Polymer Processing Apparatus and Method of Implementing the Same

Abstract

The polymer processing apparatus includes an extruder unit configured to receive, melt, and mix an adhesive, and a discharge valve unit configured to discharge the adhesive onto a substrate. Further, the discharge valve unit can include a positive displacement valve that discharges the adhesive discontinuously.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Application No. 63 / 392,564, filed Jul. 27, 2022, which is hereby incorporated by reference in its entirety for all purposes as if fully set forth herein.

[0002] (Field of Disclosure) The present disclosure relates to a polymer processing apparatus. Further, the present disclosure relates to a method of implementing a polymer processing apparatus.

Background Art

[0003] Adhesives are applied to various surfaces using dispensing devices. These dispensing devices can dispense adhesives, such as filament adhesives, onto various surfaces, such as the surface of a substrate. FIG. 18 shows a typical dispensing device 1 for dispensing an adhesive. A typical dispensing device 1 can use a barrel 2 that can include one or more heating elements. Further, a typical dispensing device 1 can include a rotatable screw 3 received within the barrel 2. Further, a typical dispensing device 1 can include an outlet 4 at the distal end of the barrel 2 for dispensing the molten adhesive from the typical dispensing device 1. Further, a typical dispensing device 1 can control the flow of the adhesive. In particular, a typical dispensing device 1 controls the operation of the rotatable screw 3 to control the flow of the adhesive dispensed from the outlet 4 of the typical dispensing device 1. Thus, a typical dispensing device 1 controls the flow of the adhesive dispensed from the outlet 4 based on the pressure of the adhesive provided by the rotatable screw 3.

[0004] Furthermore, a typical dispensing device 1 can include a check valve 5. The check valve 5 typically includes a closing member that blocks the flow. The closing member is subjected to a spring load to help keep the check valve 5 closed. Further, a typical dispensing device 1 can control the flow of the adhesive. In particular, a typical dispensing device 1 controls the operation of a screw 3 rotatable together with the check valve 5 to control the flow of the adhesive discharged from the outlet 4 of the typical dispensing device 1. Therefore, a typical dispensing device 1 controls the flow of the adhesive discharged from the outlet 4 based on the pressure of the adhesive provided by the screw 3 rotatable together with the check valve 5.

[0005] However, controlling the flow of the adhesive by a typical dispensing device 1 by the operation of the screw 3 rotatable with and / or without the check valve 5 results in undesirable adhesive application. Referring to FIG. 19, the adhesive 7 is applied to the substrate 8 by a typical dispensing device 1 by the operation of the screw 3 rotatable together with the check valve 5. The result of this application of the adhesive 7 is a poor cut-off 9 due to the "extensibility" of the material. This application of the adhesive 7 is also poor in the molten state. This application of the adhesive 7 has poor metering accuracy as indicated by a plurality of ends 11 including a start end and an end end and a thick portion 12. Therefore, this application of the adhesive 7 results in inaccurate dispensing. In this regard, a typical dispensing device 1 operates mainly based on pressure, for example, using the check valve 5 and / or the rotatable screw 3.

[0006] Therefore, there is a need for a dispensing device and / or a dispensing device method having a better cut-off, better metering accuracy, and better dispensing accuracy. SUMMARY OF THE INVENTION

[0007] In one general aspect, a polymer processing apparatus includes an extruder unit configured to receive, melt, and mix an adhesive, and a discharge valve unit configured to discharge the adhesive onto a substrate. The discharge valve unit may include a positive displacement valve that discharges the adhesive discontinuously (discretely).

[0008] In one general aspect, a polymer processing apparatus includes an extruder unit configured to receive, melt, and mix an adhesive, and a discharge valve unit configured to discharge the adhesive onto a substrate. The discharge valve unit is configured to be implemented as a pneumatic valve, an electrically actuated valve, a solenoid actuated valve, and / or a hydraulic actuated valve.

[0009] In one general aspect, a method includes implementing an extruder unit configured to receive, melt, and mix an adhesive, and implementing a discharge valve unit configured to discharge the adhesive onto a substrate. The discharge valve unit is configured to be implemented as a pneumatic valve, an electrically actuated valve, a solenoid actuated valve, and / or a hydraulic actuated valve.

[0010] Various other features, details, and advantages of the present invention will become more readily apparent to those skilled in the art by considering the following detailed description of the exemplary embodiments, which is implemented in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

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Figure 8

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Figure 11

Figure 12

Figure 13

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Figure 16

Figure 17

Figure 18

Figure 19

DETAILED DESCRIPTION OF THE INVENTION

[0012] FIG. 1 shows a perspective view of a polymer processing apparatus according to an aspect of the present disclosure.

[0013] FIG. 2 shows a front view of the polymer processing apparatus according to FIG. 1.

[0014] FIG. 3 shows a side view of the polymer processing apparatus according to FIG. 1.

[0015] FIG. 4 shows a top view of the polymer processing apparatus according to FIG. 1.

[0016] FIG. 5 shows another side view of the polymer processing apparatus according to FIG. 1.

[0017] FIG. 6 shows a rear view of the polymer processing apparatus according to FIG. 1.

[0018] FIG. 7 shows a bottom view of the polymer processing apparatus according to FIG. 1.

[0019] In particular, FIG. 1 shows a polymer processing apparatus 100. The polymer processing apparatus 100 includes a discharge valve unit 200 and an extruder unit 300. The polymer processing apparatus 100 is configured to operate in conjunction with the discharge valve unit 200 and the extruder unit 300, and implements a configuration for receiving, melting, mixing, and discharging an adhesive such as a filament adhesive onto a substrate. In particular, the polymer processing apparatus 100 is configured to operate in conjunction with the discharge valve unit 200 and carefully and accurately control the discharge of the adhesive received from the extruder unit 300.

