrier tape 126, is
substantially precluded, as the tape 126 is pulled from the roll
124 along the longitudinally oriented path 128.
[0057] 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.
[0058] As illustrated in FIG. 10, the take-up spool mounting
arrangement 146 is constructed in substantially the same manner as
described above, with relation to the supply spool mounting
arrangement 120. The take-up spool mounting arrangement 146
includes a hub 178, for receiving thereon a core (not shown), such
as a disposal cardboard tube, to which the distal end of the
flexible carrier release tape 126 is taped or otherwise affixed,
and upon which the carrier tape 126 is wound, during operation of
the dispensing apparatus 100. In contrast to the supply spool
mounting arrangement 120, however, an additional cushion, such as
the layer of felt material 170 of the supply spool mounting
arrangement 120, is not provided on the first side plate 180 of the
take-up spool mounting arrangement 146, because, once the
pressure-sensitive adhesive segments 102 are removed from the
carrier tape 126, there is little danger of slippage of an outer
layer of the take-up roll 150, with respect to an inner layer of
the take-up roll 150, of the nature which might occur in the supply
spool 124, and because slippage would actually be advantageous for
forming a compact take-up roll. The hub 178 of the take-up spool
mounting arrangement 146, in the exemplary embodiment 100 has an
outer periphery thereof configured for grasping the core, in
combination with the first and second side plates 180, 182 tightly
enough that the take-up spool mounting arrangement will be capable
of tightly wrapping the flexible carrier release tape 126 onto the
disposable core.
[0059] As best seen in FIG. 1, the exemplary embodiment of the
dispensing apparatus 100 also includes a pre-dispensing guide
roller 184 rotatably mounted to the arm 106 along the longitudinal
path 128 between the supply spool 124 and the adhesive dispensing
roller 140, for rotation about a pre-dispensing roller axis 186
extending substantially parallel to the pivot axis 110. The
pre-dispensing roller 184 has a peripheral surface 188 thereof,
adapted for bearing against the first release surface 136 of the
flexible carrier tape 126, and/or the pressure-sensitive adhesive
segments 102 attached to the first release surface 136, for guiding
the flexible carrier tape 126 along a portion of the longitudinally
extending path 128 of the tape 126 between the supply spool 124 and
the adhesive dispensing roller 140. In the exemplary embodiment,
the peripheral surface 188 of the pre-dispensing roller 184 is
resistant to adhesion thereto of the pressure-sensitive adhesive
segments 102. The pre-dispensing guide roller may have a surface,
for example, fabricated from a material such as a silicone rubber
or another polymer having a low co-efficient of adhesion to the
pressure-sensitive adhesive segments 102. In addition, and/or
alternatively, the peripheral surface 188 of the pre-dispensing
guide roller 184 may have some form of surface treatment, such as a
plurality of grooves 190 being formed therein, for reducing contact
of the peripheral surface 188 of the pre-dispensing roller 184 with
the first release surface 136 of the flexible carrier tape 126 and
the pressure-sensitive adhesive segments 102 attached to the first
release surface 136.
[0060] As shown in FIG. 1, the exemplary embodiment of the
dispensing apparatus 100 also includes a post-dispensing guide
roller 192, rotatably mounted to the arm 106 along the longitudinal
path 128, for receiving the flexible carrier tape 126 from the
adhesive dispensing roller 140. The post-dispensing guide roller
192 is mounted for rotation about a post-dispensing roller axis 194
extending substantially parallel to the pivot axis 110. The
post-dispensing roller 192 has a peripheral surface 196 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. After
leaving the post-dispensing guide roller 192, the flexible carrier
release tape 126 is directed across an upper portion of the supply
spool 124 to a point of attachment with the disposable and/or
recyclable core inside the take-up spool mounting arrangement
146.
[0061] As shown in FIG. 1, the exemplary embodiment of the
dispensing apparatus 100 includes a position sensing and control
arrangement 198, including a controller 200 operatively connected
between a position sensor 202 and the pneumatic cylinder 112, for
monitoring a position of the flexible carrier tape 126, as it is
unrolled by relative linear motion between the arm 106 and the
workpiece 104, and for pivoting the arm 106 in such a manner that
the dispensing apparatus 100 clamps at an appropriate point along
the workpiece 104 and then unclamps the flexible carrier release
tape 126 after a desired number of pressure-sensitive adhesive
segments 102 have been brought into clamped contact with the
workpiece 104, in a manner described in more detail below.
