HK1077774A - Method and system for supporting and/or aligning components of a liquid dispensing system - Google Patents

Description

Method and system for supporting and/or aligning components of a liquid dispensing system

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This application claims the benefit of U.S. provisional application No. 60/547,378 filed on 24/2/2004, the contents of which are incorporated herein by reference.

Technical Field

The present invention relates generally to liquid dispensing systems having separate components connected together, and more particularly to the manner in which these components are secured together.

Background

Viscous liquids or fluids are applied to the surface of a substrate by dispensers in a variety of dispensing applications used in product manufacturing and product packaging. These viscous liquids include thermoplastic materials such as hot melt adhesives. Liquid dispensers utilize pneumatically or electrically actuated valve assemblies for precisely metering the amount of viscous liquid and discharging the metered amount through a small diameter dispensing orifice. Many thermoplastic materials exist in solid form at room or ambient temperature and must be heated to form a flowable viscous liquid. Other hot melt adhesive materials are supplied in liquid form at room temperature. The material in solid form is placed in a holding container with heated walls and melted by heating the solid material above its melting point. The viscous liquid is pumped from the supply tube to the manifold assembly in a molten state under the pressure of the holding vessel. The manifold assembly has a liquid passage connected in fluid communication with one or more dispensing orifices of the liquid dispenser.

The dispensing modules that include the dispensing orifices are typically attached to a manifold block, sometimes called a gun body or gun manifold, by screws or bolts that extend through the module and into threaded holes in the face of the manifold. In order for the liquid dispensing system to function properly, the connection of the manifold to the module must be made so as to provide leak-proof communication between the two subassemblies or components. In the case of a pneumatic mode of operation and/or providing air-assisted liquid dispensing, cross-sectional connections of the air port with the adhesive port must be avoided. Connecting the two subassemblies requires placing the module in place and then threading the connecting bolts through the module and into the manifold while holding the module steady. Misalignment will allow adhesive to leak from the spray gun to the delivery system and/or substrate and to the pneumatic section of the dispensing unit.

To clean or connect different modules, an operator or service person often needs to remove the module from the manifold. Accordingly, there is a need for an interface between a module and a gun manifold that simplifies connection of the module, prevents misalignment of the two subassemblies and their respective fluid ports when connected, and prevents erroneous connection of the two subassemblies.

Disclosure of Invention

The present invention relates generally to a device for dispensing liquid thermoplastic material, such as hot melt adhesive, comprising at least a first component configured to be easily attached and detached with respect to a second component of the dispensing system. More specifically, the first component includes a first side and at least one channel for receiving a liquid thermoplastic material. The channel includes an opening on the first side, and the first component further includes a first interaction surface on the first side and is configured as a recess extending only partially into the first component or as a protrusion extending only partially into the second component. The first interacting surface is adapted to cooperate with a second interacting surface on a second component and thus either support the first component at least partially on the second component or the second component at least partially on the first component, depending on which component is received by that component.

The various components comprising the interactive surface of the present invention include, for example, a dispensing module, a gun manifold, an adapter or other liquid dispensing component of a system configured to dispense a liquid thermoplastic material such as a hot melt adhesive.

In a preferred embodiment, the first and second interactive surfaces cooperate to self-support one of the first and second components on the other of the first and second components. The first and second interacting surfaces have asymmetrical shapes that cooperate to achieve such self-support in one direction and not in the opposite direction. The first and second components may include respective first and second air ports that align when the first and second interacting surfaces are mated. The interaction surface may comprise an asymmetric curved surface, which may also comprise curved surfaces having different radii of curvature. The curved surfaces may have recesses or protrusions formed therebetween. The recessed and protruding portions may be generally bow-tie shaped, or may have various other shapes, such as rectangular shapes, dove-tail shapes, or other shapes that include angled surface portions or a combination of flat and curved surfaces.

Generally, a method for connecting a first component to a second component includes at least partially supporting one of the first and second components on the other of the first and second components by engaging a recessed portion of the first component with a protruding portion of the second component. First and second liquid ports, which are recessed and protruding portions on the same plane, are aligned in fluid communication with each other. Separate fasteners are then used to secure the first component to the second component.

It should be appreciated that the foregoing aspects of the invention may be used with various types of dispensing systems, including pneumatic or electric. These various aspects may also be applied to various components of such systems that would benefit from the features described herein. These and other features, objects and advantages of the present invention will become more readily apparent to those of ordinary skill in the art after reviewing the following detailed description taken in conjunction with the accompanying drawings.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain various embodiments of the invention.

FIG. 1 shows a liquid dispensing system according to an embodiment of the invention.

