U.S. patent application number 16/445176 was filed with the patent office on 2019-10-03 for hot melt adhesive supply and methods associated therewith.
The applicant listed for this patent is NORDSON CORPORATION. Invention is credited to Christopher R. Chastine, Justin A. Clark, Peter W. Estelle, Howard B. Evans, Charles P. Ganzer, Manuel A. Guerrero, Enes Ramosevac, John M. Riney, Sang Hyub Shin, Leslie J. Varga.
Application Number | 20190299242 16/445176 |
Document ID | / |
Family ID | 55527630 |
Filed Date | 2019-10-03 |
![](/patent/app/20190299242/US20190299242A1-20191003-D00000.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00001.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00002.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00003.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00004.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00005.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00006.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00007.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00008.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00009.png)
![](/patent/app/20190299242/US20190299242A1-20191003-D00010.png)
View All Diagrams
United States Patent
Application |
20190299242 |
Kind Code |
A1 |
Chastine; Christopher R. ;
et al. |
October 3, 2019 |
HOT MELT ADHESIVE SUPPLY AND METHODS ASSOCIATED THEREWITH
Abstract
A melter melts particulate hot melt adhesive into a liquefied
form. The melter includes a heated receiving device having an
interior with an inlet that receives the particulate hot melt
adhesive and an outlet. The heated receiving device melts the
particulate hot melt adhesive and directs the liquified hot melt
adhesive to the outlet. A prepackaged container holds a supply of
the particulate hot melt adhesive and includes an outlet. A
particulate hot melt adhesive feed device allows the particulate
hot melt adhesive to be directed from the outlet of the prepackaged
container to the inlet of the heated receiving device.
Inventors: |
Chastine; Christopher R.;
(Lawrenceville, GA) ; Clark; Justin A.; (Suwanee,
GA) ; Estelle; Peter W.; (Norcross, GA) ;
Evans; Howard B.; (Sugar Hill, GA) ; Ganzer; Charles
P.; (Cumming, GA) ; Guerrero; Manuel A.;
(Kennesaw, GA) ; Ramosevac; Enes; (Snellville,
GA) ; Riney; John M.; (Buford, GA) ; Shin;
Sang Hyub; (Duluth, GA) ; Varga; Leslie J.;
(Cumming, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NORDSON CORPORATION |
Westlake |
OH |
US |
|
|
Family ID: |
55527630 |
Appl. No.: |
16/445176 |
Filed: |
June 18, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15043285 |
Feb 12, 2016 |
10357796 |
|
|
16445176 |
|
|
|
|
62115964 |
Feb 13, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F27D 3/0033 20130101;
B05B 15/25 20180201; B65G 11/106 20130101; B65G 11/206 20130101;
B05C 11/1042 20130101; B05B 7/1472 20130101; B29B 13/022 20130101;
F27B 1/00 20130101; F27D 27/005 20130101; F27D 27/00 20130101 |
International
Class: |
B05C 11/10 20060101
B05C011/10; F27D 27/00 20060101 F27D027/00; B29B 13/02 20060101
B29B013/02; B05B 7/14 20060101 B05B007/14; B65G 11/10 20060101
B65G011/10; F27D 3/00 20060101 F27D003/00; F27B 1/00 20060101
F27B001/00; B65G 11/20 20060101 B65G011/20 |
Claims
1. A melter configured to melt particulate hot melt adhesive into a
liquefied form, the melter comprising: a heated receiving device
having an interior with an inlet configured to receive the
particulate hot melt adhesive and an outlet, the heated receiving
device operative to melt the particulate hot melt adhesive and
direct the liquified hot melt adhesive to the outlet; a prepackaged
container holding a supply of the particulate hot melt adhesive and
including an outlet; and a particulate hot melt adhesive feed
device allowing the particulate hot melt adhesive to be directed
from the outlet of the prepackaged container to the inlet of the
heated receiving device.
2. The melter of claim 1, wherein the prepackaged container further
comprises a flexible bag.
3. The melter of claim 1, wherein the prepackaged container further
comprises a rigid container.
4. The melter of claim 1, further comprising a cover on the outlet
of the prepackaged container, the cover capable of being opened for
establishing a flow path for the particulate hot melt adhesive
through the outlet of the prepackaged container.
5. The melter of claim 4, wherein the cover further comprises a
rupturable element.
6. The melter of claim 1, further comprising: a container mounting
component positioned adjacent the heated receiving device, wherein
the prepackaged container is directly connected to the container
mounting component, and wherein the prepackaged container is
configured to be connected to and disconnected from the container
mounting component to allow removal of one prepackaged container
and replacement by a different prepackaged container.
7. The melter of claim 1, further comprising an articulation device
comprising a driven element operative to move the particulate hot
melt adhesive held in the prepackaged container.
8. The melter of claim 7, wherein the articulation device moves the
exterior of the prepackaged container to move the particulate hot
melt adhesive held in the prepackaged container.
9. A flexible hopper configured to hold a supply of particulate hot
melt adhesive for use with a melter for heating and melting the
particulate hot melt adhesive into a liquefied form, the flexible
hopper comprising: at least one side wall defining an interior for
holding the particulate hot melt adhesive, the side wall including
at least a first section that can be moved relative to another
section to move particulate adjacent to a wall of the flexible
hopper toward a central interior location of the flexible hopper;
an outlet in communication with the interior; and a coupling
element configured to connect the outlet with a particulate hot
melt adhesive feed device of the melter.
10. The flexible hopper of claim 9, wherein the flexible hopper
further comprises a prepackaged container.
11. The flexible hopper of claim 9, wherein the flexible hopper
further comprises a bag.
12. The flexible hopper of claim 9, wherein the side wall further
comprises a fabric.
13. The flexible hopper of claim 9, further comprising particulate
hot melt adhesive in the interior and a cover on the outlet, the
cover configured to be opened for establishing a flow path for the
particulate hot melt adhesive through the outlet.
14. The flexible hopper of claim 13, wherein the cover further
comprises a rupturable element.
15. A method for heating and melting particulate hot melt adhesive
into a liquefied form, the method comprising: holding a supply of
the particulate hot melt adhesive in a first prepackaged container
including a first outlet coupled in fluid communication with a
pathway leading to an inlet of a heated receiving device; feeding
the particulate hot melt adhesive from the first outlet of the
first prepackaged container through the inlet of the heated
receiving device; melting the particulate hot melt adhesive from
the first prepackaged container in an interior of the heated
receiving device; directing liquefied hot melt adhesive from the
interior of the heated receiving device to an outlet of the heated
receiving device; pumping the liquefied hot melt adhesive from the
outlet to a hot melt adhesive dispenser; removing the first
prepackaged container from fluid communication with the pathway;
replacing the first prepackaged container with a second prepackaged
container of particulate hot melt adhesive including a second
outlet; feeding the particulate hot melt adhesive from the second
outlet of the second prepackaged container through the inlet of the
heated receiving device; melting the particulate hot melt adhesive
from the second prepackaged container in an interior of the heated
receiving device; directing liquefied hot melt adhesive from the
interior of the heated receiving device to an outlet of the heated
receiving device; and pumping the liquefied hot melt adhesive from
the outlet to a hot melt adhesive dispenser.
16. The method of claim 15, wherein the first and second
prepackaged containers further comprise flexible bags, and the
method further comprises: opening respective first and second
covers disposed over the first and second outlets either during or
after coupling the first and second prepackaged containers,
respectively, to a melter.
17. The method of claim 16, wherein opening the respective first
and second covers disposed over the first and second outlets
comprises rupturing respective first and second rupturable
elements.
18. The method of claim 15, further comprising: feeding the
particulate hot melt adhesive from the first outlet of the first
prepackaged container comprises agitating the first prepackaged
container; and feeding the particulate hot melt adhesive from the
second outlet of the second prepackaged container comprises
agitating the second prepackaged container.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/043,285, filed Feb. 12, 2016, and published
as U.S. Patent App. Pub. No. 2016/00236230 on Aug. 18, 2016, which
is claims priority to U.S. Provisional Patent App. No. 62/115,964,
filed Feb. 13, 2015, which is incorporated herein by reference in
its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to hot melt adhesive
systems.
BACKGROUND
[0003] Hot melt adhesive systems have many applications in
manufacturing and packaging. For example, thermoplastic hot melt
adhesives are used for carton sealing, case sealing, tray forming,
pallet stabilization, nonwoven applications including diaper
manufacturing, and many other applications. Hot melt adhesives
often come in the form of solid or semi-solid pellets or
particulates. These hot melt adhesive particulates are melted into
a liquid form by a melter, and the liquid hot melt adhesive is
ultimately applied to an object such as a work piece, substrate or
product by a dispensing device suitable to the application.
