Bottom-Up Adhesive Roller Application for Consistent Block Bonding
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Solution Overview
Problem
Existing adhesive application systems for automated block laying machines face challenges such as difficulty in metered dose dispensing due to varying viscosity, adhesive dripping during block rotation, and complexity in applying adhesive to blocks with complex structures, while also being costly and inefficient.
Innovation Solution
An adhesive application system that applies adhesive to the bottom surface of blocks using a roller submerged in the adhesive reservoir, which is gravity-fed and metered by a controllable valve, with a motor-driven roller for consistent application, and includes a heating element to control viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a top-down pump system is used to dispense adhesive, then adhesive can be applied to the top face of blocks, but it is difficult to achieve consistent metered dose dispensing due to varying viscosity with temperature
Solution Approach 1:
The patent inverts the traditional top-down adhesive application approach by implementing a bottom-up system where the adhesive roller is submerged in the adhesive reservoir and blocks are moved upward through the adhesive. This inversion eliminates the need for complex pump systems to meter adhesive, as the roller naturally picks up adhesive through capillary action and rotation, providing consistent application regardless of viscosity variations.
Solution Approach 2:
The patent replaces the mechanical pump-based metering system with a gravity-fed reservoir and a roller-based application mechanism. The adhesive flows into the reservoir under gravity, and the roller's rotation and submersion depth control the adhesive pickup, eliminating complex mechanical metering components while maintaining consistent application.
2Reliability
If adhesive is applied to the top face of blocks and then rotated for laying, then adhesive coverage is achieved, but adhesive drips from the block during rotation
Solution Approach 1:
By inverting the application sequence to bottom-up, the adhesive is applied to the bottom face of the block before the block is positioned for laying. This eliminates the need to rotate the block after adhesive application, thereby preventing adhesive dripping during rotation while ensuring proper adhesive retention on the bonding surface.
3Adaptability or versatility
If nozzles are used to apply adhesive, then adhesive can be dispensed, but it is difficult to apply adhesive uniformly to blocks with complex grid/core structures
Solution Approach 1:
The bottom-up application approach allows the adhesive roller to contact the entire bottom surface of the block, including complex grid and core structures. The roller's broad contact area and ability to conform to the block geometry enable uniform adhesive application across all surfaces, whereas nozzle-based systems struggle to reach and uniformly coat complex internal structures.
4Productivity
If a complex pump and nozzle system is used for adhesive application, then adhesive can be dispensed, but design complexity and running costs increase
Solution Approach 1:
The patent extracts and eliminates the complex pump and nozzle components from the adhesive application system, retaining only the essential elements: a gravity-fed reservoir, a submerged roller, and a drive mechanism. This extraction simplifies the system design, reduces component count, and lowers running costs while maintaining or improving application speed through the efficient bottom-up mechanism.
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 system reduces design complexity, minimizes adhesive dripping, ensures consistent adhesive application, and facilitates application on blocks with complex structures, while reducing costs and improving efficiency.
Implementation Method 1
adhesive from the reservoir is entrained up and around at least a portion of the adhesive roller
Implementation Method 2
adhesive from the reservoir is entrained up and around at least a portion of the adhesive roller
Implementation Method 3
includes a heating element to control viscosity
Implementation Method 4
adhesive is transferred from the adhesive roller onto a bottom surface of a block as the block is moved across the roller
Data Source
AI summary
An adhesive application system for an automated block laying machine, the adhesive application system including: (a) an adhesive supply; and, (b) an adhesive applicator including: (i) a container for storing an adhesive reservoir received from the adhesive supply via an adhesive supply line; (ii) a lid mounted to the container so as to substantially cover the adhesive reservoir; and, (iii) an adhesive roller rotatably coupled to the container so that upon rotation adhesive from the reservoir is entrained up and around at least a portion of the adhesive roller, wherein, in use, adhesive is transferred from the adhesive roller onto a bottom surface of a block as the block is moved across the roller.