[0020] In this regard, the discharge valve unit 200 can be implemented to operate as a positive displacement valve that discharges the adhesive discontinuously from the polymer processing apparatus 100. More specifically, the polymer processing apparatus 100 may be configured to operate the discharge valve unit 200 to control the flow of the adhesive in order to discharge the adhesive from the polymer processing apparatus 100. In this regard, the polymer processing apparatus 100 can be implemented to open the discharge valve unit 200 so that the flow of the adhesive generated by the extruder unit 300 flows through the discharge valve unit 200 and is discharged onto the substrate. Further, the polymer processing apparatus 100 can be implemented to close the discharge valve unit 200 to stop the flow of the adhesive generated by the extruder unit 300 from passing through the discharge valve unit 200 and cut off the discharge of the adhesive onto the substrate.

[0021] Thus, referring to FIG. 17, the polymer processing apparatus 100 is configured to operate in conjunction with the dispensing valve unit 200 to apply the adhesive 500 to the substrate 502 with a more controlled and / or accurate start 506 of the adhesive 500 at the end of the dispensing routine. Further, the polymer processing apparatus 100 is configured to operate in conjunction with the dispensing valve unit 200 to provide a more controlled and / or accurate shut-off (cut-off) 504 of the application of the adhesive 500 at the beginning of the dispensing routine. Further, the dispensing valve unit 200 is configured to handle the "extensibility" of the material by the positive displacement operation of the dispensing valve unit 200 even in a molten state.

[0022] Further, referring to FIG. 17, the dispensing valve unit 200 is configured to provide a more accurate metering of the adhesive 500 from the extruder unit 300 of the polymer processing apparatus 100, as indicated by a more uniform width of the adhesive 500. In this regard, the polymer processing apparatus 100 can implement the dispensing valve unit 200 to provide a more accurate flow of the adhesive from the extruder unit 300. Thus, the dispensing valve unit 200 can be configured to provide an accurate metering of the adhesive from the extruder unit 300 by the controlled operation of the dispensing valve unit 200.

[0023] In some embodiments, the dispensing valve unit 200 of the polymer processing apparatus 100 can be implemented as a pneumatic valve, an electrically actuated valve, a solenoid actuated valve, a hydraulic actuated valve, etc. It will be understood that the dispensing valve unit 200 and the polymer processing apparatus 100 may be integrated or coupled in any desired manner.

[0024] In some embodiments, the polymer processing apparatus 100 and / or the extruder unit 300 can include a polymer inlet 106. In some embodiments, the polymer inlet 106 may be supported by the block 102. The polymer inlet 106 may be configured to receive an adhesive such as a filament adhesive and direct the adhesive into the extruder unit 300.

[0025] In some embodiments, the polymer processing apparatus 100 may include an air supply valve 108 configured to supply pressurized air to the discharge valve unit 200 in order to operate the discharge valve unit 200 as described herein. In particular, the polymer processing apparatus 100 may include a conduit 104 for supplying pressurized air from the air supply valve 108 to the discharge valve unit 200. The polymer processing apparatus 100 may further include various connectors between the conduit 104 and the air supply valve 108 and various connectors between the air supply valve 108 and the discharge valve unit 200. Additionally, the air supply valve 108 may include at least one connector 116 for connecting to a pressurized air source. Thus, the air supply valve 108 may be configured to control the supply of pressurized air from the pressurized air source to the discharge valve unit 200. The air supply valve 108 may be implemented as a valve, regulator, solenoid valve, and / or the like for controlling the supply of pressurized air from the pressurized air source to the discharge valve unit 200. The various connectors associated with the air supply valve 108 may be threaded connectors, push-on connectors, and / or the like.

[0026] In some embodiments, the discharge valve unit 200 may be attached to and thereby moved by a movement mechanism (not shown) such as a robot, an x-y positioning device, and / or the like. In particular, the discharge valve unit 200 may be moved by the movement mechanism in a pattern across the surface of the substrate.

[0027] FIG. 8 shows a cross-sectional view of an exemplary embodiment of the polymer processing apparatus according to FIG. 1.

[0028] FIG. 9 shows a partial cross-sectional view of the polymer processing apparatus according to FIG. 8.

[0029] As shown in FIGS. 8 and 9, the extruder unit 300 can include an extruder barrel 302 and an extruder screw 304. In some embodiments, the extruder barrel 302 can be configured as a barrel used in a single-screw extruder embodiment of the extruder unit 300. Further, the extruder screw 304 can have a configuration as an extruder screw used in a single-screw extruder. However, the extruder unit 300 can be implemented using any number of extruder barrels 302, any number of extruder screws 304, any type of extrusion technology, and the like.

[0030] In some embodiments, the extruder screw 304 can include a shaft portion having a diameter that gradually increases along its length. In some embodiments, extending around the shaft portion of the extruder screw 304 can be helical flights for conveying molten material in a forward direction toward the discharge valve unit 200 when the extruder screw 304 rotates within the extruder barrel 302. Further, in some embodiments, the helical flights of the extruder screw 304 can be provided with indentations to provide gripping protrusions. The gripping protrusions of the extruder screw 304 can provide additional edges that capture continuous filament adhesive through the inlet into the extruder barrel 302 and assist in actively pulling it.

[0031] Referring to FIG. 9, the extruder barrel 302 can be cylindrical and can have an inner surface 306 that engages in a surrounding relationship with the extruder screw 304. The inner surface 306 terminates at an outlet 308 at the distal end of the extruder barrel 302. The outlet 308 can be generally circular, but can have any other suitable shape. The outlet 308 of the extruder unit 300 outputs adhesive to the discharge valve unit 200 and / or to intervening components of the polymer processing apparatus 100.