Fig. 2A to 2C illustrate an exemplary allocation unit according to an embodiment of the present invention.

FIGS. 3A-3C illustrate an exemplary gun manifold to be coupled to a dispensing module according to the principles of the present invention.

Figure 3D illustrates the assembly of the dispensing unit and manifold of figure 3A.

Fig. 4-11 illustrate exemplary embodiments of a spray gun unit according to the principles of the present invention.

FIG. 12A shows an assembly having an adapter that suspends a module from a manifold having a smooth front face in accordance with an embodiment of the present invention.

Fig. 12B shows an exploded view of the assembly of fig. 12A.

FIG. 13A shows an assembly having an adapter for hanging a module having a smooth rear face from a manifold in accordance with another embodiment of the present invention.

Fig. 13B shows an exploded view of the assembly of fig. 13A.

Fig. 14 to 19 show an alternative embodiment of the invention in which the recess on the face of the spray gun unit is not located between the gas port and the liquid port.

Fig. 20-22 illustrate an exemplary dispensing unit according to an alternative embodiment of the present invention.

Fig. 23 and 24 show perspective and side views, respectively, of an exemplary dispensing unit according to yet another embodiment of the present invention.

FIGS. 25-27 illustrate an exemplary manifold adapted for use with a plurality of modules.

FIG. 28 illustrates an exemplary manifold made in accordance with the principles of the present invention.

Detailed Description

Various spatial coordinate and directional terms are used throughout the specification, such as "vertical," "upward," "downward," and the like. These terms are not to be construed in a limiting sense and are used only for the sake of clarity in describing the examples and embodiments of the invention described herein. For example, terms such as "vertically supported" refer to one component being capable of being supported in a vertical manner relative to another component, and not necessarily in the manner in which it is supported in a given application.

Fig. 1 shows a schematic view of an assembled liquid dispensing system, or spray gun, 100. This system 100 is typically connected to a source of molten adhesive (not shown) and a source of compressed air (not shown). In packaging applications, such a spray gun 100 is provided and the substrate moves relative to the spray gun; in other applications, the spray gun 100 is mounted on a movable platform and controlled by a robot or other automated positioning system. Specifically, the gun manifold 102 is coupled to a module 104, and the module 104 includes dispensing orifices 106 for the controlled delivery of an adhesive or other liquid. The dispensing orifice 106 may be located on a nozzle 107 supported by the dispensing unit 104. The manifold 102 may include a connector 108 for connection to a source of pressurized air. Typical hot melt pneumatic adhesive spray guns operate in the range of 40 to 70 psi. Manifold 102 also includes a connector 110 that is connected to a source of high pressure fluid, such as hot melt adhesive. There may be two passageways within the manifold 102 to communicate the fluid of the manifold 102 with the module 104. The first passage 112 provides compressed air to a corresponding passage 116 in the distribution unit 104. Similarly, the channels 114 provide liquid to corresponding channels 118 in the dispensing unit 104. In addition to these passages 116 and 118, the spray gun 100 may include a number of other passages not shown. For example, electrical connections may be provided in the distribution unit 104 and the manifold 102; also, an outlet and inlet port may be provided for providing features such as "vortex air" for controlling the dispensing mode of the dispensing unit 104. Accordingly, those skilled in the art will recognize that the spray gun 100 may include a plurality of internal structures and passages, such as those found in pneumatic dispensing spray guns, as issued by the present assignee, having product models such as H100, H200, H400, CF200, and H20.

There is an interface 120 where the channels 112 and 116 meet and another interface 122 where the channels 114 and 118 meet. Each of the interfaces 120 and 122 typically includes two mating openings (one on the manifold 102 and the other on the module 104) that mate together to enable fluid communication between the respective channels. O-rings 121, 123 or other gasket-like elements are often included on the interfaces 120, 122 to help provide a seal.

The dispensing unit 104 also provides a dispensing chamber 124 that receives air and liquid from the channels 116 and 118, respectively. A liquid, such as a hot melt adhesive, is controllably released from the dispensing chamber 124 through the dispensing orifice 106, typically by gas actuation.

The manifold 102 and the module 104 are secured together with bolts 126. Two bolts are typically used, although only one bolt is visible in fig. 1. The bolt 126 passes through the module 104 via the passage 128 and engages threads on the end of the passage 128 in the manifold 102. In this configuration, the face 132 of the module 104 is placed in contact with the corresponding face 130 of the manifold 102. For purposes of orientation, the face 130 is referred to as the front of the manifold 102, and the face 132 is referred to as the rear of the module 104.

