Adhesive splitter systems and methods of using the same

Abstract

Disclosed herein are adhesive splitter systems and methods for using the same. The adhesive splitter systems comprise a multi-nozzle adapter configured to dispense multiple streams of adhesive onto a substrate. The splitter system can also include an attached adhesive dispenser for providing adhesive to the multi-nozzle adapter.

Claims

1. An adhesive splitter system comprising: a multi-nozzle adapter comprising: a fluid inlet, a plurality of fluid outlets, and a fluid dispersion assembly in fluid communication with the fluid inlet and the plurality of fluid outlets, a fluid conveyor for feeding an adhesive into the fluid inlet, the adhesive being a bicomponent resin comprising a resin and a hardener, and an adhesive dispenser connected to the fluid conveyor on an end opposite the multi-nozzle adapter and wherein the adhesive dispenser is configured to separately feed the resin and the hardener to the fluid conveyor, the fluid dispersion assembly comprising: a set of channels, each channel including a channel inlet and a plurality of channel outlets, wherein each channel is configured to receive a portion of the adhesive from the fluid inlet through the channel inlet and discharge some of that portion of the adhesive through one or more of the channel outlets, and a set of nozzle clusters, wherein each cluster is in fluid communication with one of the channel outlets and is configured to receive some of the portion of the adhesive discharged from one or more of the channel outlets, and discharge some portion of that received adhesive through one of the fluid outlets, wherein the fluid inlet is in fluid communication with at least one of the fluid outlets.

2. The adhesive splitter system of claim 1, wherein the multi-nozzle adapter is removable and replaceable.

3. The adhesive splitter system of claim 1, wherein the fluid conveyor comprises a hollow tube having an inner surface, wherein fins are disposed on the inner surface of the hollow tube to create a turbulent flow for mixing the resin and the hardener.

4. The adhesive splitter system of claim 1, wherein the adhesive dispenser further comprises one or more pneumatic valves to control adhesive flow.

5. The adhesive splitter system of claim 1, wherein the fluid conveyor is press-fitted into the fluid inlet of the multi-nozzle adapter.

6. The adhesive splitter system of claim 1, wherein the fluid conveyor is twist-locked into the fluid inlet of the multi-nozzle adapter.

7. The adhesive splitter system of claim 1, wherein the fluid conveyor is formed from polypropylene.

8. The adhesive splitter system of claim 1, wherein the adhesive dispenser comprises a heating element for heating a resin.

9. The adhesive splitter system of claim 1, wherein the multi-nozzle adapter is made of polymer.

10. The adhesive splitter system of claim 9, wherein the polymer is polyethylene terephthalate (PET).

11. The adhesive splitter system of claim 1, wherein the multi-nozzle adapter comprises from 2 to 24 nozzles.

12. The adhesive splitter system of claim 1, wherein the multi-nozzle adapter is made of one single piece.

13. The adhesive splitter system of claim 1, wherein the multi-nozzle adapter is 3D printed.

14. A method for evenly applying adhesive to a substrate, the method comprising: loading a resin and a hardener into separate chambers of an adhesive dispenser; facilitating a flow of the resin and a separate flow of the hardener from the adhesive dispenser into a fluid conveyor; mixing the resin and the hardener inside the fluid conveyor to create an adhesive; providing a multi-nozzle adapter connected to the fluid conveyor, the multi-nozzle adapter including a fluid inlet, a plurality of fluid outlets, and a fluid dispersion assembly in fluid communication with the fluid inlet and the plurality of fluid outlets, wherein the fluid dispersion assembly includes a set of channels, each channel including a single channel inlet and a plurality of channel outlets, and a set of nozzle clusters, wherein each cluster is in fluid communication with one of the channel outlets; and feeding the adhesive from the fluid conveyor into the multi-nozzle adapter through the fluid inlet, such that at a first stage of dispersion at least one channel receives a portion of the fed adhesive through its channel inlet and discharges some of that portion of adhesive through a channel outlet, and at a second stage of dispersion at least one nozzle cluster receives some portion of the adhesive from the channel outlet it is in fluid communication with and discharges some of that portion of adhesive through at least one of the fluid outlets.

15. The method of claim 14, wherein the applying adhesive to the substrate takes about 1 to 3 seconds.

16. The method of claim 14, wherein the multi-nozzle adapter is removable and replaceable.

17. The method of claim 14, wherein the multi-nozzle adapter comprises a polymer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts a perspective view of an adhesive splitter system, not necessarily drawn to scale.

