Device for intermittently applying a flowable substance, and method for applying such a substance

Abstract

A device for intermittently applying a flowable substance to a substrate includes an applicator nozzle for applying the flowable substance to the substrate, a tank for holding the flowable substance, a pump for delivering the substance, wherein the pump is actively connected to the tank, and further including an actuator actively connected to the pump and transferred into two positions, in a first position the actuator conducts the substance to the applicator nozzle, and in a second position the actuator blocks the feed to the applicator nozzle, and further including a control device for activating the actuator and for regulating the speed of the pump. A method for applying the substance using the device is also provided.

Claims

1. A device for intermittently applying a flowable substance to at least one substrate, comprising: an applicator nozzle for applying the flowable substance to the substrate; a tank for holding the flowable substance; a pump for delivering the flowable substance from the tank; and a drive means of the pump; wherein the pump is actively connected to the tank and the pump is driven by the drive means; and an actuator actively connected to the pump and operable to be transferred between two positions; wherein in a first position the actuator conveys the flowable substance to the applicator nozzle, and in a second position the actuator blocks a feed of the flowable substance to the applicator nozzle; and a control device for activating the actuator and for regulating a speed of the drive means of the pump; wherein the speed of the drive means is linear with respect to a displacement volume of the pump; wherein with the pump being driven by the drive means, in the second position the actuator feeds a flow of the flowable substance back to the tank via a return line; wherein in the first position the actuator blocks the flow of the flowable substance back to the tank; and wherein the speed of the drive means is different in the first position and the second position of the actuator.

2. The device as claimed in claim 1, wherein the speed of the drive means in the first position and the second position of the actuator is such that a pressure of the flowable substance upstream from the actuator during a discharging from the applicator nozzle and during a returning of the flowable substance to the tank is the same.

3. The device as claimed in claim 1, wherein the actuator is a switching valve which can be switched between the first position and the second position of the actuator.

4. The device as claimed in claim 1, wherein the actuator has a first valve and a second valve, and wherein, in the first position, the first valve conveys the flowable substance to the applicator nozzle and, in the second position, the first valve blocks the feed of the flowable substance to the applicator nozzle, and wherein, in the first position, the second valve blocks the flow of the flowable substance back to the tank and, in the second position, frees the flow of the flowable substance back to the tank.

5. The device as claimed in claim 1, wherein the applicator nozzle is in the form of a slotted nozzle and wherein a length of an outlet cross-section of the applicator nozzle can be modified when a width of the outlet cross-section of the applicator nozzle is constant.

6. The device as claimed in claim 1, wherein a choke is integrated into a return-flow section of the actuator or into the return line through which the flow of the flowable substance is returned back to the tank.

7. The device as claimed in claim 6, wherein it is not possible to set the choke.

8. The device as claimed in claim 6, wherein a flow resistance of the choke corresponds to a flow resistance of the applicator nozzle in an average setting of a length of an outlet cross-section of the applicator nozzle.

9. The device as claimed in claim 1, wherein a pressure sensor for determining a pressure of the flowable substance is arranged upstream from the actuator, and wherein the pressure of the flowable substance is determined by the pressure sensor and transmitted to the control device.

10. The device as claimed in claim 9, wherein the pressure sensor is installed only temporarily for adjustment purposes and/or for calibration purposes.

11. The device as claimed in claim 9, wherein a device for limiting the pressure of the flowable substance constituted by the pressure sensor, the control device and a connection line connecting the pressure sensor and the control device is present downstream from the pump and a maximum pressure is monitored by the pressure sensor, and wherein the control device switches off the drive means of the pump when the maximum pressure is exceeded and switches the actuator into a return position.

12. A method for applying a flowable substance to a substrate using a device as claimed in claim 1, wherein a ratio between a volume flow of the flowable substance during the application of the flowable substance and a volume flow of the flowable substance during a return flow to the tank is determined by an adjustment procedure.