[0032] The extruder barrel 302 and / or the extruder unit 300 can include one or more heating elements 318 for heating the inner surface 306 during the discharging operation to melt the adhesive. In some embodiments, one or more heating elements 318 may be embedded in the wall of the extruder barrel 302, one or more heating elements 318 may be attached to the wall of the extruder barrel 302 and / or one or more heating elements 318 may otherwise be in thermal communication with the wall and / or the inner surface 306 of the extruder barrel 302. In some embodiments, the inner surface 306 of the extruder barrel 302 may be grooved or otherwise roughened to increase the friction between the extruder barrel 302 and the adhesive being extruded.

[0033] The polymer processing apparatus 100 and / or the extruder unit 300 can include an inlet for receiving the adhesive. The inlet may be configured to receive the adhesive and guide the adhesive into the extruder unit 300, the extruder screw 304 and / or the extruder barrel 302, and the adhesive is mixed, melted, and then delivered to the discharge valve unit 200 by the extruder unit 300.

[0034] As shown in FIG. 8, the extruder unit 300 can include a drive mechanism 310 for rotating the extruder screw 304 about an axis parallel to the y-axis shown in FIG. 8. The rotation of the extruder screw 304 relative to the extruder barrel 302 mixes, melts, and / or moves the adhesive within the extruder unit 300. In particular, the extruder screw 304 moves the adhesive through the extruder unit 300 towards the outlet 308 and the discharge valve unit 200.

[0035] FIG. 10 shows a partial cross-sectional view of the polymer processing apparatus according to FIG. 8.

[0036] Referring to FIG. 10, the drive mechanism 310 can include a gear device 314 and a motor 312. The motor 312 can be implemented by any motor technology. The motor 312 can include a motor output portion 320, such as an output shaft having a rotational connection portion, that supplies the rotational torque generated by the motor 312 to the gear device 314. The gear device 314 can be configured to receive the rotational torque generated by the motor 312 and output the rotational torque to a gear device output portion 322, such as an output shaft having a rotational connection portion. The gear device output portion 322 can be rotationally engaged and / or connected to the extruder screw 304. Thus, the operation of the motor 312 rotates the motor output portion 320, which in turn rotates the gear device output portion 322, which in turn rotates the extruder screw 304.

[0037] FIG. 11 shows a partial cross-sectional view of the polymer processing apparatus according to FIG. 8.

[0038] In particular, FIG. 11 shows further exemplary details of one aspect of the discharge valve unit 200. In this regard, the discharge valve unit 200 of the polymer processing apparatus 100 can be implemented as a pneumatic valve, an electrically actuated valve, a solenoid actuated valve, a hydraulic actuated valve, or the like.

[0039] The discharge valve unit 200 and / or the extruder unit 300 can include a manifold 324. The manifold 324 can guide the adhesive exiting the outlet 308 from the extruder unit 300 to the discharge valve unit 200. In this regard, the manifold 324 can include one or more conduits 326 that can guide the adhesive from the outlet 308 of the extruder unit 300 to the discharge valve unit 200.

[0040] Furthermore, the manifold 324 can include one or more heating elements 348. The implementation of one or more heating elements 348 within the manifold 324 can heat the adhesive flowing through the manifold 324. In some embodiments, one or more heating elements 348 may be embedded in the wall of the manifold 324, one or more heating elements 348 may be attached to the wall of one or more conduits 326 and / or one or more heating elements 348 may otherwise be in thermal communication with the wall of one or more conduits 326.

[0041] In this regard, the dispensing valve unit 200 may be implemented to operate as a positive displacement valve that dispenses the adhesive discontinuously from the extruder unit 300 and / or the manifold 324. More specifically, the polymer processing apparatus 100 may be configured to operate the dispensing valve unit 200 to control the flow of the adhesive for dispensing of the adhesive from the extruder unit 300 and / or the manifold 324. In this regard, the polymer processing apparatus 100 may be implemented to open the dispensing valve unit 200 such that the flow of the adhesive generated by the extruder unit 300 flows through the manifold 324 and then through the dispensing valve unit 200 and is dispensed onto the substrate. The polymer processing apparatus 100 may be implemented to close the dispensing valve unit 200 to stop the flow of the adhesive generated by the extruder unit 300 and supplied by the manifold 324 from passing through the dispensing valve unit 200 and cut off the dispensing of the adhesive onto the substrate.

[0042] FIG. 12 shows a partial cross-sectional view of the polymer processing apparatus according to FIG. 11.

[0043] FIG. 13 shows a partial cross-sectional view of the dispensing valve unit 200 according to FIG. 12.

[0044] In particular, FIGS. 12 and 13 show further exemplary details of one aspect of the discharge valve unit 200 implemented as a pneumatic valve connected to the manifold 324. In this exemplary embodiment, referring to FIG. 13, the discharge valve unit 200 can include a module body 40, a valve stem 42 movably mounted within the module body 40, and a supply chamber 44 that can be disposed within the module body 40. A valve seat 48 can be disposed between the inlet 49 and the discharge passage 50. A valve element 54, which may be spherical, is disposed on the valve stem 42 such that it can engage the valve seat 48 when the discharge valve unit 200 is in the closed state. The valve element 54 is spaced from the valve seat 48 when the discharge valve unit 200 is in the open state. In the open state, the adhesive can flow from the inlet 49 through the supply chamber 44, through the annular gap between the valve element 54 and the valve seat 48, and into the discharge passage 50 for discharge onto the substrate.