(2) FIG. 2 depicts a cross-sectional view of an adhesive splitter system, not necessarily drawn to scale.

(3) FIG. 3 depicts a side view of an adhesive splitter system, not necessarily drawn to scale.

(4) FIG. 4 depicts a top view of an adhesive splitter system, not necessarily drawn to scale.

(5) FIG. 5 depicts a side view an adhesive splitter system, not necessarily drawn to scale.

(6) FIG. 6 depicts a bottom view of a multi-nozzle adapter, not necessarily drawn to scale.

(7) FIG. 7 depicts perspective views of splitter embodiments with a varying number of nozzles, not necessarily drawn to scale.

(8) FIG. 8 depicts a side view of an adhesive splitter system, not necessarily drawn to scale.

DETAILED DESCRIPTION

(9) Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention is intended to be illustrative, and not restrictive. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

(10) FIGS. 1-8 depict various embodiments of an adhesive splitter system. FIG. 1 depicts adhesive splitter 10, including a fluid conveyor 12 and a multi-nozzle adapter 14. In some embodiments, multi-nozzle adapter 14 can include a fluid inlet 16. In some embodiments, the multi-nozzle adapter 14 can be removable and replaceable. In some embodiments, the multi-nozzle adapter 14 can be single-use or few-use. In still some embodiments, multi-nozzle adapter 14 can be disposable. The fluid conveyor 12 can include a hollow tube having an inner surface and an outer surface. Mixing elements (not shown) such as fins can be disposed on the inner surface of the hollow tube to create a turbulent flow for mixing the resin and the hardener. In some embodiments, fluid conveyor 12 is removable and replaceable. In some embodiments, fluid conveyor 12 is single-use or few-use. In some embodiments, fluid conveyor 12 is disposable. In some embodiments, adhesive splitter 10 can further include rigidity shaft 20. The rigidity shaft 20 can at least partially surround the fluid conveyor 12. However, in other embodiments, the rigidity shaft 20 can fully surround the fluid conveyor 12. In some embodiments, the fluid inlet 16 is in fluid communication with at least one of the fluid outlets 22. In still some embodiments, adhesive splitter 10 can include multi-nozzle adapter 14 without the fluid conveyor 12.

(11) As shown in FIGS. 2-3, multi-nozzle adapter 14 can further include at least one channel 13. In some embodiments, adapter 14 can include a set of channels 13. The channels are preferably integrally formed or separately disposed on the inside of adapter 14. Each channel 13 can include a single channel inlet 15 and one or a plurality of channel outlets 17. The channel inlet 15 can be configured to receive a portion of adhesive from the fluid inlet 16 and discharge some of that portion of adhesive through one of the channel outlets 17. Multi-nozzle adapter 14 can further include a nozzle cluster or a set of nozzle clusters 19. There can be two more nozzle clusters 19 in the cluster set. There can be two or more nozzles 18 in each nozzle cluster. Each nozzle can have at least one inlet and at least one outlet. Each of the cluster nozzle inlets are fluidly connected to the fluid inlet and are configured to receive a portion of adhesive from the fluid inlet 16 and discharge that portion of adhesive. Preferably, each nozzle cluster 19 is connected to the fluid inlet 16 via a channel 13. For example, each of the cluster nozzle inlets can be configured to engage a channel outlet 17. In some embodiments, some of the portion of adhesive received from the engaged channel outlet 17 can be discharged through at least one of the fluid outlets 22. The adapter 14 can separate the flow of the adhesive from the fluid inlet 16 into multiple streams through the channels 13 and/or the nozzle clusters 19.

(12) In some embodiments, the fluid inlet is in fluid communication with at least one of the channels 13 and at least one of the nozzle clusters 19. In some embodiments, the fluid inlet is in fluid communication with at least two of the channels 13 and at least four of the nozzle clusters 19.

(13) FIG. 4 shows a top view of multi-nozzle adapter 14. Fluid inlet 16 can be integrally or separately formed into the top side of multi-nozzle adapter 14. The fluid inlet 16 can further include ridging or similar design such that fluid conveyor 12 can be twisted into inlet 16 and locked into place. However, any suitable means for connecting the fluid inlet 16 and the fluid conveyor 12 can be used. For example, fluid conveyor 12 can be press-fitted into the fluid inlet 16 of the multi-nozzle adapter. In some embodiments, fluid conveyor 12 can be connected to the inlet 16 by screw, magnet, snap-in, friction-fit, a combination thereof, or any comparable mechanism now known or later discovered. In some embodiments, fluid conveyor 12 can indirectly engage inlet 16 through an intermediary connecting component. In other embodiments, fluid conveyor 12 can feed adhesive to the multi-nozzle adapter without engaging it directly (e.g. floating above the fluid inlet 16). In some embodiments, the top side of the adapter can be shorter in length than the bottom side of the adapter.

