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US 7,467,452 B2Granted
Method for applying flowable materials
AssigneeZephyros, Inc.
InventorsMaurice Lande, Michael J. Czaplicki
Life of this patent
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Abstract
Methods and apparatuses are disclosed for applying melt flowable materials to components of articles of manufacture. The methods and apparatuses disclosed herein are concerned with formation of appropriate flowable materials, control over the manner in which the flowable materials are applied, treatment of the components prior to application of the flowable materials and the like. Moreover, the apparatuses and methods may be particularly suited for applying flowable materials to surfaces and components found in automotive, aerospace, and marine vehicles.
Claims17
A method for applying a flowable material to a component of an article of manufacture, the method comprising:
- providing a first surface of the component;
- and
- extruding the flowable material upon the first surface in a slightly flowable state, using an extruder including an ectruder screw such that the flowable material wets and adheres to the first surface wherein:
- i) a controller employs closed loop control to control output of flowable material based upon a metering system that relates screw rotational speed of the extruder and positioning angle of the extruder to the output;
- ii) the output of the flowable material from the extruder has been experimentally related to the positioning angle of the extruder and the rotational speed of the extruder screw for creating an output profile that is programmed to the controller;
- iii) the profile relates the desired amount of flowable material output over time and the desired positioning angle of the extruder, to the desired rotational speed of the extruder screw for a chosen component;
- iv) as the flowable material is output, data regarding the angle of the extruder and the rotational speed of the extruder screw are monitored via sensors;
- and v) an amount of torque applied to the extruder screw is either raised, lowered or maintained such that the output of flowable material or the rotational speed of the extruder screw closely mirrors the output profile.
5 more elements
A method for applying a flowable material to a component of an article of manufacture, the method comprising:
- providing a first surface of the component;
- extruding the flowable material upon the first surface in a slightly flowable state, using an extruder including an ectruder screw such that the flowable material wets and adheres to the first surface wherein a controller employs closed loop control to control output of flowable material based upon a metering system that relates screw rotational speed of the extruder screw to the output;
- heating the surface of the component prior to applying the flowable material to the surface wherein the step of heating the surface includes exposing the surface to a lamp, exposing the surface to a blower, exposing the surface to a flame or combinations thereof;
- transporting the component along with a plurality of other components wherein the flowable material is substantially tack-free at temperatures near room temperature;
- and
- assembling the component to the article of manufacture wherein the article of manufacture is an automotive vehicle;
- wherein the step of extruding the flowable material includes extruding the flowable material with an automated apparatus, the automated apparatus including:
- i) a supply of the flowable material, the flowable material being provided as pellets in a container;
- ii) an extruder in communication with the supply of flowable material for receiving the pellets, the extruder capable of intermixing the pellets of flowable material into a viscoelastic state and dispensing the flowable material, the extruder including the rotatable screw for dispensing the flowable material;
- and
- iii) a system for moving the extruder or the component during dispensing of the flowable material;
- wherein the controller is in communication with the extruder and the system and wherein the extruder includes a heating element for heating the flowable material to a desired temperature and wherein the component is formed of a metal selected from steel, aluminum, or stamped metal and wherein the controller is a programmable logic controller in communication with the extruder, the programmable logic controller programmed with a profile that relates an output rate of flowable material to a position angle of the extruder and a rotational speed of the extruder screw and wherein the programmable logic controller employs closed loop control in conjunction with the profile to set the output rate at a desired level.
9 more elements
A method for applying a flowable material to a component of an article of manufacture, the method comprising:
- providing a first surface of the component;
- and
- extruding the flowable material upon the first surface in a slightly flowable state such, using an extruder including an extruder screw that the flowable material wets and adheres to the first surface wherein:
- i. a controller employs closed loop control to control output of flowable material based upon a metering system that relates screw rotational speed of the extruder screw to the output;
- and
- ii. the controller is programmed to reverse a direction of rotation of the extruder screw for retracting the flowable material a short distance after an application of the flowable material to the component;
- and
- iii. a screw bearing assembly is associated with the extruder, the assembly having a first thrust bearing and a second thrust bearing, wherein the first and second thrust bearings act in opposite directions.
5 more elements
A method for applying a flowable material to a component of an article of manufacture, the method comprising:
- providing a first surface of the component:
- and
- extruding the flowable material upon the first surface in a slightly flowable state, using an extruder including an extruder screw such that the flowable material wets and adheres to the first surface wherein:
- i. a controller employs closed loop control to control output of flowable material based upon a metering system that relates screw rotational speed of the extruder screw to the output;
- and
- ii. the controller is programmed to reverse a direction of rotation of the extruder screw for retracting the flowable material a short distance after an application of the flowable material to the component:
- wherein the output of the flowable material from the extruder has been experimentally related to the positioning angle of the extruder and the rotational speed of the extruder screw for creating an output profile that is programmed to the controller and wherein, as the flowable material is output, an amount of torque applied to the extruder screw is either raised, lowered or maintained such that the output of flowable material or the rotational speed of the extruder screw closely mirrors the output profile.
4 more elements
Dependencies are inferred from the claim text.