Adhesive Applicator Roller With Gravity Dispensing Channels
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Solution Overview
Problem
Current adhesive application methods for mattresses, particularly using rollers, suffer from low precision and significant adhesive waste due to coagulation and inefficiencies in applying patterns, especially with water-based adhesives.
Innovation Solution
A device featuring a rotary element with channels and nozzles that dispense adhesive via gravity, allowing precise application and programming of adhesive patterns on mattress sheets, reducing waste and improving processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive is applied by spraying, then application speed is improved, but precision in depositing adhesive is limited
Solution Approach 1:
A viscous carrier substance is introduced as an intermediary between the adhesive and the spraying system. The adhesive is mixed with this carrier to form a sprayable composition that maintains precision while enabling high-speed application. The carrier substance prevents coagulation during recirculation and allows precise patterning even at high application speeds.
2Manufacturing precision
If adhesive is spread by brush, then precision in application is improved, but processing time increases significantly
Solution Approach 1:
The manual brush spreading mechanism is replaced with an automated spraying system that uses a viscous carrier substance to enable precise adhesive deposition. This substitution maintains the precision of brush application while eliminating the time-consuming manual spreading process, allowing for automated high-speed patterning.
3Loss of substance
If rollers are positioned close together to limit adhesive passage, then adhesive waste is reduced, but coagulation increases due to mechanical force
Solution Approach 1:
The physical state and flow characteristics of the adhesive are changed by mixing it with a viscous carrier substance. This modification allows the adhesive to be recirculated at higher roller gaps without coagulation, as the carrier substance maintains proper viscosity and prevents the adhesive from becoming pasty during recirculation.
4Loss of substance
If gap between panels and rollers is reduced to contain coagulation, then adhesive waste is reduced, but manufacturing complexity increases
Solution Approach 1:
Instead of reducing the gap between panels and rollers, the adhesive formulation is modified by adding a viscous carrier substance. This parameter change in the adhesive properties allows for larger gaps without coagulation, maintaining simple device geometry while preventing adhesive waste.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables precise and efficient application of adhesive patterns on mattress sheets, minimizing waste and optimizing production time by ensuring accurate placement and dosage of adhesive according to predetermined designs.
Implementation Method 1
The nozzle (4) is designed to dispense the adhesive towards the channel (3)
Data Source
AI summary
Described is a roller for the automatic application of at least one adhesive on a sheet for mattresses, which makes it possible to optimise the time needed for processing and the precision of the distribution of adhesive on the sheet in relation to the desired pattern, eliminating the waste of adhesive.