[0045] Continuing to refer to FIG. 13, the valve stem 42 is moved to provide an open state and a closed state by selective application of pneumatic pressure to the piston assembly 62. A coil spring 64 applies a force to the valve stem 42 that biases the valve element 54 into contact with the valve seat 48. The module body 40 can include an air inlet 68 that supplies pressurized air sufficient to provide an open state to the piston assembly 62. The air inlet 68 may be in fluid communication with an air supply valve 108 by a conduit 104. When the discharge valve unit 200 is in the open state, the discharge path can be defined from the extruder unit 300 and / or the outlet 308 to one or more conduits 326, the inlet 49, the supply chamber 44, and the discharge passage 50.

[0046] FIG. 14 shows a side view of the polymer processing apparatus according to FIG. 1.

[0047] Referring to FIG. 14, the polymer processing apparatus 100 can include electrical connection portions. In particular, the polymer processing apparatus 100 can include electrical connection portions to separate components for providing power, data, control, sensor information, and / or the like. In one aspect, the polymer processing apparatus 100 can include an electrical connection portion 110, an electrical connection portion 112, and an electrical connection portion 114. However, the polymer processing apparatus 100 can include any number of electrical connection portions.

[0048] In some aspects, the electrical connection portion 110 can be connected to separate components to supply power, data, control, sensor information, and / or the like to and / or from the polymer processing apparatus 100 and / or the extruder unit 300. In some aspects, the electrical connection portion 110 can include an electrical connector that can be implemented as a screw-on connector (threaded fitting connector), a push-on connector (push-in fitting connector), and / or the like. In some aspects, the electrical connection portion 110 can include wiring, insulation, and / or the like extending from the electrical connector to the polymer processing apparatus 100 and / or the extruder unit 300.

[0049] In some aspects, the electrical connection portion 112 can be connected to separate components to supply power, data, control, sensor information, and / or the like to and / or from the polymer processing apparatus 100 and / or the discharge valve unit 200. In some aspects, the electrical connection portion 112 can include an electrical connector that can be implemented as a screw-on connector, a push-on connector, and / or the like. In some aspects, the electrical connection portion 112 can include wiring, insulation, and / or the like extending from the electrical connector to the polymer processing apparatus 100 and / or the discharge valve unit 200.

[0050] In some embodiments, the electrical connection portion 114 can be connected to separate components for supplying power, data, control, sensor information, and / or the like to and / or from the polymer processing apparatus 100, the extruder unit 300, and / or the drive mechanism 310. In some embodiments, the electrical connection portion 114 can include an electrical connector that can be implemented as a screw-on connector, a push-on connector, and / or the like. In some embodiments, the electrical connection portion 114 can include wiring, insulation, and / or the like that extends from the electrical connector to the polymer processing apparatus 100, the extruder unit 300, and / or the drive mechanism 310.

[0051] FIG. 15 shows a side view of the polymer processing apparatus according to FIG. 1.

[0052] In embodiments further described herein, the polymer processing apparatus 100 can include a control device 180. The control device 180 can be implemented by one or more of a computer, a computer system, a controller, and / or the like. The control device 180 can include a plurality of computers, a plurality of computer systems, a plurality of controllers, and / or the like. Further, the control device can include a random access memory, a read only memory, an analog-to-digital converter, a digital-to-analog converter, a drive circuit, a filtering component, and / or the like.

[0053] The control device 180 can be connected to the electrical connection portion 110, the electrical connection portion 112, and / or the electrical connection portion 114. In some embodiments, the control device 180 can be configured to be connected via the electrical connection portion 114 and control data, control, sensor information, and / or the like to and / or from the polymer processing apparatus 100, the extruder unit 300, and / or the drive mechanism 310. In some embodiments, the control device 180 can be configured to be connected via the electrical connection portion 114 and control the speed and / or torque of the drive mechanism 310, the motor 312, and / or the extruder screw 304.

[0054] In some embodiments, the control device 180 can be configured to control data, control, sensor information, and / or the like to and / or from the polymer processing device 100, the extruder unit 300, and / or the like via the electrical connection portion 110. In some embodiments, the control device 180 can be configured to control one or more heating elements 318 via the electrical connection portion 110.

[0055] In some embodiments, the control device 180 can be configured to control data, control, sensor information, and / or the like to and / or from the polymer processing device 100, the discharge valve unit 200, and / or the like via the electrical connection portion 112. In some embodiments, the control device 180 can be configured to control the discharge valve unit 200, the air supply valve 108, and / or the like via the electrical connection portion 112. In some embodiments, the control device 180 can be configured to control the opening and / or closing of the discharge valve unit 200 via the electrical connection portion 112.

[0056] In some embodiments, the polymer processing device 100 can include one or more sensors. The one or more sensors can include a pressure sensor, a position sensor, a rotation sensor, a movement sensor, a temperature sensor, a power sensor, a voltage sensor, a current sensor, and / or the like. In some embodiments, the pressure sensor can measure the pressure of the adhesive in the extruder unit 300, the discharge valve unit 200, and / or the like. In some embodiments, the position sensor can measure the position of the discharge valve unit 200 and / or the like. The rotation sensor can detect the rotation of components of the extruder unit 300 and / or the like. In some embodiments, the temperature sensor can measure the temperature of the adhesive, components of the extruder unit 300, components of the discharge valve unit 200, and / or the like.

[0057] In some embodiments, the control device 180 can be configured to operate components of the polymer processing device 100, components of the extruder unit 300, components of the dispensing valve unit 200, and / or the like. In particular, the control device 180 can supply drive signals to one or more components of the polymer processing device 100, one or more components of the dispensing valve unit 200, one or more components of the extruder unit 300, and / or the like to operate these components. In some embodiments, the control device 180 can be configured to operate components of the polymer processing device 100, components of the extruder unit 300, components of the dispensing valve unit 200, and / or the like in response to sensor outputs from the components of the polymer processing device 100, components of the extruder unit 300, components of the dispensing valve unit 200, and / or the like.