[0004] A supply of unmelted hot melt adhesive pieces (referred to
variously herein as "particulate hot melt adhesive," "hot melt
adhesive particulate," "adhesive particulate", or simply
"particulate") must be maintained and delivered to the melter in
order for the melter to produce the liquid hot melt adhesive used
by the dispensing device. For example, it is known for a person to
employ a scoop or bucket to retrieve hot melt adhesive particulate
from a bulk supply, and to deliver the particulate to a melter.
Typically, this involves filling a hopper or other container
associated with the melter one scoop of hot melt adhesive
particulate at a time. This requires the person to handle the hot
melt adhesive particulate closely, which may be undesirable because
hot melt adhesive dust may be stirred up during handling. In
addition, transferring hot melt adhesive particulate in this manner
is prone to waste caused by spillage.
[0005] Other challenges relate to issues surrounding the propensity
for particulates of hot melt adhesive to become stuck together
under certain storage and use conditions. If particulates stick or
agglomerate together, it becomes difficult to feed the particulate
into a hopper and/or into an associated melter tank. Once the
particulates are in the hopper associated with a melter tank, and
the hopper is separated from the melter tank by a particulate feed
device, clumping and sticking of particulates can be caused by heat
emanating from the melter tank. Therefore, improvements generally
related to these and related areas of hot melt adhesive dispensing
systems are needed.
SUMMARY
[0006] In a first illustrative embodiment, the invention provides a
melter for heating and melting particulate hot melt adhesive into a
liquefied form. The melter includes a heated receiving device
having an interior with an inlet configured to receive the
particulate hot melt adhesive and an outlet, the heated receiving
device operative to heat and melt the particulate hot melt
adhesive, and direct the hot melt adhesive as a liquefied form to
the outlet. A flexible hopper is configured to hold a supply of the
particulate hot melt adhesive. A particulate hot melt adhesive feed
device allows the particulate hot melt adhesive to be directed from
the flexible hopper to the inlet of the heated receiving
device.
[0007] The melter may have various alternative or additional
aspects or components. For example, the flexible hopper further
comprises a bag, and the bag may be formed of any suitable material
for the application needs. One advantageous material is fabric,
such as any strong woven or nonwoven material that can hold
particulate hot melt adhesive. The flexible hopper further
comprises at least a first section that can be articulated relative
to another section to move particulate adjacent to a wall of the
flexible hopper toward a central interior location of the flexible
hopper.
[0008] In another embodiment, the invention provides a melter for
heating and melting particulate hot melt adhesive into a liquefied
form, including a heated receiving device having an interior with
an inlet configured to receive the particulate hot melt adhesive
and an outlet. The heated receiving device is operative to heat and
melt the particulate hot melt adhesive, and direct the hot melt
adhesive as a liquefied form to the outlet. A flexible hopper is
configured to hold a supply of the particulate hot melt adhesive.
An articulation device includes a driven element operative to move
the particulate hot melt adhesive held in the flexible hopper. A
particulate hot melt adhesive feed device allows the particulate
hot melt adhesive to be directed from the flexible hopper to the
inlet of the heated receiving device. This embodiment, as with the
remaining embodiments, may also have alternative or additional
aspects and/or components, such as described herein.
[0009] The flexible hopper further comprises movable wall portions
and an articulation device moves the wall portions to move the
particulate hot melt adhesive held in the flexible hopper. The
articulation device may be operatively coupled to the interior
and/or exterior of the movable wall portions associated with the
flexible hopper.
[0010] In another embodiment, the invention provides a melter for
heating and melting particulate hot melt adhesive into a liquefied
form, including a heated receiving device having an interior with
an inlet configured to receive the particulate hot melt adhesive
and an outlet. The heated receiving device is operative to heat and
melt the particulate hot melt adhesive, and direct the hot melt
adhesive as a liquefied form to the outlet. A hopper is configured
to hold a supply of the particulate hot melt adhesive. A driven
device is positioned within the hopper. The driven device is
capable of moving to thereby move the particulate hot melt adhesive
within the hopper. A particulate hot melt adhesive feed device
allows the particulate hot melt adhesive to be directed from the
hopper to the inlet of the heated receiving device. The driven
device may take on any suitable form. For example, the driven
device may further comprise at least one rotating element
configured to stir the particulate hot melt adhesive.
[0011] In another embodiment, the invention provides a melter for
heating and melting particulate hot melt adhesive into a liquefied
form, including a heated receiving device having an interior with
an inlet configured to receive the particulate hot melt adhesive
and an outlet. The heated receiving device is operative to heat and
melt the particulate hot melt adhesive, and direct the hot melt
adhesive as a liquefied form to the outlet. A hopper is configured
to hold a supply of the particulate hot melt adhesive. A
particulate hot melt adhesive feed device includes a driven feed
element operative to move the particulate hot melt adhesive from
the hopper to the inlet of the heated receiving device. A cover
element is mounted for movement adjacent to the inlet of the heated
receiving device between an open condition and a closed condition.
The cover element is in the open condition when the feed device is
activated to move the particulate hot melt adhesive to the inlet,
and the cover element is in the closed condition when the feed
device is not moving the particulate hot melt adhesive to the
inlet. The driven feed element may take any suitable form. As
examples, the feed element may further comprise at least one of: a
rotating wheel, an auger, or a conveyor. The cover element may, for
example, be heated and in the closed condition particulate hot melt
adhesive will melt and flow past the cover element into the
interior of the heated receiving device.
[0012] In another embodiment, the invention provides a melter for
heating and melting particulate hot melt adhesive into a liquefied
form, including a heated receiving device having an interior with
an inlet configured to receive the particulate hot melt adhesive
and an outlet. The heated receiving device is operative to heat and
melt the particulate hot melt adhesive, and direct the hot melt
adhesive as a liquefied form to the outlet. A hopper is configured
to hold a supply of the particulate hot melt adhesive. A
particulate hot melt adhesive feed device includes a driven feed
element operative to move the particulate hot melt adhesive from
the hopper to the inlet of the heated receiving device. An air
mover device is positioned proximate the inlet opening of the
heated receiving device, and the air mover device directs air
across the inlet opening.
[0013] In another embodiment, the invention provides a melter for
heating and melting particulate hot melt adhesive into a liquefied
form, including a heated receiving device having an interior with
an inlet configured to receive the particulate hot melt adhesive
and an outlet. The heated receiving device is operative to heat and
melt the particulate hot melt adhesive, and direct the hot melt
adhesive as a liquefied form to the outlet. A prepackaged container
is provided and holds a supply of the particulate hot melt
adhesive. The prepackaged container includes an outlet. A
particulate hot melt adhesive feed device allows the particulate
hot melt adhesive to be directed from the outlet of the prepackaged
container to the inlet of the heated receiving device.
[0014] The prepackaged container may take many forms. As examples,
the prepackaged container can further comprise a bag and,
therefore, be flexible. Or, the prepackaged container may comprise
a rigid container. Even when the container comprises a bag, it may
include rigid portions for support and/or at various locations such
as at the outlet. A cover is provided on the outlet of the
prepackaged container, and the cover is capable of being opened for
establishing a flow path for the particulate hot melt adhesive
through the outlet of the prepackaged container. For example, the
cover may comprise a rupturable element that opens when mounted to
the melter, such as by a piercing element. Alternatively, the cover
may be manually or automatically opened during or after a process
used to connect the prepackaged container to the melter.
[0015] In another embodiment, the invention provides a melter for
heating and melting particulate hot melt adhesive into a liquefied
form, including a heated receiving device having an interior with
an inlet configured to receive the particulate hot melt adhesive
and an outlet. The heated receiving device is operative to heat and
melt the particulate hot melt adhesive, and direct the hot melt
adhesive as a liquefied form to the outlet. A container mounting
component is positioned adjacent the heated receiving device. A
prepackaged container is directly connected to the container
mounting component and holds a supply of the particulate hot melt
adhesive. The prepackaged container includes an outlet. The
prepackaged container is capable of being connected to and
disconnected from the container mounting component to allow removal
of one prepackaged container and replacement by a different
prepackaged container. A particulate hot melt adhesive feed device
allows the particulate hot melt adhesive to be directed from the
outlet of the prepackaged container to the inlet of the heated
receiving device. The prepackaged container may have various
alternative or additional features or components, such as described
herein as examples.
[0016] In another embodiment, the invention provides a flexible
hopper configured to hold a supply of the particulate hot melt
adhesive for use with a melter for heating and melting particulate
hot melt adhesive into a liquefied form. The flexible hopper
comprises at least one side wall defining an interior for holding
the particulate hot melt adhesive. The side wall includes at least
a first section that can be moved relative to another section to
move particulate adjacent to a wall of the flexible hopper toward a
central interior location of the flexible hopper. An outlet of the
flexible hopper is in communication with the interior. A coupling
element is configured to connect the outlet with a particulate hot
melt adhesive feed device of the melter. The flexible hopper may
have various additional or alternative features or components, such
as those described herein.
[0017] In another aspect, the invention provides various methods.
