Extrusion Application System for Non-Newtonian Adhesive Control
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Solution Overview
Problem
Existing glue application systems face challenges in precise control of glue quantity, consistency, and minimizing glue volume, particularly with hot melt glue, leading to issues like glue splatter, machine downtime, and adhesive property degradation, especially at varying labeling speeds.
Innovation Solution
A system that modulates pressure based on temperature, speed, and flow characteristics of non-Newtonian liquids, using a servo motor controller and empirical data to ensure consistent adhesive deposition, even with high-speed labeling operations, and is adaptable for various applications beyond container labeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a slit die nozzle directly contacts the label to apply hot melt glue, then glue can be applied to the trailing edge of the label, but the quantity of glue laid down cannot be controlled precisely resulting in variation in glue lay down weight as labeling speeds increase
Solution Approach 1:
The system dynamically adjusts the extrusion parameters of the slit die nozzle based on the labeling speed. The controller modifies the glue flow rate and nozzle positioning in real-time to compensate for speed variations, ensuring consistent glue application weight across different operating speeds.
Solution Approach 2:
The system incorporates sensors to monitor the actual glue application weight and provides feedback to the controller. The controller then adjusts the extrusion parameters to correct any deviations from the target glue weight, maintaining precision even at varying labeling speeds.
2Productivity
If the spring contacts the slot gun with the trailing edge pad to apply glue, then glue application is achieved, but the spring does not compensate for increases in centrifugal forces as labeling speeds increase which results in an increase in the contact force that may damage the trailing edge pad
Solution Approach 1:
The contact force mechanism is made dynamic to compensate for centrifugal forces. The system adjusts the spring pressure or nozzle positioning based on the rotational speed of the vacuum drum, reducing contact force at high speeds to prevent damage to the trailing edge pad while maintaining glue application effectiveness.
3Ease of operation
If glue is extruded from the nozzle and waits on the head until the glue is smeared onto the trailing edge of the label material, then glue application is achieved, but a lack of control over the quantity of glue laid down results in variation in glue lay down weight
Solution Approach 1:
The system replaces manual or mechanical smear-based glue application with a controlled extrusion system. The slit die nozzle precisely meters and deposits the exact required amount of glue onto the label trailing edge, eliminating the variability inherent in mechanical smearing operations.
4Productivity
If a valve is opened and closed to apply the glue, then glue application is achieved, but an uneven distribution of glue is applied to the label
Solution Approach 1:
The system uses periodic pulsing of the glue supply to the slit die nozzle, synchronized with the label passage. This controlled periodic delivery ensures uniform glue distribution across the label surface while maintaining high application rates.
5Quantity of substance
If the speed of the glue pump is changed to control the volume of glue applied, then glue volume control is attempted, but it results in an intermittent pattern of pressure spikes and thickness variation in the adhesive deposits
Solution Approach 1:
The system replaces mechanical pump speed control with a precision extrusion system. The slit die nozzle, controlled by a metering mechanism, directly delivers the precise volume of glue required without the pressure fluctuations and thickness variations associated with pump speed modulation.
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 achieves accurate and consistent application of non-Newtonian liquids with controlled thickness and volume, reducing variations and adhesive property degradation, enabling reliable high-speed labeling with improved adhesive properties.
Implementation Method 1
Pressure is modulated at a given temperature of the composition as a function of the speed of the extrusion to obtain desired target deposit thickness and consistent lay down weights
Implementation Method 2
A system that modulates pressure based on temperature, speed, and flow characteristics of non-Newtonian liquids
Implementation Method 3
The composition is received through an inlet and is dispensed through an outlet of a nozzle that deposits a controlled layer of the composition on the surface as the surface moves relative to the nozzle
Data Source
AI summary
A machine and a method of applying a non-Newtonian liquid composition onto a surface in a controlled manner. The composition is held in a chamber at a controlled variable pressure and is dispensed through a slit die nozzle as controlled by a valve. Characteristics of the composition are empirically developed and provided to a logic control circuit to assure that the composition is dispensed on either the entire surface or in one or more precise locations.