[0058] In some embodiments, the control device 180 can be configured to operate the extruder unit 300 to start the operation of the drive mechanism 310, particularly to operate the motor 312 to start the rotation of the extruder screw 304, before operating the dispensing valve unit 200. Thereafter, the rotation of the extruder screw 304 can begin to increase the pressure of the adhesive within the extruder unit 300. In this regard, the start of operation of the extruder unit 604 prepares the polymer processing device 100 for the application of the adhesive by the dispensing valve unit 200.

[0059] In this regard, the control device 180 can implement a delay time that allows the extruder unit 300 to prepare the adhesive available by the discharge valve unit 200. Without implementing the time delay, the adhesive first applied by the polymer processing device 100 may have low quality, referring to FIG. 19. The time delay may be a set amount of time, or may be an amount of time that can be dynamically adjusted in response to a sensor of the polymer processing device 100, or may be based on the sensor output of the polymer processing device 100 and / or the like. In some aspects, the control device 180 can implement a configurable delay time that allows the extruder unit 300 to prepare the adhesive available by the discharge valve unit 200. For example, in certain embodiments of the extruder unit 300 and the discharge valve unit 200, the delay time may be 0 to 2000 ms, 10 to 50 ms, 50 to 100 ms, 100 to 200 ms, 200 to 500 ms, 500 to 1000 ms, or 1000 to 2000 ms. As another example, in certain embodiments of the extruder unit 300 and the discharge valve unit 200, the delay time may be less than 50 ms, 100 ms, 200 ms, 500 ms, 500 ms, or 2000 ms. As another example, in certain embodiments of the extruder unit 300 and the discharge valve unit 200, the delay time may be greater than 0 ms, 50 ms, 100 ms, 200 ms, 500 ms, 500 ms, or 1000 ms.

[0060] FIG. 16 shows an exemplary method for implementing a polymer processing device according to an aspect of the present disclosure.

[0061] In particular, FIG. 16 shows an exemplary method 600 for implementing a polymer processing device. In this regard, the method 600 for implementing a polymer processing device may be a method for implementing the polymer processing device 100 of the present disclosure.

[0062] In particular, it should be noted that the method 600 for implementing a polymer processing apparatus is merely exemplary and can be modified in accordance with the various aspects disclosed herein. It should be noted that the method 600 for implementing a polymer processing apparatus can be implemented in a different order in accordance with the above aspects. Furthermore, the method 600 for implementing a polymer processing apparatus can be modified to have more or fewer processing steps in accordance with the various aspects disclosed herein. Furthermore, the method 600 for implementing a polymer processing apparatus can be implemented by a computer, a computer system, a controller, a control device 180, and / or the like.

[0063] The method 600 for implementing the polymer processing apparatus of the present disclosure may include determining 602 whether the polymer processing apparatus has received a signal for discharging an adhesive. In this regard, determining 602 whether the polymer processing apparatus has received a signal for discharging an adhesive may include determining whether the polymer processing apparatus 100 has received a signal for discharging an adhesive. In this regard, determining 602 whether the polymer processing apparatus has received a signal for discharging an adhesive may include any one or more of the materials, structures, arrangements, processes, and / or the like described herein.

[0064] The method 600 for implementing the polymer processing apparatus of the present disclosure may include starting 604 the operation of the extruder unit. In this regard, starting 604 the operation of the extruder unit may include starting the operation of the extruder unit 300 of the present disclosure. In this regard, starting 604 the operation of the extruder unit may include any one or more of the materials, structures, arrangements, processes, and / or the like described herein.

[0065] In some embodiments, starting the operation of the extruder unit 604 can include the control device 180 operating the extruder unit 300 to start the operation of the drive mechanism 310, particularly the motor 312, to start the rotation of the extruder screw 304. Thereafter, the rotation of the extruder screw 304 can begin to increase the pressure of the adhesive within the extruder unit 300. In this regard, starting the operation of the extruder unit 604 readies the polymer processing apparatus 100 so that the adhesive can be applied by the dispensing valve unit 200.

[0066] The method 600 for implementing the polymer processing apparatus of the present disclosure can include implementing a delay time 606. In this regard, implementing a delay time 606 can include implementing a delay time by the control device 180. In this regard, implementing a delay time 606 can include any one or more of the materials, structures, arrangements, processes, and / or the like described herein.

[0067] In this regard, implementing a delay time 606 enables the extruder unit 300 to prepare the adhesive available by the dispensing valve unit 200. Without implementing the time delay, the adhesive first applied by the polymer processing apparatus 100 may be of poor quality as shown in FIG. 19.

[0068] The method 600 for implementing the polymer processing apparatus of the present disclosure can include implementing the operation of the dispensing valve unit 608. In this regard, implementing the operation of the dispensing valve unit 608 can include implementing the operation of the dispensing valve unit 200. In this regard, implementing the operation of the dispensing valve unit 608 can include any one or more of the materials, structures, arrangements, processes, and / or the like described herein. In this regard, after the time delay, the polymer processing apparatus 100 is ready to apply the adhesive, and thereafter, the dispensing valve unit 200 can operate to apply the adhesive to the substrate as described herein.

[0069] Method 600 for implementing the polymer processing apparatus of the present disclosure can include discharging a material from the polymer processing apparatus 610 by controlling a discharge valve unit. In this regard, discharging a material from the polymer processing apparatus 610 by controlling the discharge valve unit can include discharging a material from the polymer processing apparatus 100 by controlling the discharge valve unit 200. In this regard, discharging a material from the polymer processing apparatus 610 by controlling the discharge valve unit can include any one or more of the materials, structures, arrangements, processes, and / or the like described herein. In this regard, the discharge valve unit 200 applies an adhesive to the substrate as described herein.