For example, a method is provided for heating and melting
particulate hot melt adhesive into a liquefied form. The method
includes holding a supply of the particulate hot melt adhesive in a
flexible hopper including an outlet coupled in fluid communication
with a pathway leading to an inlet of a heated receiving device.
Particulate hot melt adhesive is fed from the outlet of the
flexible hopper through the inlet of the heated receiving device.
The particulate hot melt adhesive is heated and melted in an
interior of the heated receiving device. Liquefied hot melt
adhesive is directed from the interior of the heated receiving
device to an outlet of the heated receiving device. The liquefied
hot melt adhesive is directed from the outlet to a hot melt
adhesive dispenser.
[0018] This method, as well as the other methods disclosed herein
may have various additional or alternative aspects or steps. For
example, agglomerated masses of the particulate hot melt adhesive
in the flexible hopper may be broken apart by 1) moving at least
one wall portion of the flexible hopper relative to another wall
portion of the flexible hopper and/or 2) moving a device within the
flexible hopper configured to contact and break apart the
agglomerated masses.
[0019] Another method for heating and melting particulate hot melt
adhesive into a liquefied form includes holding a supply of the
particulate hot melt adhesive in a flexible hopper including an
outlet coupled in fluid communication with a pathway leading to an
inlet of a heated receiving device. The particulate hot melt
adhesive in the flexible hopper is moved by a device within the
flexible hopper. The particulate hot melt adhesive is fed from the
outlet of the flexible hopper through the inlet of the heated
receiving device. The particulate hot melt adhesive is heated and
melted in an interior of the heated receiving device. Liquefied hot
melt adhesive is directed from the interior of the heated receiving
device to an outlet of the heated receiving device. The liquefied
hot melt adhesive is pumped from the outlet to a hot melt adhesive
dispenser.
[0020] Moving the particulate hot melt adhesive further comprises
rotating the device within the flexible hopper. Moving the
particulate hot melt adhesive can further or alternatively comprise
moving at least one wall portion of the flexible hopper with
respect to another wall portion of the flexible hopper.
[0021] Another method for heating and melting particulate hot melt
adhesive into a liquefied form includes holding a supply of the
particulate hot melt adhesive in a flexible hopper including an
outlet coupled in fluid communication with a pathway leading to an
inlet of a heated receiving device. At least one wall portion of
the flexible hopper is moved with respect to another wall portion
of the flexible hopper. The particulate hot melt adhesive is fed
from the outlet of the flexible hopper through the inlet of the
heated receiving device. The particulate hot melt adhesive is
heated and melted in an interior of the heated receiving device.
Liquefied hot melt adhesive is directed from the interior of the
heated receiving device to an outlet of the heated receiving
device. The liquefied hot melt adhesive is pumped from the outlet
to a hot melt adhesive dispenser.
[0022] Moving the particulate hot melt adhesive in the flexible
hopper further comprises engaging an interior surface of the wall
portion with a driven device and moving the wall portion inward and
outward. Moving the particulate hot melt adhesive in the flexible
hopper can further or alternatively comprise engaging an exterior
surface of the wall portion with a driven device and moving the
wall portion inward and outward.
[0023] Another method for heating and melting particulate hot melt
adhesive into a liquefied form includes holding a supply of the
particulate hot melt adhesive in a first prepackaged container
including a first outlet coupled in fluid communication with a
pathway leading to an inlet of a heated receiving device. The
particulate hot melt adhesive is fed from the first outlet of the
first prepackaged container through the inlet of the heated
receiving device. The particulate hot melt adhesive from the first
prepackaged container is heated and melted in an interior of the
heated receiving device. Liquefied hot melt adhesive is directed
from the interior of the heated receiving device to an outlet of
the heated receiving device. The liquefied hot melt adhesive is
directed from the outlet to a hot melt adhesive dispenser. The
first prepackaged container is removed from fluid communication
with the pathway, and replaced with a second prepackaged container
of particulate hot melt adhesive including a second outlet. The
particulate hot melt adhesive is then fed from the second outlet of
the second prepackaged container through the inlet of the heated
receiving device, and the corresponding heating, melting, directing
and pumping steps are performed with regard to the particulate from
the second prepackaged container.
[0024] As exemplary additional aspects, the first and second
prepackaged containers further comprise flexible bags, and the
method further comprises opening respective first and second covers
disposed over the first and second outlets either during or after
coupling the first and second prepackaged containers, respectively,
to a melter.
[0025] Various additional aspects and features of the invention
will become more readily apparent to those of ordinary skill in the
art upon review of the following detailed description of the
illustrative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is perspective view of a melter constructed in
accordance with a first embodiment of the invention.
[0027] FIG. 2 is a perspective view of interior components of the
melter shown in FIG. 1, including a first embodiment of a flexible
hopper.
[0028] FIG. 3 is a perspective view similar to FIG. 2, but
illustrating the flexible hopper in dash-dot lines to show interior
details.
[0029] FIG. 4 is a perspective view illustrating the components
shown in FIG. 3, from an opposite perspective.
[0030] FIG. 5 is an elevational view, partially sectioned to show
further interior details and operation.
[0031] FIG. 6A is a cross sectional view similar to FIG. 5 and
illustrating further operational details.
[0032] FIG. 6B is a cross sectional view similar to FIG. 6A, and
showing further operational details.
[0033] FIG. 7 is a top elevational view of the melter shown in
FIGS. 1 through 6B.
[0034] FIG. 8 is a perspective view, cross sectioned to show the
various details of the melter, hot melt adhesive feed device, and
flexible hopper.
[0035] FIG. 9 is a perspective view showing another embodiment of a
melter and flexible hopper.
[0036] FIG. 10A is a partially fragmented perspective view of the
flexible hopper shown in FIG. 9.
[0037] FIG. 10B is an enlarged perspective view of the feed device
shown in FIG. 10A.
[0038] FIG. 100 is a perspective view similar to FIG. 10B, but
illustrating the feed device in a different position for feeding
adhesive particulate to the melter tank.
[0039] FIG. 11 is a side elevational view showing the melter of
FIGS. 10A-100.
[0040] FIG. 11A is a view similar to FIG. 11, but illustrating
portions of the melter in cross section to illustrate internal
components and operation.
[0041] FIG. 11B is a side elevational view, partially cross
sectioned as with FIG. 11A, but illustrating further operational
details.
[0042] FIG. 11C is a side elevational view, partially cross
sectioned as with FIG. 11B, but illustrating further operational
details.
[0043] FIG. 12 is a top view of the melter shown in FIGS. 11A
through 110.
[0044] FIG. 13 is a perspective view of another embodiment of a
melter constructed in accordance with the invention.
[0045] FIG. 14A is a perspective view of a portion of the melter
shown in FIG. 13.
[0046] FIG. 14B is a perspective view similar to FIG. 14A, but
showing further operational details.
[0047] FIG. 15A is a side view, in cross section, illustrating the
melter of FIGS. 14A and 14B.
[0048] FIG. 15B is a side cross sectional view similar to FIG. 15A,
but illustrating further operational details.
[0049] FIG. 16 is a perspective view illustrating another
embodiment of a melter constructed in accordance with the
invention.
[0050] FIG. 17A is a perspective view of the melter shown in FIG.
16, with the cover element or lid of the melter in a closed
condition.
[0051] FIG. 17B is a perspective view similar to FIG. 17A, but
illustrating the cover element or lid in an open condition.
[0052] FIG. 18 is a perspective view from an alternative
orientation showing the cover in the open condition.
[0053] FIG. 18A is a perspective view of the enlarged, encircled
portion of FIG. 18.
[0054] FIG. 19A is a side cross sectional view of the melter shown
in FIG. 18.
[0055] FIG. 19B is a side cross sectional view similar to FIG. 19A,
but illustrating further operational details.
[0056] FIG. 20 is a top view of the melter shown in FIGS. 19A and
19B.
[0057] FIG. 21 is a perspective view of a portable container and
docking and particulate transport unit for holding and transporting
particulate hot melt adhesive to a melter, constructed in
accordance with an illustrative embodiment of the invention.
[0058] FIG. 22 is a perspective view similar to FIG. 21, but
illustrating the portable container being inserted into the docking
and particulate transport unit.
[0059] FIG. 22A is a perspective view similar to FIG. 22, but
schematically illustrating a first portable container being removed
and a second portable container being inserted into the docking and
particulate transport unit.
[0060] FIG. 23A is a side cross sectional view illustrating the
portable container of FIGS. 21 and 22 being inserted into the
docking and particulate transport unit.
[0061] FIG. 23B is a side cross sectional view similar to FIG. 23A,
but showing the portable container fully received in the docking
and particulate transport unit.
[0062] FIG. 24 is a front cross sectional view of the portable
container received in the docking and particulate transport
unit.
[0063] FIG. 25 is a perspective view illustrating another
alternative embodiment of a melter in combination with a
prepackaged container of particulate hot melt adhesive.