[0062] 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.
[0063] FIG. 3 illustrates the manner in which the exemplary
embodiment of the dispensing apparatus 100 may be utilized for
transferring the pressure-sensitive adhesive segments 102 to
workpieces 104, in an application where the arm 106 is held
stationary, by virtue of attaching the arm support member 108
fixedly to a stationary structure, while the workpieces 104 are
moved linearly, relative to the arm 106, by an appropriate
arrangement, such as the conveyor 206 illustrated schematically in
FIG. 3. As will be understood from examination of FIG. 3, in
combination with the description given above, when the workpiece
104 is approaching a desired position for deposition thereupon of
one of the adhesive segments 102, the dispensing mechanism is
actuated, the arm 106 is pivoted to the position illustrated by
dashed lines in FIG. 3, wherein the dispensing roller 140 clamps
the carrier tape 126 against the surface of the workpiece 104. As
the conveyor 206 continues to move the workpiece 104 in a linear
direction relative to the arm 106, clamping force generated by the
dispensing roller 140, in conjunction with the relative motion,
causes the carrier tape 126 to be pulled from the supply spool 124
to the point that a desired one or more of the pressure-sensitive
adhesive segments 102 passes beneath and is clamped between the
dispensing roller 140 and the surface of the workpiece 104. The
pressure-sensitive adhesive segment 102 bonds with the surface of
the workpiece 104 more strongly than with the first release surface
136 of the carrier tape 126, in such a manner that as the relative
motion between the workpiece 104 and the arm 106 continues, the
pressure-sensitive adhesive segment 102 separates from the carrier
tape 126 and remains bonded to the surface of the workpiece 104. If
it is desired to transfer only one adhesive segment 102 to the
surface of the workpiece 104, the arm 106 is pivoted angularly
following deposition of the single adhesive segment 102 to thereby
unclamp the carrier tape 126. If it is desired to transfer multiple
pressure-sensitive adhesive segments 102, the arm 106 is simply
left in the apply position for a longer period of time, so that
successive adhesive segments sequentially pass beneath and are
clamped between the dispensing roller 140 and the surface of the
workpiece 104.
[0064] FIG. 4 illustrates operation of the exemplary embodiment of
the dispensing apparatus 100 in an installation where the
workpieces 104 are resting on a stationary support surface, and the
relative motion between the arm 106 and the surface of the
workpieces 104 is generated by attaching the arm support member 108
to a linear guide rail apparatus 208, as schematically illustrated
in FIG. 4. Operation of the dispensing apparatus 100, in the
application illustrated in FIG. 4, is substantially the same as
described above in relation to the application of FIG. 3, with the
exception that the angular position of the arm 106 is controlled in
relation to a linear position of the dispensing apparatus 100 along
the guide rail 208, rather than in relation to a linear position of
a workpiece on the conveyor 206 of the arrangement shown in FIG.
3.
[0065] 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 102, 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.
[0066] FIG. 11 illustrates a second exemplary embodiment of a
pressure-sensitive adhesive segment dispensing apparatus 300,
according to the invention, for selectively attaching the
pressure-adhesive segments 102 to a surface of a workpiece 104,
generally in the same manner as described in relation to the first
exemplary embodiment of the dispensing apparatus 100 described
above. As will be understood, from the description below, the
second exemplary embodiment of the dispensing apparatus 300 is
substantially identical to the first exemplary embodiment of the
dispensing apparatus 100, described above, except that the belt and
pulley drive arrangement 152, of the first exemplary embodiment
100, is replaced by a different drive arrangement, to be described
in greater detail below, for driving the take-up spool mounting
arrangement 301, and controlling motion of the supply-spool
mounting arrangement 303, in the second exemplary embodiment of the
dispensing apparatus 300.
[0067] The second exemplary embodiment of the dispensing apparatus
300 includes an arm 302 and arm support member 304 having a
configuration somewhat different, but essentially functionally
identical to the arm 106 and support member 108 of the first
exemplary embodiment 100 described above. The arm 302 of the second
exemplary embodiment 300 is pivotably mounted to the arm support
member 304, for pivotable movement about a pivot axis 306. An
actuator arrangement, including a pneumatic cylinder 308,
operatively connects the arm 302 to the arm support member 304, in
such a manner that the arm 302 may be pivoted about the pivot axis
306, from a first (apply) angular position of the pivot arm 302, to
a second (retracted) angular position of the pivot arm 302, in a
manner essentially identical to that shown in FIG. 6, for the first
exemplary embodiment of the invention.