(14) As shown in FIG. 5, in some embodiments, the top portion of the adapter can taper from a wider top side to a narrower bottom side. As shown in FIG. 6, in some embodiments, nozzles 18 and corresponding fluid outlets 22 are substantially linearly aligned. In other embodiments, nozzles 18 and corresponding fluid outlets 22 do not form a line but can be offset from each other. As shown in FIG. 7, multi-nozzle adapter 14 can include any suitable number of nozzles—and corresponding outlets—for applying multiple streams of adhesive onto a flooring substrate. For example, multi-nozzle adapter 14 can include 2 to 100 nozzles (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95) and 2 to 100 corresponding fluid outlets (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95). In certain embodiments, adapter 14 includes from 2 to 24 nozzles and from 2 to 24 fluid outlets.

(15) The multi-nozzle adapter 14 can be formed in a single piece. Preferably the multi-nozzle adapter can be made using any suitable 3D printing technique, such as with a fused deposition modeling (FDM) machine or a stereolithography (SLA) machine. In other embodiments, the multi-nozzle adapter is molded in two shells, e.g. via injection molding, and then the shells are joined together, preferably welded, for example with ultrasonic welding.

(16) In some embodiments, as shown in FIG. 8, adhesive splitter system 10 can further comprise an adhesive dispenser 30. In certain embodiments, the adhesive dispenser is a gun. In other embodiments, adhesive dispenser 30 is a sprayer. Still any suitable dispenser mechanism can be used. In one embodiment, the adhesive dispenser 30 can connect to multi-nozzle adapter 14 through threaded attachment 32 and/or tubular member 34. Inside adhesive dispenser 30 can be at least one chamber (not shown) for housing an adhesive component. For example, the chamber can house a mono-component resin, such as a thermal-activated resin. In other embodiments, inside adhesive dispenser 30 can be at least two chambers (not shown) for housing a resin and a hardener, separate. In other embodiments, adhesive dispenser 30 can include any suitable structure to house an adhesive component (e.g. tubes). In some embodiments, adhesive dispenser 30 will not have an adhesive storage chamber or adhesive storage structure but may receive the adhesive component or components from an external reservoir. In this embodiment, the component could flow freely in open space inside the dispenser 30. A drive mechanism for moving the resin and the hardener through the adhesive dispenser 30 and subsequently through tubular member 34 can also be included inside or outside of adhesive dispenser 30. The drive mechanism can include at least one pump, for example a piston pump, or a gear pump, a combination thereof, or any other suitable means now known or later discovered. In some embodiments, where the fluid conveyor 12 is disposed between the adhesive dispenser 30 and the multi-nozzle adapter 14, the adhesive dispenser 30 can be connected to the fluid conveyor 12 on an end opposite the multi-nozzle adapter 14. Moreover, adhesive dispenser 30 can include a valve assembly to control the flow of the resin and the hardener. For example, the valve assembly can include a pneumatic valve or any other suitable valve system now known or later discovered. The valve assembly can control speed of flow, rate of flow, volume of flow, and the like. The valve assembly can further control stop and start of flow. In lieu of threaded attachment 32, any suitable intermediary connecting component can be used. The system can be attached to a robot or a pantograph or a moving and/or orientating device and can be included in a gluing line. In still other embodiments, the adhesive dispenser 30 can further include a heating element for heating the resin and/or the hardener before being fed to the fluid conveyor 12. The resin and/or the hardener can be heated to a temperature of 30 degrees C. to 50 degrees C. (e.g., 35 degrees C., 40 degrees C., 45 degrees C.).

(17) According to the preferred embodiment of the invention, the multi-nozzle adapter 14 can be made of any suitable polymer now known or later discovered or developed, including but not limited to thermoplastics such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyamide (PA), photopolymer resins, combinations thereof, and the like. In a preferred embodiment, the multi-nozzle adapter is formed from polyethylene terephthalate (PET). In some embodiments, the fluid conveyor 12 can be made of any suitable polymer now known or later discovered or developed, including but not limited to thermoplastics such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyamide (PA), photopolymer resins, combinations thereof, and the like. In certain embodiments, the fluid conveyor 12 can be made of polypropylene (PP). In some embodiments, rigidity shaft 20 can be made of generally all metals and alloys thereof now known or later developed or discovered, including, but not limited to copper, steel, aluminum, tungsten, titanium, and/or any combination thereof.