[0064] FIG. 26 is a side elevational view of another melter similar
to FIG. 25 and illustrating the removal and replacement of a
prepackaged container of particulate hot melt adhesive.
[0065] FIG. 27 is a side view of a supply system.
[0066] FIG. 28 is a rear view of the supply system shown in FIG.
27.
[0067] FIG. 29 is a perspective view of the supply system shown in
FIG. 27.
[0068] FIG. 30 is a cross-sectional view of a supply system with an
agitator plate.
[0069] FIG. 31 is a perspective cross-sectional view of the supply
system shown in FIG. 30.
[0070] FIG. 32 is a perspective view of interior components of the
supply system shown in FIG. 30.
[0071] FIG. 33 is a cross-sectional view of a supply system with an
agitator ring.
[0072] FIG. 34 is a cross-sectional view of a supply system with an
agitator bar.
[0073] FIG. 35 is a partially-transparent perspective view of a
flexible hopper with an articulation device.
[0074] FIG. 36 is a perspective view of the flexible hopper of FIG.
35 showing a connection to a feed device and melter.
[0075] FIG. 37 is a perspective view of the flexible hopper of FIG.
35 supported by a frame structure.
DETAILED DESCRIPTION
[0076] FIGS. 1 through 8 illustrate a first illustrative embodiment
of a melter 10 constructed in accordance with various aspects of
the invention. It will be appreciated that like reference numbers
throughout the figures of the same or different embodiments refer
to like elements of structure. Therefore, with regard to later
embodiments, descriptions of such like structure will not need to
be repeated. FIG. 1 illustrates generally an outer housing 12 and a
controller 14 with a control panel 14a for allowing an operator to
control the various parameters and operational aspects of the
melter 10. The housing 12 includes a lid 18 which may be opened for
purposes of filling a particulate hot melt adhesive hopper 20
within the housing 12. As more specifically shown in FIGS. 2
through 4, which eliminate the outer housing 12 of the melter 10,
the hopper 20 comprises a flexible container or bag 22 in this
embodiment. It will be appreciated that various aspects of the
melter 10 may be practiced instead with a melter that uses a hopper
made with an inflexible or more rigid construction. In this
embodiment, the bag 22 is constructed from a strong fabric type
material, such as woven or nonwoven material that may be easily
flexed without tearing or otherwise weakening the structure of the
bag 22 through repeated motions. In other embodiments, the flexible
hoppers 20 of this invention instead may be formed in multiple
sections of rigid polymer, sheet metal, or other materials, and the
sections may be coupled together for movement relative to each
other such as by the use of hinge structures. As used herein, the
term "flexible hopper" means a hopper having one or more side wall
portions capable of repeatedly moving back and forth toward and
away from an opposite wall portion by a distance more than that
caused by mere vibration. For example, the material forming a
flexible hopper wall portion is capable of moving back and forth
through a distance equal to 10% or more of the total distance to an
opposite wall portion without plastic deformation of the moving
wall portion.
[0077] The melter 10 further comprises a heated receiving device
30, which may comprise a melting tank having a melting grid 32 in a
lower portion (FIG. 5). Generally, in this embodiment the tank 30
includes a chamber 34 for receiving pellets or other particulate
forms of hot melt adhesive 40 (FIGS. 6A and 6B). It will be
appreciated that the heated receiving device 30 may be a large or
small tank, or may be a much smaller heating device with a chamber
that receives a small amount of particulate hot melt adhesive 40
for melt-on-demand purposes. A space 42 below the melting grid 32
receives liquefied hot melt adhesive for directing the adhesive to
an outlet (not shown) and then to a pump 50 and manifold 52 for
delivery to a suitable dispensing device or devices (not
shown).
[0078] Referring further to FIGS. 5, 6A, 6B and 8, a particulate
hot melt adhesive feed device 60 is mounted between an outlet 20a
at the bottom of the flexible hopper 20 and the heated receiving
device 30. This feed device 60 may take any suitable form for
carrying or otherwise delivering the particulate hot melt adhesive
40 from the flexible hopper 20 into the heated receiving device 30.
It may be motorized, or it may simply rely on gravity feed. Feed
devices such as augers or other screw-style conveyors, belt driven
devices or other conveying devices may be used to feed the
particulate adhesive. In this embodiment the feed device comprises
a rotary valve 70 or wheel device having flexible paddle elements
72. The rotary valve 70 is constructed with a central rotating
member 74 coupled to a motor 76 by a belt 78 (FIG. 7). The paddle
elements 72 are affixed to and extend generally radially outward
from the central rotating member 74. As shown in FIG. 3, the motor
76 is used to rotate the rotary valve 70 and a microswitch 80 is
used to detect and control the various rotational positions of the
rotary valve 70 for purposes of determining when the rotary valve
70 rotates and stops to thereby control the feed rate of
particulate hot melt adhesive 40 from the flexible hopper 20 into
the receiving device 30 or tank used for heating and liquefying the
thermoplastic hot melt adhesive. The rotary valve 70 is rotated in
a clockwise direction, and through controlled and sequential
angular movements as best depicted in FIGS. 6A and 6B, delivers
precise amounts of particulate hot melt adhesive 40 by carrying the
amounts of particulate hot melt adhesive 40 between adjacent paddle
elements, as shown in FIG. 6B, and dropping or delivering these
amounts downwardly into an outlet of the feed device 60 when
prompted by the controller 14, such as when the controller 14
receives a signal from a level sensor (not shown) that the tank 30
needs more adhesive. As shown further in FIGS. 5, 6A and 6B, a
flexible skimmer flap 73 is provided in proximity to the rotary
valve 70. The flexible skimmer flap 73 is positioned above the
rotary valve 70 such that it skims across or rides above the
particulate adhesive 40 that is deposited in each quadrant of the
rotary valve 70 on the blades or paddle elements 72. This skimming
action controls the amount of particulate adhesive 40 in each
quadrant thereby improving the volumetric consistency of
particulate hot melt adhesive 40 delivered by the rotary valve 70.
The flexible skimmer flap 73 further prevents uncontrolled flow of
particular hot melt adhesive 40 over the tops of the blades or
paddle elements 72, such as when processing a particular hot melt
adhesive 40 that is free-flowing. FIGS. 5, 6A, 6B and 8 also show a
plurality of blade or paddle flicking elements 75. Especially when
processing adhesives in high ambient temperature conditions, the
potential exists for adhesives to bond to the individual flexible
blades or paddle elements 72. To help mitigate this problem, the
elements 75 provide bumps aligned with each paddle element or blade
72 for individually engaging each flexible blade or paddle element
72 as it passes during rotation of the rotary valve 70. As the
blade or paddle element 72 passes over a bump 75, it will be flexed
and "flicked" such that it releases any adhesive particulate that
is stuck to or bonded with the paddle element 72. This feature
provides a mechanism for preventing jamming of the rotary valve 70
and to ensure that accurate amounts of particulate adhesive 40 are
transferred by the valve 70. Specifically, the particulate hot melt
adhesive 40 is delivered onto a downwardly inclined ramp 86. The
ramp 86 is perforated and angled downwardly toward the open top or
inlet 88 of the heated receiving device 30. A flexible skirt of
rubber, fabric or similar material 90 creates a small opening 92
between a lower end 90a of the panel 90 and the lower end 86a of
the ramp 86 for providing a controlled flow of the particulate hot
melt adhesive 40 through the opening 92 and into the inlet or open
top 88 of the heated receiving device 30 or tank. The skirt 90 also
minimizes migration of hot gases from the tank 30 into the adhesive
feed device 60.
[0079] In addition, the melter 10 includes a cooling air input,
which may include a fan or other source for moving air 94 (FIG. 4)
coupled with an air inlet supply conduit 96. The air supply conduit
96 leads to the inclined ramp 86 and, because of the perforated
nature of the ramp 86, the cooling air passes through the ramp 86
and through the lower opening 92 for the particulate hot melt
adhesive 40. The skirt 90 is fixed to the feed device housing along
a top edge of the skirt 90, in order to leave minimal gaps along
the sides of the skirt 90 and the small opening 92 at the bottom,
through which the cooling air travels. The cooling air then travels
across the open top 88 of the heated receiving device 30 or tank
and through an outlet plenum or conduit 98. This cooling air
provides a heat transfer mechanism for carrying away the heat from
the open top 88 of the hot chamber 34. In this way, the heat
emanating upwardly from the open top 88 of the chamber 34 is
directed away from the particulate hot melt adhesive 40 in the feed
device 60, and in the flexible hopper 20. Therefore, heat from the
tank 30 is less likely to cause the particulate hot melt adhesive
40 to become sticky, or even melt before it reaches the chamber
34.