13. The method as claimed in claim 12, wherein the adjustment process is dependent only on a set length of an outlet cross-section of the applicator nozzle at least one of a speed of the substrate being conveyed relative to the applicator nozzle and/or a thickness of the flowable substance to be applied to the substrate and/or a viscosity of the flowable substance and/or a flow behavior of the flowable substance in an average range of use are chosen for the adjustment process.

14. The method as claimed in claim 13, wherein the adjustment process takes place with software control and automatically such that the whole adjustment range of the applicator nozzle is first covered and, when the lengths of the outlet cross-section of the applicator nozzle are chosen, a pressure prevailing at a pressure sensor and the speed of the drive means are determined, and the actuator is then switched to circulation mode and the respective speeds of the drive means are determined at which in each case the pressure at the pressure sensor is the same as during the application of the substance by means of the applicator nozzle, for the same selected lengths with the same selected conditions, and wherein multiple determined ratios between a volume flow during the application of the flowable substance and the circulation are stored and used by the control device during the subsequent operation of the device.

15. The method as claimed in claim 12, wherein during the adjustment procedure, when operating with a constant conveying speed of the substrate, a percentage deviation in the pressure of the flowable substance upstream from the actuator between a start and an end of the application of the flowable substance to the substrate is measured and averaged over a plurality of application cycles, and a speed ratio of the pump between the application of the flowable substance and the circulation of the flowable substance changes automatically in increments until a measured deviation in pressure during the application of the flowable substance is minimal.

16. The method as claimed in claim 12, wherein the flowable substance is a flowable adhesive.

17. The device as claimed in claim 1, wherein the flowable substance is a flowable adhesive.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

(1) The invention is illustrated in schematic views in the drawings with reference to exemplary embodiments without being limited thereto.

(2) FIG. 1 shows a device for intermittently applying a flowable substance, which is adhesive, to a substrate, which is a book spine.

(3) FIG. 2 shows the device of FIG. 1 in a detailed view of the part regions.

(4) FIG. 3 shows the device of FIG. 1 in a part region in which is arranged the applicator nozzle with a length which can be adjusted in terms of its outlet cross-section.

(5) FIG. 4 shows a book spine with applied adhesive.

(6) FIG. 5 shows an adhesive flow diagram for a first exemplary embodiment.

(7) FIG. 6 shows an adhesive flow diagram for a slightly modified second exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

(8) FIG. 1 illustrates the installed situation of a device 1 for intermittently applying a flowable adhesive to substrates, in the present case to book spines 2 of book blocks 3. The adhesive is, for example, polyurethane. This hot melt adhesive has a particularly high resistance to the sheets being pulled out, and moreover an optimum lay-flat behavior for book blocks 3.

(9) With reference to the view in FIGS. 1 and 2, with respect to the device 1, a pre-melter 4, a feed line 5 for the heated adhesive, a return line 6 for the heated adhesive, and an application station 7 for the heated adhesive are shown. The book blocks 3 are clamped in transport clamps 8 and are moved by a pulling means 9 in a direction of movement which corresponds to the illustrated coordinates X of a coordinate system, over the application station 7, and to be precise an applicator nozzle 10 of the application station 7. The other coordinates Y and Z are illustrated. A rectangular outlet cross-section 11 of the applicator nozzle 10, viewed in the plan view, in an opposite direction to the coordinate Z, has an adjustable longitudinal extent in the direction Y, and a constant widthwise extent in the direction X. The variable longitudinal extent of the outlet cross-section is matched to the respective width of the book block 3, wherein this width extends in the direction Y, and the applied length of the adhesive on the book spine 2 of the book block 3 results from the conveying movement of the respective book block 3 in the direction X when the applicator nozzle 10 is open. Depending on the conveying speed of the book spine 2 relative to the open applicator nozzle 10 and on the mass flow rate of the adhesive through the outlet cross-section 11 of the applicator nozzle 10, a defined application thickness in the direction Z results on the book spines 2 (see in particular the view in FIG. 4).

(10) The adhesive is applied uniformly to the book spines 2 with the aid of a control device 12, an electric drive means 13, and a pump 14, which can be driven by means of the drive means 13, for conveying the flowable adhesive. The speed of the drive means 13 can be regulated. The pump 14 is a geared pump.