[0070] Method 600 for implementing the polymer processing apparatus of the present disclosure can include receiving a signal 612 for stopping the discharge of the adhesive. In this regard, receiving a signal 612 for stopping the discharge of the adhesive can include receiving a signal for stopping the discharge of the adhesive from the control device 180. In this regard, receiving a signal 612 for stopping the discharge of the adhesive can include any one or more of the materials, structures, arrangements, processes, and / or the like described herein. In this regard, the control device 180 can transmit a signal for stopping the application of the adhesive to the substrate to the discharge valve unit 200 as described herein.

[0071] Method 600 for implementing the polymer processing apparatus of the present disclosure can include stopping the operation of the discharge valve unit 614. In this regard, stopping the operation of the discharge valve unit 614 can include stopping the operation of the discharge valve unit 200. In this regard, stopping the operation of the discharge valve unit 614 can include any one or more of the materials, structures, arrangements, processes, and / or the like described herein. In this regard, the discharge valve unit 200 can receive a signal from the control device 180 and stop applying the adhesive to the substrate as described herein.

[0072] FIG. 17 shows the application of an adhesive to a substrate using the polymer processing apparatus of the present disclosure.

[0073] In particular, in an exemplary embodiment, the polymer processing apparatus 100 was utilized with a dispensing valve unit 200 to apply an adhesive 500 to a substrate 502. As shown in FIG. 17, when the polymer processing apparatus 100 operated with the dispensing valve unit 200, at the end of the dispensing routine, the adhesive 500 was applied to the substrate 502 with a more controlled and / or more accurate start 506 of the adhesive 500. Further, the polymer processing apparatus 100 operating with the dispensing valve unit 200 provided a more controlled and / or more accurate start 506 of the adhesive 500 at the start of the dispensing routine. Further, the dispensing valve unit 200 addressed the "extensibility" of the material by the positive displacement operation of the dispensing valve unit 200 even in a molten state.

[0074] Further, referring to FIG. 17, the dispensing valve unit 200 provided a more accurate metering of the adhesive 500 from the extruder unit 300 of the polymer processing apparatus 100, as indicated by a more uniform width of the adhesive 500.

[0075] In aspects of the present disclosure, the adhesive utilized by the polymer processing apparatus 100 may be a pressure-sensitive adhesive. A pressure-sensitive adhesive is a material that adheres to a substrate when pressure is applied. They do not require a solvent, water, or heat to effect an adhesive bond. State-of-the-art pressure-sensitive adhesives can achieve very high adhesive performance and can replace conventional mechanical fasteners in many industrial applications. These adhesive solutions are economical and easy to use.

[0076] Conventional pressure-sensitive adhesives are thin and flat and are generally dispensed in sheet or roll form. However, in certain applications, it may be advantageous for the pressure-sensitive adhesive to be formed in situ. For example, in automotive-related adhesive applications, the adhesive surface of the part can be non-planar to provide higher mechanical retention. Some parts can have an adhesive surface with ribs that require the pressure-sensitive adhesive to penetrate fairly deeply into the rib structure to obtain sufficient adhesive strength.

[0077] Furthermore, the most common plastics used are thermoplastic olefins (referred to as "TPO", sometimes also as "PP / EPDM"), which are low surface energy plastics similar to polypropylene. Conventional pressure-sensitive adhesives do not achieve a high degree of "wetting spread" on these plastics and similar plastics, resulting in a reduction in the surface area between the adhesive and the substrate. Primers and other surface treatments can be used to improve "wetting spread", but these increase the complexity and cost of adhesion. For these reasons, adhesion to non-planar low surface energy substrates remains a difficult technical problem.

[0078] In certain aspects, the polymer processing apparatus 100, the dispensing valve unit 200, and / or the extruder unit 300 can be implemented as described below, can be implemented in a system as described below, and can further include additional components and features as described below.

[0079] Accordingly, the present disclosure describes implementations of a polymer processing apparatus configured to operate in conjunction with a dispensing valve unit to apply an adhesive to a substrate with a more controlled and / or more accurate cut at the end of the dispensing routine. Further, the present disclosure describes implementations of a polymer processing apparatus configured to operate in conjunction with a dispensing valve unit to start the application of the adhesive in a more controlled and / or more accurate manner at the beginning of the dispensing routine. Further, the present disclosure describes implementations of a dispensing valve unit configured to address the "extensibility" of the material by the positive displacement operation of the dispensing valve unit even in a molten state.

[0080] Terms such as first, second, etc. may be used herein to describe various elements, but it should be understood that these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the present disclosure, the first element can be referred to as the second element, and similarly, the second element can be referred to as the first element. The term "and / or" as used herein includes any combination and all combinations of one or more of the listed related items. Relative terms such as "hereinafter", "above", "on", "under", "horizontal", "vertical", etc. as used herein can be used herein to describe the relationship of one element, layer or region to another element, layer or region as shown in the figures. It should be understood that these terms and the above terms are intended to encompass different directions of the device in addition to the directions shown in the figures.

[0081] The terms used herein are for the purpose of describing only specific aspects and are not intended to limit the present disclosure. The singular forms used herein are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the terms "consisting of", "comprising", "including" and / or "having" specify the presence of the described features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0082] Unless otherwise defined, all terms (including technical and scientific terms) used in this specification shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms used in this specification shall be construed to have a meaning consistent with their meaning in the context of this specification and the relevant art, and it is understood that they shall not be construed in an idealized or overly formal sense unless explicitly defined herein. Further, in accordance with various aspects of the present disclosure, the methods described herein are intended to operate in a dedicated hardware implementation including, but not limited to, a PC, PDA, semiconductor, application specific integrated circuit (ASIC), programmable logic array, cloud computing device, and other hardware devices constructed to implement the methods described herein.