[0080] Referring to FIGS. 2 through 8, the flexible bag 22 is
attached to a suitable rigid frame structure 100. An articulation
device 102 is attached to the bag 22. It will be appreciated that
the articulation devices described herein are only examples. These
devices may take any form suitable for moving the flexible hopper
to maintain fluidity of the particulate adhesive 40. In this
embodiment, the articulation device 102 comprises a multi-armed
device 104 having end pieces 106 rigidly affixed or otherwise
engaging corner portions of a generally square shaped bag 22. Any
other shape may be used for the bag 22 or other flexible container,
and a bag articulation or deforming device may be designed in any
suitable and desired manner to effect movements of the bag 22
designed to break up any clumps or agglomerations of particulates
40 therein. The central portions of each arm 104a are coupled with
a bearing structure 107 and an eccentric drive mechanism 108 that
rotates the central portions of the arms 104a and the bearing
structure 107. A motor 110 is secured to a central shaft 112 and
the central shaft 112 is affixed to an eccentric coupling element
114 which then is affixed to a short rotating shaft 116. The short
rotating shaft 116 is affixed for rotation relative to a stationary
fixture 120 which, in turn, is affixed to a mounting grid structure
124 (FIG. 1) near the upper opening of the flexible hopper 20. The
hopper 20 may be filled with particulate adhesive 40 through the
grid structure. The shafts 112, 116 and the eccentric coupling
element 114 rotate slowly, such as at about 12 to 15 rpm, about a
central axis 130 and this rotates the center or radial inner
portions of the arms 104a. This is best shown in FIGS. 3 and 7. As
the arm assembly 104 rotates, the arms 104a effectively move
radially inwardly and outwardly as indicated by the arrows 132.
This moves the corners of the bag 22 inwardly and outwardly toward
and away from opposite wall portions of the bag 22 in a generally
reciprocating manner, however, also in a slightly rotating manner.
The effect is that the particulate hot melt adhesive 40 within the
bag 22 is moved from an outer peripheral area of the bag 22
adjacent to the bag 22 itself toward a radially inward or central
area and, in the process, any clumps or agglomerated masses of the
particulates 40 are broken up. In addition, the rotating shaft 112
includes a plurality of elongate paddle members or elongate pins
136 extending generally radially outward. These paddle members 136
extend generally outwardly from the central axis 130 and therefore,
as the shaft 112 rotates, these paddle members 136 travel through
the particulate hot melt adhesive 40 in a rotating fashion and
disrupt the particulate hot melt adhesive 40 at the center of the
flexible bag 22. The paddle members 136 are resilient and flexible
and, therefore, as the shaft 112 rotates, these paddle members 136
can bend or flex in an arc generally around the shaft 112. The
paddle members 136 provide scraping action as the paddles 136 force
their way to a more straightened condition until fully extended.
This minimizes motor torque required to agitate the particulate
adhesive mass 40. The combined effect is that any clumps or
agglomerated masses of particulate hot melt adhesive 40 in the
outer peripheral regions of the flexible hopper 20, or at the inner
or central regions of the flexible hopper 20, are broken apart. In
this manner, the particulate hot melt adhesive 40 exiting the
flexible hopper 20 at the lower end, and entering the inlet of the
feed device 60 comprises the smallest portions broken up for
purposes of delivery to the tank 30.
[0081] FIGS. 9 through 12 are directed to another illustrative
embodiment of a melter 150. This embodiment also utilizes a
flexible bag type hopper 20, which may be constructed as set forth
for the first embodiment. However, the main difference is that an
alternative, illustrative articulation device 152 is used for
moving or articulating the bag 22 inwardly and outwardly in order
to move particulate hot melt adhesive 40 (not shown, for clarity)
from peripheral portions of the bag interior to more central
regions of the bag interior. In this regard, first and second
elongate elements 154, 156 are secured on opposite sides of the bag
22 and include end sections 154a, 156a. The end sections 154a, 156a
of the opposite elements 154, 156 are pivotally coupled together by
pneumatic cylinders 158, 160 each having a reciprocating piston rod
162, 164. The rods 162, 164 move inwardly and outwardly relative to
the associated cylinder 158, 160. The first and second elongate
elements 154, 156 are relatively rigid and attached to or otherwise
engage the exterior of the bag 22. This is unlike the first
embodiment in which most of the structure for articulating or
moving the flexible bag 22 is contained within the flexible hopper
20. In addition, this articulation structure is secured to a lower
portion of the bag 22, closer to the outlet of the bag 22 to help
ensure that the particulate 40 is broken apart as close as possible
to the upper inlet of the feed device 60. In this manner, the
particulate hot melt adhesive 40 is broken up just as it exits the
flexible hopper 20 and enters the feed device 60. Similar to the
first embodiment, a central stirring device 170 is included within
the hopper 20, and generally comprises a central rotating shaft 172
and a plurality of generally radially extending paddle elements
174. As with the first embodiment, this central stirring device 170
stirs and breaks up any agglomerated masses or clumps of
particulate hot melt adhesive 40 in the central regions of the
flexible hopper 20 as the outer or peripheral regions of the bag 22
are flexed and moved inwardly and outwardly by the exterior
articulation device 152.
[0082] This embodiment also includes a lid or cover element 180 for
the heated receiving device 30. This lid 180 is opened to allow
controlled delivery of the particulate hot melt adhesive 40 from
the flexible hopper 20 into the chamber 34 of the heated receiving
device 30 or tank. In this embodiment, the particulate hot melt
adhesive 40 falls by gravity down and inclined ramp or chute 182
from an outlet 20a of the flexible hopper 20. The rotating paddle
elements 174 at the lower end of the shaft 172 will continuously
move the particulate hot melt adhesive 40 into the chute 182. When
the melter or hot melt adhesive receiving device 150 indicates that
there is a low level of adhesive in the chamber 34, an air cylinder
184 is activated to retract a rod 186. The rod 186 is coupled with
a lever 190 by way of a pivot and slot connection 194 (see FIGS.
11A and 11B). This connection 194 ensures that the lid 180 opens
before a gate 198 is lowered (FIG. 11C). The gate 198 is coupled to
the rod 186 as well but, as shown in the succession from FIG. 11B
to FIG. 11C, the lid 180 has already partially opened by the time
the gate 198 begins to open to allow particulate 40 to begin to
fall down the chute 182. Particulate 40 will be prevented from
falling onto a closed lid 180 in this manner. A motor 200 may be
operated for rotating the shaft 172 so as to be on and slowly
rotating when the gate 198 opens, such as at 15 rpm. At the same
time, the piston rods 162, 164 are retracted and extended to
articulate the outer periphery of the bag 22. When the control 14
(FIG. 1) indicates that the tank chamber 34 is full, the motor 200
will stop operating and the rod 186 extends to close the gate 198,
and then close the lid 180 sequentially, i.e., the reverse
operation to that described above. A spring 210 is included to
ensure that in the event that there is no air pressure for the
cylinder 184, the normal position for gate 198 and lid 180 will be
a closed position. This stops the flow of particulate hot melt
adhesive 40 before the lid 180 of the tank 30 closes. Stickier
particulate hot melt adhesives need more agitation. Therefore, in
embodiments that include both bag or other container flexion and
internal stirring, the large masses of agglomerated particulates 40
will be broken up by the bag flexion and directed into a central
region of the bag 22, and the internal stirring device will break
the agglomerated masses into small portions of particulates 40 and
individual particulates. Without the bag flexion, the internal
stirring elements, paddles, pins, etc. may just core out the
radially inward or central region of sticky particulate hot melt
adhesive. The flexible hopper 20 may be again made of any suitable,
strong flexible material such as woven or nonwoven materials,
polymeric materials, etc. For example, the fabric can be a woven
fabric that is embedded in a polymer. One type of suitable fabric
is sold under the brand name Cordura.RTM.. Other heavy duty
fabrics, such as ballistic materials, canvas materials, rip stop
materials or other natural or synthetic materials that can retain
their shape and require little outside support, may be used
instead. The air cylinders 158, 160 and rods 162, 164 for
constructing the articulation device 152 may be compressed in
unison or out of phase with one another. For example, each rod 162,
164 may extend and retract simultaneously, or one may be extending
when the other one is retracting. Alternatively, the rod 162 on one
side of the bag 22 could remain stationary while the other rod 164
is moving.