(11) The respective transport clamp 8 has a front jaw 15 in the form of a plate and a rear jaw 16 also in the form of a plate. The jaws 15, 16 of the respective transport clamp 8 are moved synchronously in the direction X. The respective rear jaw 16 cannot move in the direction Y. Only the front jaw 15 can move in the direction Y and in the opposite direction such that the distance between the two jaws 15, 16 can be modified in order to clamp the book blocks 3 between the jaws 15, 16. The respective rear jaw 16 forms, on the side facing the front jaw 15, a plane spanned by the coordinates X and Z which essentially lies on the same plane, apart from slight deviations, as a bearing surface 17 of a fixed feed guide 18 of the application station 7. This feed guide 18 forms a guide for the book blocks 3 on an applicator head 19 of the application station 7.

(12) Actively connected to the control device 12 are a sensor 20 for detecting the transport speed of the book block 3 in the direction X, a sensor 21 for detecting the beginning and end of the respective book block 3, relative to the direction X, and an actuator 22, in the form of a valve, for feeding the flowable adhesive to the applicator head 19 and, if required, a pressure sensor 23 via a connection line 24. The flowable adhesive is fed from the pre-melter 4 via the feed line 5 by positive displacement from the pump 14, which is driven by means of the drive means 13, and controlled via the control device 12. Adhesive conveyed by the pump 14 is returned to the pre-melter 4 via the return line 6 during periods when no adhesive is being applied.

(13) FIG. 3 illustrates details of the applicator head 19 with an adjusting mechanism 25 for adjusting the outlet cross-section 11 of the applicator nozzle 10 by a cover, which covers the outlet cross-section 11 to a greater or lesser degree, being displaceable in the direction Y and in the opposite direction by means of the adjusting mechanism 25. The respective book block 3 is moved linearly in the direction X over the applicator nozzle 10 in the form of a slotted nozzle. The flowable adhesive is thus transferred onto the book spine 2 via the outlet cross-section 11. The movable cover 26 is guided, with as little play as possible, by a linear guide 27 and is activated via the adjusting mechanism 25, which is driven by a drive means 28 of the cover 26, and is in each case adjusted such that the length Y of the outlet cross-section 11 corresponds essentially to the book block thickness.

(14) FIG. 4 shows a schematic diagram of a book block 3 and its most important dimensions, and moreover an application of adhesive 29. The adhesive is applied to the book spine 2. The application thickness 30 of adhesive can be set within a range of 0.05 to 4 mm. The application thickness preferably lies within the range of 0.3 to 0.6 mm for PUR. The distance from the beginning of the application 31 to the front side 32 of the book block 3 and the distance from the end of the application 33 to the rear side 34 of the book block 3 can be set to be between −5 and 100 mm. These values preferably lie between 0 and 15 mm. The application width, i.e. the dimension in the direction Y, corresponds essentially to the book block thickness and lies within the range of 1 to 80 mm. The maximum production rate of the book block 3 to be expected can be set to be between 1000 per hour and approximately 6000 per hour. The system described can, however, also be used for significantly higher production rates. The change in the application width is then restricted by adjusting the cover 26 between two successive book blocks.

(15) The drive means 13 and the pump 14 are arranged underneath the pre-melter 4. The drive means 13 is connected to the pump 14 via a clutch.

(16) FIG. 5 shows the basic design of the device 1 connected to an adhesive binder. The transport clamps 8 of the adhesive binder are fastened to the pulling means 9 and are moved in the direction X at a defined speed. This speed generally remains constant during production. The book blocks 3 are clamped in the transport clamps 8 and moved together with the transport clamps 8. The speed of the book blocks 3 is detected by the sensor 20 and forwarded to the control device 12 for processing. The book front edge associated with the front side 32 and the book rear edge associated with the rear side 34 are detected by the sensor 21 and forwarded to the control device 12 for processing. The adhesive binder transmits the signals for the book block thickness in a suitable fashion to the control device 12 such that the latter can associate the book block thicknesses to be processed explicitly with the book blocks to be processed. The important thing here is that the control device 12 has the data for the speed and the book block thickness and can determine the time at which each application of adhesive starts and finishes. The manner in which the data required for this pass to the control device 12 can also take a different form to the one which has been shown or described.