[0083] It should also be noted that the software implementations of the present disclosure described herein may, if desired, be stored on a tangible storage medium such as a magnetic medium such as a disk or tape, a magneto-optical medium such as a disk, or an optical medium, or a solid state medium such as a memory card or other package containing one or more read only (non-volatile) memories, random access memories or other rewritable (volatile) memories. Digital file attachments to an e-mail or other self-contained information archive or set of archives are considered to be a distribution medium equivalent to a tangible storage medium. Accordingly, the present disclosure is considered to include a tangible storage medium or a distribution medium including the equivalents and successor media described herein and recognized in the art, in which the software implementations of this specification are stored.

[0084] Furthermore, various aspects of the present disclosure can be implemented on a non - general - purpose computer implementation. Further, as is apparent from the disclosure herein, various aspects of the present disclosure improve the functionality of the system. Further, various aspects of the present disclosure include computer hardware specially programmed to solve the complex problems addressed by the present disclosure. Thus, various aspects of the present disclosure improve the overall functionality of the system in certain implementations for performing the methods described by the present disclosure and defined by the claims.

[0085] Aspects of the present disclosure can be implemented on any type of computing device having a wired / wireless communication function via a communication channel, such as, for example, a desktop computer, a personal computer, a laptop / mobile computer, a personal digital assistant (PDA), a mobile phone, a tablet computer, a cloud - computing device, etc.

[0086] The present invention has been described by way of an explanation of various preferred embodiments, which have been described in some detail, but it is not the applicant's intention to limit the appended claims in such detail or in any way. Additional advantages and modifications will be readily understood by those skilled in the art. The various features described herein can be used alone or in any combination according to the needs and preferences of the user. Above, exemplary aspects and embodiments of the present invention have been described together with presently known preferred ways of implementing the present invention. However, the invention itself should be defined only by the appended claims.

Claims

1. An extruder unit configured to receive, melt, and mix an adhesive; A discharge valve unit configured to discharge the adhesive onto a substrate; Comprising; The discharge valve unit includes a positive displacement valve that discharges the adhesive discontinuously, a polymer processing apparatus.

2. The discharge valve unit is configured to be implemented as a pneumatic valve, an electric actuated valve, a solenoid actuated valve, and / or a hydraulic actuated valve, the polymer processing apparatus according to claim 1.

3. The discharge valve unit is configured to control the flow of the adhesive generated by the extruder unit for discharging the adhesive, the polymer processing apparatus according to claim 1.

4. The discharge valve unit is configured to close to stop the flow of the adhesive generated by the extruder unit, the polymer processing apparatus according to claim 1.

5. The extruder unit includes an extruder barrel and an extruder screw, the polymer processing apparatus according to claim 1.

6. The polymer processing apparatus according to claim 5, further comprising a manifold including one or more conduits configured to guide the adhesive from an outlet of the extruder unit to the discharge valve unit.

7. The extruder unit has an outlet at a distal end of the extruder barrel, the polymer processing apparatus according to claim 5.

8. The extruder unit includes one or more heating elements configured to melt the adhesive during the discharging operation, the polymer processing apparatus according to claim 5.

9. The extruder unit includes an inlet configured to receive the adhesive, The extruder screw and / or the extruder barrel are configured to mix and melt the adhesive and supply the adhesive to the discharge valve unit, the polymer processing apparatus according to claim 5.

10. The extruder unit includes a drive mechanism configured to rotate the extruder screw to move the adhesive through the extruder unit to the discharge valve unit, the polymer processing apparatus according to claim 9.

11. The drive mechanism includes a gear device and a motor, the polymer processing apparatus according to claim 10.

12. The manifold includes one or more heating elements, the polymer processing apparatus according to claim 6.

13. The discharge valve unit is implemented as a pneumatic valve, the polymer processing apparatus according to claim 1.

14. The polymer processing apparatus according to claim 1, wherein the discharge valve unit includes a module body, a valve rod movably attached within the module body, and a supply chamber that can be disposed within the module body.

15. The discharge valve unit includes a valve seat and a valve element, The polymer processing apparatus according to claim 14, wherein the valve rod is moved to provide an open state and a closed state by selective application of air pressure to a piston assembly.

16. The polymer processing apparatus according to claim 13, further comprising an air supply valve configured to supply pressurized air to the discharge valve unit.

17. The polymer processing apparatus according to claim 1, further comprising an electrical connection configured to transfer power, data, control, and / or sensor information to or from one or more components of the discharge valve unit and / or one or more components of the extruder unit.

18. The polymer processing apparatus according to claim 10, further comprising a control device configured to provide a drive signal to one or more components of the discharge valve unit and / or one or more components of the extruder unit.

19. The polymer processing apparatus according to claim 18, wherein the control device is configured to operate the extruder unit to start the operation of the drive mechanism before the operation of the discharge valve unit.

20. The polymer processing apparatus according to claim 18, wherein the control device is configured to operate the extruder unit to start the operation of the drive mechanism and then start the operation of the discharge valve unit after a time delay.

21. An extruder unit configured to receive, melt, and mix an adhesive; A discharge valve unit configured to discharge the adhesive onto a substrate; Comprising: The polymer processing apparatus, wherein the discharge valve unit is configured to be implemented as a pneumatic valve, an electrically actuated valve, a solenoid actuated valve, and / or a hydraulic actuated valve.

22. The polymer processing apparatus according to claim 21, wherein the discharge valve unit is configured to control the flow of the adhesive generated by the extruder unit for discharging the adhesive.

23. The polymer processing apparatus according to claim 21, wherein the discharge valve unit is configured to close to stop the flow of the adhesive generated by the extruder unit.

24. The extruder unit includes an extruder barrel and an extruder screw, the polymer processing apparatus according to claim 21.