[0068] The second exemplary embodiment of the dispensing apparatus
300 also includes a motor 310, having an output shaft operatively
connected, through a slippable clutch 312, to the take-up spool
mounting arrangement 301, for applying a torque to the take-up
spool mounting apparatus 301 in a manner causing the take-up spool
to rotate about a take-up spool axis 314. In various embodiments of
the invention, the motor 310 may take any appropriate form, such as
an electric motor, a pneumatic motor, a hydraulic motor, etc.
[0069] The motor 310 and clutch 312 are operatively connected to
the take-up spool mounting arrangement 301 in such a manner that
the clutch 312 applies a torque to the take-up spool mounting
arrangement 301, for urging the take-up spool mounting arrangement
301 to rotate the take-up spool in a direction resulting in winding
the flexible carrier tape onto the take-up spool. The clutch 312,
is configured to slip whenever the flexible carrier tape 126 is not
being pulled from the supply spool 303, so that while the
dispensing apparatus 300 is not dispensing the flexible carrier
tape 126, the motor 310 and clutch 312 maintain a torque on the
take-up spool in a direction precluding having the flexible carrier
tape 126 unwind from the take-up spool 301. The clutch 312, in
various embodiments of the invention, may take any appropriate
form, such as a magnetic clutch, or a mechanical slip-clutch. In
some embodiments of the invention, the motor 310 may drive the
take-up spool mounting arrangement 301 at a higher rotational speed
than the rotational speed achieved by the supply-spool mounting
arrangement 303 while dispensing the dots 102 onto the surface
104.
[0070] The second exemplary embodiment of the dispensing apparatus
300 also includes a braking arrangement 316 which is operatively
connected for resisting rotation of the supply-roll mounting
arrangement 303, when the flexible carrier tape 126 is not being
pulled from the supply spool along the longitudinally directed
path. Specifically, in the embodiment depicted in FIG. 11, the
braking arrangement 316 includes a brake shoe 318, having a braking
surface 320 which is moved into, and out of, engagement with a side
plate 324 of the supply-spool mounting arrangement 303, by a
pneumatic cylinder 326 which is operatively attached between the
arm 302 and the brake pad 318. The brake pad 318 also has attached
thereto, a guide rod 328 which is slidably received within a bore
(not shown) of a guide bushing 330 extending from a bracket
attached to the arm 302.
[0071] The motor 310, and the pneumatic cylinders 308, 326 are all
operatively connected to a controller 332, of the exemplary
embodiment of the invention, in such a manner that the motor 310
runs continually, and the hydraulic cylinders 308, 326 act
simultaneously in such a manner that the motor 310 maintains a
constant winding torque on the flexible carrier tape, whenever the
dispensing apparatus 300 is in operation, and further such that the
pneumatic cylinders 308, 326 operate in a simultaneous, coordinated
manner. Specifically, when the pneumatic cylinder 308 connecting
the arm and the arm support member 302, 304 is actuated to move the
arm 302 to the apply position, the pneumatic cylinder 326 connected
to the brake pad 318 simultaneously retracts the brake pad 318 from
the side plate 324 so that the supply-spool may be rotated about
the supply-spool mounting arrangement axis 306 as the dots are
dispensed onto the surface in the manner described above. When the
controller 332 commands the cylinder 308 between the arm and arm
support member to move the arm out of the apply position, toward
the retracted position, the pneumatic cylinder 326 attached to the
brake pad 318 moves the braking surface 320 of the brake pad 318
into contact with the side plate 324, to thereby preclude rotation
of the supply spool while the arm is not in the apply position.
[0072] In other variations of the second exemplary embodiment,
those having skill in the art will recognize, that other
arrangements may be utilized for coordinating operation of the
motor 310 and pneumatic cylinders 308, 326. For example, the motor
310 could be an electric motor, driven from a direct connection to
a power source (not shown), and the pneumatic cylinders 308, 326
may be connected in a parallel circuit fashion, to a common supply
valve (not shown) of a pneumatic system.
[0073] 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.
[0074] 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.
[0075] 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.
[0076] 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.
* * * * *