[0083] FIGS. 13 through 15B are directed to another illustrative
embodiment of a melter 250. In this embodiment, the flexible hopper
20 and articulation/stirring mechanisms are configured and designed
to operate generally the same as discussed above with respect to
the any of the other embodiments described herein. Therefore,
further description of these components is not necessary. This
embodiment includes a slightly different feed device 60 and
different lid operation for the heated receiving device or melting
tank 30. Specifically, a downwardly inclined chute 252 is
constructed between the outlet 20a of the flexible hopper 20 and
the top 88 of the heated receiving device 30. A cover element or
lid 256 is provided at the top 88 of the heated receiving device 30
and is specifically constructed with two cover portions 258, 260
that are pivotally coupled to an actuation structure 264. The
actuation structure 264 comprises first and second linkages 270,
272 each pivotally connected at one end to a reciprocating element
276 and pivotally coupled at the opposite ends to the respective
cover or lid portions 258, 260. The cover or lid portions 258, 260
rotate about axes defined by hinge elements 280, 282. One of the
hinge elements 280 includes a cam 286 that operates a microswitch
290 for indicating to the control 14 (FIG. 1) when the cover or lid
256 is in the open and closed positions. This information is used
by the control 14 to determine when to feed further particulate
adhesive 40 (FIGS. 15A, 15B) into the chute 252, i.e., when to
activate the rotary valve feed device 70. Pins 296 provide physical
stop elements for the lid portions 258, 260 in the closed position
as shown in FIG. 13. The inner ends 258a, 260a of the lid portions
258, 260 are angled downwardly into the chamber 34 such that if
particulate hot melt adhesive 40 falls on top of the lid 256, the
heated lid 256 will melt the adhesive and it will drain or drip
through a central slot 298 into the chamber. As shown in FIGS. 15A
and 15B, this embodiment also includes a rotary valve feed device
70 generally as discussed with regard to the first embodiment. As
shown in FIGS. 15A and 15B, the rotary valve feed device 70 rotates
counterclockwise and each approximately 90 degree segment of the
rotary valve movement carries an amount of particulate hot melt
adhesive 40 between the adjacent paddle elements 72 and past paddle
contact elements 300 such that the particulate hot melt adhesive 40
is dumped into the chute 252. The paddle contact elements 300 align
with the paddle elements 72 and can flex away from the paddle
elements 72 as the rotary valve 70 rotates. The flexing of the
paddle contact elements 300 is designed to prevent the rotary valve
70 from jamming or locking up during operation. Another panel
element 304 is flexible rubber, fabric or a similar material and
provides flow control for the particulate hot melt adhesive 40 at
the lower outlet of the chute 252 and toward the inlet or upper
opening 88 of the tank 30 past the lid portions 258, 260. It will
also be appreciated that the design of the rotary valve 70 in
conjunction with its surrounding structure will ensure that it may
be stopped at a position as shown, for example, in FIG. 15A in
which free flow of particulate adhesive 40 down the chute 252 will
be prevented. In other words, at each of the four stopped
positions, only one of the four quadrants of the rotary valve 70
will be aligned and in communication with the chute 252. An
actuator 310 for moving the lid portions 258, 260 between the open
and closed conditions includes a belt 312 having a pair of switch
actuating elements 314, 316. The switch actuating elements 314, 316
respectively contact a microswitch 320 to start and stop a motor
324, respectively, at the open and closed conditions of the lid
256. The remaining portions or components of the melter 250 may be
as described above, or generally conventional in nature, including
the pump 50 and manifold 52 in fluid communication with the outlet
of the heated receiving device 30 or tank. It will be appreciated
that the tank or heated receiving device 30 may be constructed in
many various forms, and sizes, depending on capacity needs, and/or
melt on demand needs.
[0084] Another embodiment of a melter 330 is shown in FIGS. 16
through 20. In this embodiment, a flexible bag-type hopper 20 is
shown and is very similar to the flexible hopper shown and
described with regard to FIG. 1 and the first embodiment. However,
in this embodiment, radial arms 332 of an articulation device 334
are directed toward the side portions of the flexible bag 22 and
connecting elements 336 are affixed to or otherwise engage the
flexible bag 22 essentially at central portions of each of the
sides of the generally square bag 22. In addition, a cam structure
340 at the central region of the articulation device 334 is
designed with four pivoting elements 342 secured to a central cam
element 344 and dual bearing structure 348. Upper and lower shaft
portions 352, 354 rotate about a central axis 356 and carry the cam
structure 340 in an eccentric path around and spaced from the
central axis 356. This causes the inward and outward radial bag
movement generally as described above with regard to the first
embodiment to move the flexible bag 22 radially inward and outward
during each successive rotation of the upper and lower shafts 352,
354. Again as with the first embodiment, at least the lower shaft
354 includes generally radially outward directed paddle elements
360 that stir and break up central regions of the particulate hot
melt adhesive 40 before the adhesive enters the feed device 60. As
shown in FIGS. 19A and 19B, the rotary feed device 70 is
constructed in a manner similar to the rotary valves previously
described. In this embodiment, however, the paddle elements 72
contact a projection 364 for flexing the paddle elements 72 during
each approximately 90 degrees of rotation. A stationary panel
member 368, in the form of a flexible curtain or skirt, provides a
flow control and a lower, small outlet 370 in a chute 374 leading
to an upper end 88 of the tank 30, generally as previously
described. The lower, small outlet 370 is defined by the rigid
surfaces of the chute 374 on the bottom and sides and by the
flexible curtain 368 at the top. In this embodiment, the tank or
heated receiving device 30 includes a pivotal lid 380 that is
raised and lowered between open and closed conditions by a belt 382
and motor 384. A microswitch 386 is used to indicate the open and
closed conditions to the control 14 (FIG. 1). This microswitch 386
is used to control operation of the motor 384 for allowing
particulate hot melt adhesive 40 to enter the tank 30 when the lid
380 is open. The operation of the motor 384 for actuating the lid
380 is coordinated with the operation of the feed device 60 to
ensure that the lid 380 is opened before the feed device 60 is
operated to send a further amount of particulate hot melt adhesive
40 down the chute 374 and into the tank 30. The flexible curtain
368 blocks heat from emanating into the chute 374 and toward the
outlet 20a of the flexible hopper 20. This creates a thermal break
for helping to prevent melting or softening of the particulate hot
melt adhesive 40. When the lid 380 is in the closed condition, as
shown in FIG. 16, two lid portions 380a, 380b are angled downwardly
toward edges 380c of each lid portion 380a, 380b and the lid
portions angle both toward each other and toward a notch 388 which
acts as a drain. Therefore, if any particulate adhesive falls from
the chute 374 onto the closed lid 380, the particulate 40 will melt
and drain through the notch 388 into the tank 30.
[0085] Referring generally to FIGS. 21, 22 and 22A, in another
embodiment an apparatus 410 includes a docking and particulate
transfer unit 412 and a container 414 constructed in accordance
with an illustrative embodiment of the invention. As shown in FIG.
22, the container 414 holds particulate hot melt adhesive 40 and is
inserted into a container receiving space 418 of the docking and
particulate transfer unit 412. The container 414 may be sized to
hold an amount of adhesive 40 equal to a specific time period of
use, such as one production shift. The container receiving space
418 is defined by a pair of curved sidewalls 420, 422 converging
toward a lower end. A piercing member 424 of the unit 412 is fixed
at the lower end of the container receiving space 418 for purposes
to be described below. The curved sidewalls 420, 422 define a
central slot 430 which is configured to receive an elongate
protruding segment 432 of the container 414 as shown in FIG. 21. At
least this exposed segment 432 of the container 414 is transparent
or at least translucent so that an operator can see the level of
particulate hot melt adhesive 40 in the container 414. The
container 414 has a shape which is generally complementary to the
shape of the internal container receiving space 418 so that a snug
fit is formed between the container 414 and the docking and
particulate transfer unit 412. The container 414 includes a flat
rear wall 440 that engages or is parallel to an interior rear
surface 442 of the docking and particulate transfer unit 412. The
docking and particulate transfer unit 412 further includes a flat
exterior, rear surface 444 with suitable structure (not shown) for
hanging the unit 412 on a wall 446 (FIGS. 23A and 23B). As further
discussed below, and illustrated schematically in FIG. 22A, a first
container 414 may be removed from the unit 412, such as when it is
depleted of unmelted particulate hot melt adhesive 40, and then
replaced by a second container 414a of particulate hot melt
adhesive 40. If empty, the first container 414 may be discarded or
recycled if it is a single-use, disposable or recyclable container
or it may be refilled, as desired.
[0086] As further shown in FIGS. 22, 23A and 23B, the particulate
container 414 includes a lower, generally cylindrical end 460 which
registers within the lower end of the container receiving space
418. The end 460 includes threads 460a that receive an internally
threaded cap 461 (FIG. 22). The cap 461 is used while storing and
transporting the container 414 of particulate adhesive 40 and is
removed prior to inserting the container 414 into the unit 412. The
piercing member 424 pierces a rupturable element or membrane 462
covering a lower end or outlet opening 464 of the container 414
such that the interior of the container 414 and its particulate
contents 40 communicate with a vertically oriented conduit 470. The
particulate adhesive 40 flows by gravity through the vertical
conduit 470 and then into a generally horizontally oriented conduit
472. As further shown in FIGS. 21, 22 and 23B, the container 414
includes a handle 480 coupled with a lid or cover 482 at an upper
end of the container 414 as another manner to access the interior
of the container 414.
