Hot Melt Adhesive Flow Tracking with Single Manifold Meter

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Solution Overview

Problem

Conventional metering systems for hot melt adhesive dispensing are economically impractical and require excessive maintenance due to the need for multiple flow meters, and they are not retrofittable on existing systems, making it difficult to monitor adhesive output effectively.

Innovation Solution

A single flow meter is placed in direct fluid communication with the manifold of a hot melt adhesive system, coupled with a product detector and controller to measure and track the adhesive output, allowing for precise monitoring and data association with applied products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional metering systems use individual flow meters on each liquid discharge outlet, then flow monitoring accuracy is improved, but system cost and maintenance requirements increase significantly

Engineering Contradiction:

Improveflow monitoring accuracyVSAvoidsystem cost

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple flow measurement functions into a single flow meter located at the manifold. The flow meter measures total adhesive flow from the manifold, and the controller allocates this flow to individual applicators based on product detection and timing, eliminating the need for multiple separate flow meters while maintaining monitoring accuracy

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single flow meter at the manifold serves as a universal measurement device for the entire dispensing system. It provides flow data that the controller uses to monitor and track adhesive application across multiple applicators and products, making one device perform the function previously requiring multiple specialized devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional metering systems install individual flow meters on each outlet, then independent flow monitoring is improved, but maintenance costs and component parts increase

Engineering Contradiction:

Improveindependent flow monitoringVSAvoidmaintenance costs

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The system merges multiple monitoring functions into a single flow meter and controller combination. The controller independently tracks flow allocation to each applicator through software logic, eliminating the need for multiple physical flow meters that would require separate maintenance, while preserving independent monitoring capability

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conventional metering systems use multiple flow meters, then flow restriction detection is improved, but system adaptability and retrofittability decrease

Engineering Contradiction:

Improveflow restriction detectionVSAvoidretrofittability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system segments the monitoring function into two parts: a single flow meter that measures total flow at the manifold, and a controller that divides and tracks flow allocation to individual applicators. This segmentation allows the simple flow meter to be easily retrofitted while the controller handles the complex allocation logic, improving overall system adaptability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The controller acts as an intermediary between the single flow meter and the multiple applicators. It receives total flow data from the flow meter and uses product detection signals to allocate and track flow to individual applicators, enabling retrofittability while maintaining flow restriction detection capability

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution provides accurate and cost-effective monitoring of adhesive output, reducing maintenance needs and enabling retrofits to existing systems, while ensuring consistent adhesive application across multiple applicators.

Implementation Method 1

a flow meter having a flow inlet and a flow outlet, where the flow meter is configured to measure an amount of the adhesive flowing out of the flow outlet

Methodology Applied

Scientific EffectFluid flow measurement:

Implementation Method 2

at least one product detector configured to sense a presence of a product to which the adhesive is applied

Methodology Applied

Scientific EffectProduct detection:

Data Source

PatentUS11041745B2System and method for monitoring liquid adhesive flow

Publication Date: 2021.06.22 NORDSON CORP

AI summary

A hot melt adhesive system includes an adhesive supply for receiving solid or semi-solid hot melt adhesive, and a heater associated with the adhesive supply for melting the solid or semi-solid hot melt adhesive into liquid hot melt adhesive. An adhesive tracking system monitors an output of the liquid hot melt adhesive, and includes a flow meter having a flow inlet and a flow outlet. The flow meter measures an amount of the adhesive flowing out of the flow outlet. A product detector may be used to sense a presence of a product to which the adhesive is applied. A controller then determines the total amount of the liquid adhesive dispensed and the average amount of liquid adhesive dispensed per product.