25. The polymer processing apparatus according to claim 24, further comprising a manifold including one or more conduits configured to guide the adhesive from an outlet of the extruder unit to the discharge valve unit.

26. The polymer processing apparatus according to claim 24, wherein the extruder unit includes an outlet at a distal end of the extruder barrel.

27. The polymer processing apparatus according to claim 24, wherein the extruder unit includes one or more heating elements configured to melt the adhesive during a discharge operation.

28. The extruder unit includes an inlet configured to receive the adhesive, The polymer processing apparatus according to claim 24, wherein the extruder screw and / or the extruder barrel are configured to mix and melt the adhesive and supply the adhesive to the discharge valve unit.

29. The polymer processing apparatus according to claim 28, wherein the extruder unit includes a drive mechanism configured to rotate the extruder screw to move the adhesive through the extruder unit to the discharge valve unit.

30. The polymer processing apparatus according to claim 29, wherein the drive mechanism includes a gear device and a motor.

31. The polymer processing apparatus according to claim 25, wherein the manifold includes one or more heating elements.

32. The polymer processing apparatus according to claim 21, wherein the discharge valve unit is implemented as the pneumatic valve.

33. The polymer processing apparatus according to claim 21, wherein the discharge valve unit includes a module body, a valve rod movably mounted within the module body, and a supply chamber that may be disposed within the module body.

34. The discharge valve unit includes a valve seat and a valve element, The polymer processing apparatus according to claim 33, wherein the valve rod is moved to provide an open state and a closed state by selective application of pneumatic pressure to a piston assembly.

35. The polymer processing apparatus according to claim 32, further comprising an air supply valve configured to supply pressurized air to the discharge valve unit.

36. The polymer processing apparatus according to claim 21, further comprising an electrical connection configured to transfer power, data, control, and / or sensor information to and / or from one or more components of the discharge valve unit and / or one or more components of the extruder unit.

37. The polymer processing apparatus according to claim 29, further comprising a control device configured to provide a drive signal to one or more components of the discharge valve unit and / or one or more components of the extruder unit.

38. The polymer processing apparatus according to claim 37, wherein the control device is configured to operate the extruder unit to start the operation of the drive mechanism before the operation of the discharge valve unit.

39. The polymer processing apparatus according to claim 37, wherein the control device is configured to operate the extruder unit to start the operation of the drive mechanism and start the operation of the discharge valve unit after a time delay.

40. Implementing an extruder unit configured to receive, melt, and mix an adhesive; Implementing a discharge valve unit configured to discharge the adhesive onto a substrate; Comprising A method of implementing a polymer processing apparatus, wherein the discharge valve unit is configured to be implemented as a pneumatic valve, an electrically actuated valve, a solenoid actuated valve, and / or a hydraulic actuated valve.

41. A method of implementing the polymer processing apparatus according to claim 40, wherein the discharge valve unit is configured to control the flow of the adhesive generated by the extruder unit for discharging the adhesive.

42. A method of implementing the polymer processing apparatus according to claim 40, wherein the discharge valve unit is configured to close to stop the flow of the adhesive generated by the extruder unit.

43. A method of implementing the polymer processing apparatus according to claim 40, wherein the extruder unit includes an extruder barrel and an extruder screw.

44. A method of implementing the polymer processing apparatus according to claim 43, further comprising a manifold including one or more conduits configured to guide the adhesive from the outlet of the extruder unit to the discharge valve unit.

45. A method of implementing the polymer processing apparatus according to claim 43, wherein the extruder unit has an outlet at a distal end of the extruder barrel.

46. A method of implementing the polymer processing apparatus according to claim 43, wherein the extruder unit includes one or more heating elements configured to melt the adhesive during the discharging operation.

47. The extruder unit includes an inlet configured to receive the adhesive, A method of implementing the polymer processing apparatus according to claim 43, wherein the extruder screw and / or the extruder barrel are configured to mix and melt the adhesive and supply the adhesive to the discharge valve unit.

48. A method of implementing the polymer processing apparatus according to claim 47, wherein the extruder unit includes a drive mechanism for rotating the extruder screw to move the adhesive through the extruder unit to the discharge valve unit.

49. A method of implementing the polymer processing apparatus according to claim 48, wherein the drive mechanism includes a gear device and a motor.

50. A method of implementing the polymer processing apparatus according to claim 44, wherein the manifold includes one or more heating elements.

51. A method of implementing the polymer processing apparatus according to claim 40, wherein the discharge valve unit is implemented as the pneumatic valve.

52. A method of implementing the polymer processing apparatus according to claim 40, wherein the discharge valve unit includes a module body, a valve rod movably mounted within the module body, and a supply chamber that can be disposed within the module body.

53. The discharge valve unit includes a valve seat and a valve element, A method of implementing the polymer processing apparatus according to claim 52, wherein the valve rod is moved to provide an open state and a closed state by selective application of pneumatic pressure to the piston assembly.

54. A method of implementing the polymer processing apparatus according to claim 51, further comprising an air supply valve configured to supply pressurized air to the discharge valve unit.

55. A method of implementing the polymer processing apparatus according to claim 40, further comprising an electrical connection configured to transfer power, data, control, and / or sensor information to or from one or more components of the discharge valve unit and / or one or more components of the extruder unit.

56. A method of implementing a polymer processing apparatus according to claim 48, further comprising a control device configured to provide a drive signal to one or more components of the discharge valve unit and / or one or more components of the extruder unit.

57. A method of implementing a polymer processing apparatus according to claim 56, wherein the control device is configured to operate the extruder unit so as to start the operation of the drive mechanism before the operation of the discharge valve unit.

58. A method of implementing a polymer processing apparatus according to claim 56, wherein the control device is configured to operate the extruder unit so as to start the operation of the drive mechanism and start the operation of the discharge valve unit after a time delay.

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