[0087] FIG. 24 schematically illustrates the operation of
transporting or moving the particulate adhesive 40 in the container
414 through the outlet opening 464 and into the vertical conduit
470. The particulate adhesive 40 is further moved, such as by using
a pneumatic air moving device or eductor 490 in the direction shown
by the arrows 492 through the generally horizontal conduit 472 to a
melter 494 (FIG. 21). The conduit 472 may include one or more
different types of conduit and these conduits may be rigid and/or
flexible. For example, a flexible hose 496 may be used of any
suitable length to direct the particulate adhesive to the melter
494, as needed, to operate the melter 494 during a dispensing
operation.
[0088] As best illustrated in FIG. 22A, one illustrative embodiment
provides a system for holding and transferring unmelted particulate
hot melt adhesive from a plurality of containers 414, 414a, used
one after the other, to the melter (FIG. 21). In this type of
system, the unit 412 is used to hold a first container 414 as
previously described. When it is desired to remove that container
414 because the container is depleted of unmelted particulate hot
melt adhesive or for other reasons, that container 414 is removed
from the unit 412 and replaced by a new container 414a of unmelted
particulate hot melt adhesive 40. It will be understood that the
containers 414, 414a illustrated herein are merely examples of the
constructions, configurations and shapes that are possible. The
containers 414, 414a may take on many optional forms, and may be
formed as rigid containers, semi-rigid containers, or even flexible
containers such as bags. If a flexible container or bag is used as
the container 414, 414a, it may be formed of various flexible
materials, such as reinforced fabric or mesh materials formed from
polymer or other synthetic material. The unheated docking and
particulate transfer unit 412 is thermally isolated from other
heated components of a hot melt adhesive dispensing system, such as
the heated melter 494 (FIG. 21). It is important to note that the
unmelted particulate hot melt adhesive 40 in the containers 414,
414a remains unsoftened and unmelted by any external heat source,
such as other hot melt adhesive systems components. The first and
second containers 414, 414a may be single use containers which are
discarded or recycled after the unmelted particulate hot melt
adhesive 40 is transferred from the container 414, 414a. Further,
it will be appreciated that many different designs of mechanisms
for opening the outlet 464 of the containers 414, 414a may be used.
For example, as options to the rupturable element 462, various
types of movable gate mechanisms or other selectively actuating
covering elements may be used instead. Such covering elements may
be selectively moved between open and closed positions. Other
single use covering elements, other than the rupturable element
462, may be used to carry out embodiments of the invention.
[0089] FIG. 25 illustrates another alternative embodiment of a
melter 500 utilizing a prepackaged container 414a' of particulate
adhesive 40. In this regard, instead of coupling the prepackaged
container 414a' to a remote unit for delivering the particulate
adhesive to a melter, the prepackaged container 414a' of
particulate adhesive is coupled directly to the melter 500. For
example, the container 414a' of particulate hot melt adhesive 40
may be inserted directly into a receiving unit 502 such that an
outlet 504 of the container 414a' communicates with a suitable
particulate hot melt adhesive feed device, such as one of the feed
devices 60 described hereinbefore, or another suitable feed device.
The feed device 60 then directs the particulate hot melt adhesive
40 into a melting tank 30, such as generally as previously
described. The container 414a' shown in FIG. 25 is rigid, however,
it will be appreciated that any of the flexible hoppers or
containers as described herein may be used instead. The lower end
or outlet 504 of the container 414a' has a suitable cover element
(not shown) that may be opened, such as described in the previous
embodiment or in any other suitable manner. For example, the cover
element may be capable of selectively being opened and closed by a
user in accordance with intermittent needs of the particular
application.
[0090] FIG. 26 schematically illustrates another embodiment of a
prepackaged container 510 of particulate hot melt adhesive 40
coupled with a melter 512. In this embodiment, an outlet cover
element 514 is a rupturable element at the lower end of the
container 510 and a piercing element 520 associated with the melter
512 is used to open the outlet of the container 510 as the
container 510 is inserted thereby facilitating communication
between the interior of the container 510 and the contents of the
particulate hot melt adhesive 40 and a feed device 60. The feed
device 60 is coupled with a suitable heated receiving device 522,
such as a hot melt adhesive melt-on-demand device. It will be
appreciated that the outlet of the prepackaged container 510 may
include any other type of cover element appropriate for sealing and
covering the outlet of the container 510 during shipping and
storage, but capable of being opened either simultaneously with the
insertion of the container 500 into a receiving component or
simultaneous with some other type of coupling of the container 510
to the melter 512. Or, the cover element 514 may be capable of
being opened by a user after the prepackaged container is coupled
with the melter.
[0091] FIGS. 27 through 34 depict illustrative embodiments of a hot
melt adhesive supply system 610 (the "supply system," hereinafter)
including a lateral agitator. In general, the supply system 610 is
configured to receive a supply of hot melt adhesive particulate and
provide the adhesive particulate to an attached adhesive melter.
The adhesive melter, in turn, may provide melted hot melt adhesive
to an adhesive dispensing module.
[0092] Referring to FIGS. 27 through 29, the supply system 610 may
include a rigid outer housing 612. In some aspects, the outer
housing 612 may fully or substantially enclose the components
therein. For example, the outer housing 612 may be formed from a
plastic bin. In other aspects, the outer housing 612 may not fully
enclose the internal components of the supply system 10. For
example, the outer housing 612 may be comprised of a structural
frame with open sides. A lid 618 may be hingedly attached to the
top of the outer housing 612. Further, one or more wheels 616 may
be attached to a bottom portion of the outer housing 612 to
facilitate movement of the supply system 610.
[0093] The outer housing 612 may include a transfer hose connection
614 through which adhesive particulate may be suctioned or
otherwise discharged from the supply system 610. The transfer hose
connection 614 may be a connection piece that allows the supply
system 610 to connect to and supply a separate device with adhesive
particulate. The transfer hose connection 614 may be configured to
create a seal with the separate device, such as a melter, such that
suction is created between the supply system 610 and the separate
device, thus allowing for the discharge of adhesive
particulates.
[0094] Referring to FIGS. 30 through 32, which further depict
internal components of the supply system 610, a flexible inner
housing 640 (not shown in FIGS. 31 and 32) is disposed within the
outer housing 612 to receive the adhesive particulate. The flexible
inner housing 640 may be formed as a bag or similar shape and
constructed from a fabric or other flexible material that is
suitably durable to sustain repeated motions without tearing or
weakening. The flexible inner housing 640 at least partially
defines an inner cavity 630 in which the adhesive particulate is
held and dispensed from. In some aspects, the inner cavity 630 may
be partially defined by the outer housing 612 and partially defined
by the flexible inner housing 640. A top opening 631 of the
flexible inner housing 640, and thus also of the inner cavity 630,
may be defined by a periphery of a top portion 632 of the flexible
inner housing 640. The adhesive particulate may be supplied to the
flexible inner housing 640 via the top opening 631.
[0095] The flexible inner housing 640 may be supported by the outer
housing 612. For example, the top portion 632 of the flexible inner
housing 640 may be affixed to the outer housing 612 while side
portions 633 and a bottom portion 634 of the flexible inner housing
640 remain un-affixed to the outer housing 612. An outer cavity 635
may be defined between the flexible inner housing 640 and the outer
housing 612.
[0096] A suction lance 643, which may include an elongated hollow
tube, is connected to the transfer hose connection 614 at an upper
end and situated within the inner cavity 630 at a lower end. At the
lower end of the suction lance 643, a transfer pump 646 having a
transfer opening 650 provides suction or other motive means to
cause, at least in part, the transfer of adhesive particulate from
the inner cavity 630 to an attached device through the transfer
hose connection 614. In some aspects, the suction or other motive
means may be provided additionally or alternatively by a pump or
other mechanism at the transfer hose connection 614 or further
downstream from the transfer hose connection 614.
[0097] An agitator 636 facilitates movement of adhesive particulate
within the inner cavity 630 and/or prevents clumping and sticking
of adhesive particulate. In the embodiment depicted in FIGS. 30
through 32, the agitator 636 includes one or more elongated
agitator plates 642 situated in the outer cavity 635 external to
and on opposite sides of the flexible inner housing 640. The
agitator plates 642 may be coupled, at respective elongate ends
642a, to one another or another structure in the outer housing 612
via one or more actuators 641, such as pneumatic or hydraulic
actuators. Each actuator 641 may include a cylinder 648 and a
reciprocating rod 649. The agitator 636, including the one or more
agitator plates 642 and one or more actuators 641, may preferably
be situated above (i.e., closer to the top portion 632 of the
flexible inner housing 640) the transfer opening 650 of the
transfer pump 646.