(18) In some embodiments, multi-nozzle adapter 14 can be any height and/or any width suitable to accommodate nozzles 18 and/or fluid outlets 22. In some embodiments, multi-nozzle adapter 14 can have multiple heights and/or widths. It can be any overall height and/or width suitable to at least partially house nozzles 18 and/or fluid outlets 22. In some embodiments, multi-nozzle adapter 14 can have a height of from 10 mm or more, preferably 20 mm or more (e.g. 25 mm to 40 mm, 30 mm to 35 mm). In some embodiments, multi-nozzle adapter 14 can have a width, of from 10 cm to 50 cm. In some embodiments, multi-nozzle adapter 14 can have a width of 2 cm or more (e.g. 15 cm to 45 cm, 10 cm to 15 cm, 3 cm to 7 cm). In some embodiments, multi-nozzle adapter 14 can have a width of from 20 cm to 40 cm. In some embodiments, the diameter of each of nozzles 18 and each of fluid outlets 22 can be substantially the same and/or uniform. In some embodiments, the diameter of each of nozzles 18 can be 10 mm or lower, preferably 5 mm or lower, for example 3 mm or lower, from 0.5 mm to 5 mm, 1 mm to 3 mm or 1 mm to 10 mm (e.g. 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm). In some embodiments, fluid conveyor 12 can have a length of from 15 cm to 25 cm (e.g., 17 cm, 18 cm, 19 cm, 20 cm, 21 cm, 22 cm, 23 cm, 24 cm). In some embodiments, the diameter of each of fluid outlets 22 can be 1 mm to 10 mm (e.g. 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm). The diameter of each nozzle 18 can be equal to or less than the diameter of a corresponding fluid outlet 22. In some embodiments, fluid conveyor 12 can have a length of from 15 cm to 25 cm (e.g., 17 cm, 18 cm, 19 cm, 20 cm, 21 cm, 22 cm, 23 cm, 24 cm).

(19) In some embodiments, the resin viscosity can be lower than 1000 cps, for example it can range from 500 cPs to 700 cPS, preferably 640 cPs. In some embodiments, the hardener viscosity can range from 200 cPs to 400 cPs, preferably 350 cPs. The viscosity of the adhesive formed by the mixing of the resin and the hardener can range from 400 to 600 cPs, preferably 500 cPs. All viscosities are at 25 degrees C. In some embodiments, flow ratio of the adhesive can range from 10 CC/second to 20 CC/second. Without the splitter adapter 14, the adhesive application time was about 13 to 15 seconds (e.g. 13.6 seconds for 14 rows) and the pressing time was about 14 to 16 seconds (e.g. 15 seconds). In case of gluing two or more objects, such as in sheet form, pressing time is the time that pressure must be kept for spreading the adhesive on the contact surfaces. With the splitter adapter, the adhesive application takes about 2 to 3 seconds (e.g. 2.6 seconds for 48 rows), and the pressing time 7 to 9 seconds (e.g. 8 seconds). For an adapter with 24 fluid outlets, the application time decreased to 1 to 3 seconds (e.g. 1.76 seconds). The decreased application and pressing times have resulted in increased productivity of the process from about 2 to 2.5 pieces per minute to about 4.5 to 5 pieces per minute. Moreover, the overall spread of the glue is better and more controllable.

(20) In some embodiments, a method for evenly applying adhesive to a flooring substrate is contemplated. It includes loading a resin and a hardener into separate chambers of an adhesive dispenser 30. It can also include facilitating a flow of the resin and a separate flow of the hardener from the adhesive dispenser 30 into fluid conveyor 12. In some embodiments, it further includes mixing the resin and the hardener inside the fluid conveyor 12, or otherwise, to create an adhesive. Multi-nozzle adapter 14 can be connected to the fluid conveyor 12. The adhesive can then be fed into the multi-nozzle adapter 14 through the fluid inlet 16. Each nozzle 18 can receive a portion of the fed adhesive and discharge that portion of adhesive through a coupled fluid outlet 22. In some embodiments, the adhesive can be fed to the multi-nozzle valve at ambient temperature. In other embodiment the resin and/or the hardener can be heated before being loaded into the dispenser 30.