(17) The adhesive is melted in the pre-melter 4 in molten and held ready in flowable form. The pump 14 delivers the adhesive held ready in the pre-melter 4 via the feed line 5 and the actuator 22 or valve either to the applicator nozzle 10, during the application of adhesive to the book spines 2, or via the return line 6 back to the pre-melter 4. The pressure of the adhesive is detected by the optional pressure sensor 23 directly upstream from the actuator 22 and transmitted to the control device 12. The pressure sensor 23 is not strictly necessary for satisfactory functioning of the system and can be omitted for cost reasons or only installed temporarily.

(18) The cover 26 of the applicator nozzle 10 for adjusting the application width of adhesive is activated, adjusted, and set via the adjusting mechanism 25 and the drive means 28. The signal and the triggering of the drive means 28 can either be provided or take place by the control device of the adhesive binder or by the control device 12 of the device 1. The actuator 22 for feeding the adhesive to the applicator nozzle 10 is activated by the control device 12 in such a way that the beginning of each adhesive application and the end of each adhesive application correspond precisely to the previously determined values. The actuator 22 takes the form of a switching valve. In a first position of the actuator 22, the flow from the feed line 5 to the applicator nozzle 10 is free and the return line 6 is blocked. In a second position of the actuator 22, the feed of the adhesive to the applicator nozzle 10 is interrupted and the feed line 5 is connected to the return line 6 via a choke 35 integrated into the actuator 22. Instead of this choke being integrated into actuator 22, this choke or a choke element can also be installed in the return line 6 as a separate component.

(19) The drive means 13 of the pump 14 is triggered with the aid of all the above described signals by the control device 12 in such a way that the application of adhesive to the book blocks 3 has a well-defined start, a well-defined end, and a uniform distribution over the length of the application. This is effected by the adhesive being delivered by means of the pump 14 working essentially in a positive displacement fashion. The theoretical volume flow of adhesive during the application is determined from the speed of the book blocks 3 being moved, from the application width, and from the application thickness of the adhesive on the book block 3. The application thickness must be fed to the control device 12 as a parameter. This is generally effected via an input terminal which is operated by the user of the device 1. As part of digital book production, the predefined value for the application thickness can also be fed to the control device 12 by the adhesive binder or from a higher-level control system. It is likewise conceivable for the signal for the book block thickness to be fed to the control device 12 from a higher-level control system. Whilst the application of adhesive to the book blocks 3 is interrupted and the actuator 22 is switched to recycle adhesive to the pre-melter 4, the pump 14 generally delivers a volume flow of adhesive which differs from the volume flow of adhesive of the applied adhesive. This volume flow of adhesive during the recycling to the pre-melter 4, i.e. during the circulation of adhesive, is of a magnitude such that the pressure of adhesive upstream from the actuator 22 is as uniform as possible, as it is during the application of adhesive to the book spines 2 via the applicator nozzle 10.

(20) The ratio between the volume flow of adhesive during the application of adhesive and the volume flow of adhesive during the circulation or the return of adhesive is primarily dependent on the set length of the outlet cross-section 11 of the applicator nozzle and hence on the application width of the adhesive on the respective book block 3. The flow resistance through the applicator nozzle 10 is dependent on the set length of the outlet cross-section 11 of the applicator nozzle 10. Secondly, the ratio between the volume of adhesive during the application of adhesive and the volume of adhesive during the circulation is dependent on the speed of the book blocks 3 and the application thickness 30, and on the viscosity and flow behavior of the adhesive used. The viscosity of the adhesive is furthermore dependent on the temperature of the adhesive and on the age or the ageing of the adhesive.