[0098] Upon the reciprocating operation of the one or more
actuators 641, the agitator plates 642 may laterally engage with
the side portions 633 of the flexible inner housing 640 to
manipulate the shape of the flexible inner housing 640 and, thus,
the adhesive particulate therein. The external lateral forces
imparted upon the adhesive particulate by the agitator plates 642
may serve to prevent undesirable bridging or "ratholing" near the
transfer opening 650 of the transfer pump 646 of the suction lance
643 and/or prevent or break up clumping of adhesive particulate
before it reaches the area of the inner cavity 630 (e.g., the area
proximate the bottom portion 34 of the flexible inner housing 40)
from which the transfer pump 646 draws adhesive particulate. For
example, "ratholing" may occur when a central void forms above the
transfer opening 650 of the transfer pump 646 while adhesive
particulate along the circumferential periphery of the inner cavity
630 fails to flow into the central void. The lateral force and
manipulation caused by the actuation of the agitator plates 642
urges the adhesive particulate along the circumferential periphery
of the inner cavity 630 to move to and fill in the central void and
thus be suctioned into the transfer opening 650 of the transfer
pump 646.
[0099] To further facilitate movement of adhesive particulate
within the inner cavity 630, the transfer pump 646 may be
configured with a vibrator 644 and pins 645. The vibrator 644
causes the transfer pump 646 and attached pins 645 to vibrate, thus
agitating any adhesive particulate located near the transfer pump
646. The pins 645 may be affixed to the transfer pump 646 around a
periphery of the transfer opening 650 and extend in a direction
generally parallel to an elongate axis of the transfer pump 646
and/or the suction lance 643.
[0100] A vertical agitator 647 may be disposed in the outer cavity
635 between the bottom portion 634 of the flexible inner housing
640 and the bottom of the outer housing 612. The vertical agitator
647 may engage the bottom portion 634 of the flexible inner housing
640 to agitate by, for example, vertical oscillations, the adhesive
particulate therein. For example, the vertical agitator 647 may
include a vertical agitator plate 652 operatively connected to a
vertical actuator 654. The vertical actuator 654 may be configured
to vertically oscillate (i.e., in directions generally towards and
away from the top opening 631 of the flexible inner housing 640)
the vertical agitator plate 652, which is in contact with the
bottom portion 634 of the flexible inner housing 640. The vertical
oscillation of the vertical agitator plate 652 causes agitation of
the adhesive particulate within the flexible inner housing 640,
particularly the adhesive particulate proximate the transfer
opening 650 of the transfer pump 646, to facilitate flow of the
adhesive particulate into the transfer pump 646.
[0101] FIG. 33 depicts an alternative embodiment of the supply
system 610 in which the agitator 636 comprises an agitator ring
670, which may be circular, elliptical, or other generally round
shape. The agitator ring 670 may be disposed in the outer cavity
635 between the outer housing 612 and the flexible inner housing
640 such that the agitator ring 670 may at least partially contact
the flexible inner housing 640. The agitator ring 670 may be
configured to rotate eccentrically around the flexible inner
housing 640 such that the agitator ring 670 applies a lateral force
to the flexible inner housing 640. Due the eccentric rotation of
the agitator ring 670, the circumferential point of the flexible
inner housing 640 at which the agitator ring 670 applies a lateral
force to the flexible inner housing 640 will be continuously
varied. The lateral force applied by the agitator ring 670 causes
adhesive particulates inside of the flexible inner housing 640 to
agitate, urging the adhesive particulates to drop down to the
transfer pump 646 and be discharged.
[0102] In an aspect, the agitator 636 may include multiple agitator
rings 670. The multiple agitator rings 670 may be configured to
rotate eccentrically in concert with each other, in a specified
pattern or sequence, or in an unrelated manner (e.g., the rotation
of a first agitator ring 670 is out of sync with a second agitator
ring 670). Each agitator ring 670 may rotate at the same speed or
variable speeds (e.g., a first agitator ring 670 rotates at a
different speed as that of a second agitator ring 670). Similarly,
the agitator rings 670 may be formed in the same shape or different
shapes. It will be appreciated that agitator rings 670 that are not
perfectly round may rotate on a fixed axis and still accomplish the
desired function in agitating the adhesive particulates inside of
the flexible inner housing 640.
[0103] FIG. 34 depicts an alternative embodiment of the supply
system 610 in which the agitator 636 includes one or more agitator
bars 680. As indicated by the corresponding arrows, the one or more
agitator bars 680 may each move generally vertically up and down in
the outer cavity 635 between the outer housing 612 and the flexible
inner housing 640. During at least a portion of the vertical travel
of the one or more agitator bars 680, the one or more agitator bars
680 may be in contact with the flexible inner housing 640. The one
or more agitator bars 680 may be spaced from one another or an
opposite side wall of the outer housing 612 such that as the one or
more agitator bars 680 move vertically up and down, the flexible
inner housing 640 therebetween is compressed, thus causing a
lateral force to the adhesive particulate within the corresponding
portion of the inner cavity 630 and facilitating its movement.
[0104] The agitator 636 may include one or multiple agitator bars
680. The agitator bars 680 may be of varying cross-sectional
shapes, such as round, square, triangular, etc. and may be
straight, curved, or other shape. The agitator bars 680 may each be
formed as a roller. In embodiments with multiple agitator bars 680,
the agitator bars 680 may move up and down in concert with each
other, in a specified pattern or sequence, or in an unrelated
manner. For example, the agitator bars 680 may be configured such
that one more upwards while another moves downward and vice versa.
The agitator bars 680 may move at the same speed or at variable
speeds.
[0105] It will be appreciated that the various agitation components
of the supply system 610, such as the agitator 636, the agitator
plates 642, the vibrator 644, the pins 645, the vertical agitator
647, the agitator ring 670, and/or the agitator bars 380, may be
operated sequentially, concurrently, or in concert in a
predetermined pattern. For example, in the embodiment depicted in
FIGS. 32 through 33, the agitator plates 642 may be initially
operated following an extended period of disuse of the supply
system 610 to break up any agglomerations of adhesive particulate
that formed during the period of disuse. During this initial period
of agitator plate 642 operation, the vibrator 644 and the vertical
agitator 647 may remain idle. After the agglomerations of adhesive
particulate are broken up and the supply system 610 is ready to
supply adhesive particulate, the agitator plates 642, the vibrator
644, and the vertical agitator 647 may all operate simultaneously.
As another example, the agitator plates 642 and vibrator 644 may be
configured to operate such that the vibrator 644 does not vibrate
during the compressive stroke of the agitator plates 642 but does
vibrate during the expansive stroke of the agitator plates 642.
[0106] FIG. 35 depicts an illustrative embodiment of an independent
flexible hopper 702, having a plurality of side walls defining an
interior, that is configured to hold a supply of particulate hot
melt adhesive. The side walls of the flexible hopper 702 are
depicted as transparent in FIG. 35 so that the various other
components may be visualized. The flexible hopper 702 includes an
aperture 704 defining an outlet 706 through which the particulate
hot melt adhesive may be supplied, such as to another device. In
some aspects, the aperture 704 may be positioned in a bottom
surface of the flexible hopper 702 (as shown in FIG. 35) so that
the flow of particulate hot melt adhesive through the outlet 706 is
generally in a direction parallel with the longitudinal axis of the
flexible hopper 702. While in other aspects, the aperture 704 may
be positioned at the bottom of one of the plurality of side walls
so that the flow of particulate hot melt adhesive through the
outlet 706 is generally in a direction perpendicular to the
longitudinal axis of the flexible hopper 702.
[0107] The flexible hopper 702 further includes an articulation
device 708, such as the articulation device 102 depicted in FIGS. 2
through 5, that is operable to move a section of a side wall of the
flexible hopper 702 relative to another section of the side wall.
This movement of the section of the side wall may move a portion of
the particulate hot melt adhesive that is adjacent to the side wall
towards a central interior location of the flexible hopper 702.
[0108] The flexible hopper 702 is configured with a coupling
element 710, which may include the aperture 704, to connect the
flexible hopper 702 with another device, such as a melter or an
intermediate distribution or feed device connected to a melter,
that receives the particulate hot melt adhesive supplied from the
flexible hopper 702. For example, FIG. 36 depicts the connection of
the flexible hopper 702, via the coupling element 710, with a feed
device 720 which, in turn, is connected to a melter 722.
[0109] As shown in FIG. 37, the flexible hopper 702 may be
supported by a frame structure 730. The frame structure 730 may be
configured such that a top portion 732 of the frame structure 730
accommodates and supports the flexible hopper 702 and a bottom
portion 734 of the frame structure 730 accommodates a device, such
as a melter or an intermediate feed device connected to a melter,
that receives the particulate hot melt adhesive from the flexible
hoper 702.
[0110] While the present invention has been illustrated by the
description of specific embodiments thereof, and while the
embodiments have been described in considerable detail, it is not
intended to restrict or in any way limit the scope of the appended
claims to such detail. The various features discussed herein may be
used alone or in any combination. Additional advantages and
modifications will readily appear to those skilled in the art. The
invention in its broader aspects is therefore not limited to the
specific details, representative apparatus and methods and
illustrative examples shown and described. Accordingly, departures
may be made from such details without departing from the scope or
spirit of the general inventive concept.
* * * * *