Adhesive Reconditioning Device Shear Viscosity Control
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Solution Overview
Problem
Dispensing systems for adhesive materials face inaccuracies in volume flow control due to changes in adhesive viscosity, leading to inconsistent application and potential defects in production parts.
Innovation Solution
The introduction of a reconditioning device that shears adhesive material to reduce viscosity and improve flow rate, coupled with a control module that monitors parameters like pressure, flow rate, and temperature to adjust shear rates and ensure consistent material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive material is stored in a dispensing system for extended periods, then the adhesive viscosity increases, but this leads to inaccurate volume flow control and inconsistent application
Solution Approach 1:
The patent applies parameter changes by using a reconditioning device that alters the physical state of the adhesive material through shearing action. The reconditioning device changes the viscosity parameter of the adhesive by subjecting it to controlled shear forces, thereby restoring optimal flow characteristics even after extended storage periods. This resolves the contradiction by dynamically adjusting the viscosity parameter to maintain reliable volume flow control.
Solution Approach 2:
The patent implements feedback control through sensors that continuously monitor adhesive material properties (such as viscosity and flow characteristics) and provide real-time data to the control system. The control system adjusts the reconditioning device operation based on this feedback, dynamically compensating for viscosity changes during storage and ensuring consistent volume flow control throughout the dispensing process.
2Manufacturing precision
If a reconditioning device is added to the dispensing system, then adhesive flow rate consistency is improved, but the device complexity increases
Solution Approach 1:
The patent merges the reconditioning device with the existing dispensing system architecture, integrating the shearing mechanism into the material flow path. The reconditioning device is positioned within the dispensing system such that it processes the adhesive in-line without requiring separate handling or additional complex subsystems. This integration approach maintains manufacturing precision while minimizing the increase in overall device complexity.
Solution Approach 2:
The reconditioning device is designed with multi-functionality, serving both as a viscosity control mechanism and as part of the overall material delivery system. The same shearing mechanism that conditions the adhesive also helps maintain consistent flow characteristics throughout dispensing operations, effectively performing multiple functions within a single device structure to reduce overall system complexity.
3Productivity
If shear rate is increased to reduce adhesive viscosity, then flow rate control is improved, but energy consumption increases
Solution Approach 1:
The patent applies dynamics by implementing a variable shear rate mechanism that adjusts the shearing force based on real-time adhesive material conditions. The reconditioning device dynamically modulates the shear rate applied to the adhesive, using higher shear rates only when viscosity increases during storage, and reducing or eliminating shear when the adhesive is already at optimal viscosity. This dynamic adjustment maintains productivity while minimizing unnecessary energy consumption.
Solution Approach 2:
The feedback control system monitors adhesive viscosity and flow characteristics, adjusting the shear rate applied by the reconditioning device based on actual material conditions. The control algorithm increases shear rate only when and where needed to restore optimal flow properties, rather than applying continuous high shear. This feedback-driven approach ensures high dispensing efficiency while significantly reducing overall energy consumption compared to constant high-shear operation.
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 enables consistent and accurate control of adhesive flow rates and volumes, reducing the need for visual inspection and minimizing defects in production parts by maintaining optimal adhesive viscosity.
Implementation Method 1
The shaft extends through the second member, is connected to the second shearing plate, and is configured to be rotated to shear the material disposed in the gap between the first shearing plate and the second shearing plate
Data Source
AI summary
A reconditioning device includes: a first shearing plate; a second shearing plate; and a housing. The housing includes: a first member configured to hold the first shearing plate and comprising an input for receiving a material; a second member connected to the first member to form an inner cavity, a portion of the inner cavity is located in a gap between the first shearing plate and the second shearing plate; and an output member connected to a pipeline of a production applicator and configured to output the material subsequent to shearing. The shaft extends through the second member, is connected to the second shearing plate, and is configured to be rotated to shear the material disposed in the gap between the first shearing plate and the second shearing plate.