(21) In order to determine the ratio between the volume flow of adhesive during the application of adhesive and the volume flow of adhesive during the circulation, the following options are proposed:

(22) The ratio can be determined empirically without measuring pressures. The ratio is thus altered until the quality of applied adhesive reaches an optimum level. This procedure is repeated for a series of different parameters. All of the determined ratios for the volume flows are integrated into the control unit. In this way, it is conceivable that adhesive-application devices can be constructed and delivered without there being any need to carry out any adjustment or calibration procedures. If the present parameters differ from the parameters which exist during the empirical determination of the ratios of the volume flows, a somewhat reduced quality for the adhesive application needs to be taken into account.

(23) A further option for determining the volume flow ratios can be to use a so-called default setting. An adjustment or calibration procedure is here performed for each individual adhesive-application device. The advantage of such a solution consists in the fact that the adjustment is tailored precisely to the components that are actually used, the hoses, the pre-melter, the applicator nozzle and also to the manufacturing and assembly tolerances of the actually used parts. The adhesive used later is then also used as much as possible for the temperature settings used later. It is conceivable to install the pressure sensor only for this default setting. The adjustment procedure can then run automatically with software control. Here, the whole adjustment range of the applicator nozzle is first covered and when the application widths for an average speed of the book blocks are chosen and an average application thickness of the adhesive, the adhesive pressure prevailing at the pressure sensor is determined. In a second step, the actuator is switched to circulation mode and, for the same selected application widths, those speeds of the pump or the drive means at which the adhesive pressure at the pressure sensor is in each case the same as during the adhesive application by means of the applicator nozzle. The ratios determined thereby between the adhesive volume flow during the adhesive application and the adhesive volume flow during circulation are stored and used by the control device during subsequent operation of the device.

(24) A possible further alternative embodiment consists in the above described so-called default setting being performed again not only in the factory but also by customers before each time important operating parameters are changed, such as type of adhesive, speed setting, temperature setting, and modification of the application thickness. For this purpose, the pressure sensor is rigidly installed in the applicator head.

(25) A further important alternative embodiment for the adjustment is represented by an automatic adjustment of the ratios between the adhesive volume flow during the application of adhesive and the adhesive volume flow during circulation. Values which have, for example, been determined via the default setting here serve as a basis or starting value. During ongoing operation, a check is carried out on an ongoing basis as to whether the prevailing adhesive pressure during the application of adhesive and the prevailing adhesive pressure during circulation are the same or lie within a tolerance which can be set. This tolerance is no more than ±10 percent, preferably no more than ±5 percent. If the difference in the two pressures is outside the set tolerance, the corresponding ratio of the adhesive volume flows is adapted in increments until the difference in the two pressures is within the predetermined tolerance.

(26) In the adjustment process, it is also completely possible for the percentage deviation of the pressure between the start and end of the application of the flowable substance to the substrate and averaged over multiple application cycles during operation at a constant conveying speed of the substrate, and for the speed ratio of the pump to be modified automatically in increments between application of the flowable substance and circulation of the flowable substance until the measured pressure deviation during the application of the flowable substance is minimal.

(27) Combinations of the above described methods can be used for determining the ratios of the adhesive volume flows for the application of adhesive and the adhesive volume flows for the circulation.

(28) It is completely possible also for a maximum pressure, which can be set, to be monitored using the pressure sensor 23. When the maximum pressure is exceeded, the drive means 13 of the pump 14 switches off and the actuator moves into the return position.

(29) FIG. 6 shows an arrangement which is slightly modified in comparison with the arrangement in FIG. 5. In contrast to the embodiment in FIG. 5 with the switching valve, the actuator 22 is designed such that it has two valves, a first valve 36 and a second valve 37. Two standard valves are used hereby. In a first position, the first valve 36 conveys the flowable substance to the applicator nozzle 10 and, in a second position, the first valve 36 blocks the feed to the applicator nozzle 10. In the first position, the second valve 37 blocks the return flow to the pre-melter 4 and, in the second position, the second valve 37 frees the return flow to the pre-melter 4. The choke element 35 is associated with the return line 6 immediately behind the second valve 37. The mechanical complexity and the technical complexity of the control system are greater for the alternative embodiment with the two valves 36, 37 than for the alternative embodiment with the switching valve.