The manifold 102 also includes a projecting portion 140 that extends outwardly from its face 130. The module 104 includes a complementary shaped recess or groove 142 on its face 132 that matches the shape of the projection 140. Together, these two structures enable the module 104 to be held by, or hung or resting on, the manifold 102, even without the bolts 126. Thus, the module 104 is supported by the manifold 102 in a vertical orientation. The recessed portion 142 and the projecting portion 140 are advantageously shaped so that the module 104 is self-supporting by the manifold 102 in a vertical direction, or in other words, the module 104 is suspended from the manifold 102 without additional support. With the module 104 and manifold 102 so aligned, the module 104 does not need to be held in place by an operator as the bolts 126 are threaded through the passages 128. The bolt 126 extends through an aperture in the component (e.g., the module 104 and manifold 102) that may or may not be open to the recess or projection (e.g., recess 142 or projection 140).

The recessed portion 142 and the protruding portion 140 may optionally be configured to provide substantially vertical support, but still require slight stabilization of the dispensing unit 104 by an operator. Thus, while the module 104 may not be freely suspended, it is supported sufficiently so that it does not require an operator to hold the module in place while attempting to attach the module 104 to the manifold 102. Rather, the projections 140 and recesses serve to align the module 104 and manifold 102 so that an operator can stabilize the module 104 with one hand while easily attaching a bolt or other retaining device with the other hand. Thus, embodiments of the invention described herein relate to a module and a manifold as follows: which cooperate with each other to support the dispensing unit in a vertical direction and advantageously cooperate with each other to self-support the dispensing unit in a vertical direction.

Whether the module 104 is free-hanging or requires additional operator stability, the interface 120 between the air passages 116 and 112 is properly aligned and the interface 122 between the liquid passages 114 and 118 is properly aligned by the interfitting projections 140 and recesses 142. As additional embodiments of the invention are described in detail herein, the projections 140 and recesses 142 may act as dams to prevent adhesive from flowing into the air passages 116 of the module 104 in the event of a seal failure or other leak, and may also include slots or similar areas to enable the adhesive to be diverted from the module 104.

The projections 140 and recesses 142 of fig. 1 are exemplary, and many alternative configurations are possible. The present invention contemplates a variety of interacting complementary surfaces and shapes that enable the dispensing unit 104 to be temporarily retained by the dispensing unit 102. Generally, the front face 130 of the manifold 102 will include one or more interactive surfaces, while the rear face 132 of the module 104 will include complementary interactive surfaces. When the front and rear faces 130, 132 are positioned together, the interacting surfaces communicate with each other and cooperate to allow the module 104 to be self-supporting in a direction perpendicular to the manifold 102.

Fig. 2A to 2C show an exemplary allocation unit according to another embodiment of the present invention. The following description of the module 202 focuses on the rear face 201, and specifically the recessed structure 212, that it mates with a gun manifold (not shown). However, it should be understood that the gun manifold 202 may include all of the internal and external structures typically found in hot melt pneumatic adhesive guns.

The module 202 includes a threaded extension 218 for receiving a nozzle (not shown) for dispensing liquid and a rear face 201 that mates with a gun manifold (not shown). Threaded bores 208, 210 are included to allow the module 202 to be connected to a gun manifold. The rear 201 of the exemplary dispensing unit 202 of fig. 2A includes an opening 204 to an air passage and an opening 206 to a liquid passage. In this particular example, each opening 204, 206 has a surrounding recess 214, 216, respectively, that can accommodate an O-ring (not shown) between the module 202 and the manifold.

A recess 212 is disposed between the air port 204 and the liquid port 206. In this exemplary embodiment, the recessed portion 212 resembles a "bow-tie" in that it has a narrower central region that flares outward on both sides. It should be understood that the embodiments shown in fig. 3A, 4, 7, 8, 10, 20, 23, 26 and 28 are also examples of bow-tie shapes. The recessed portion 212 includes a top curved portion 240 and a bottom curved portion 242. Fig. 2B is a side view focusing on the shape of the recess 212, and fig. 2C is an enlarged view of the recess 212. Specifically, top curved portion 240 includes an undercut region 220 that extends to form lip 226, while bottom curved portion 242 includes its own undercut region 222 that extends to form lip 224. The lip 226 allows the module 202 to be self-supporting in a direction perpendicular to the direction shown in FIGS. 2A-2C when the module 202 is placed on a gun manifold (not shown) having a complementary projecting portion. Thus, the module 202 is temporarily held by, or suspended from, the manifold until bolts or other retainers can be inserted into the openings 208 and 210. As shown in fig. 2C, the opposing surfaces of the lips 224, 226 may be chamfered or angled to facilitate mating of the dispensing unit 202 with another component.

In those instances in which the module is configured to dispense in an upward direction, it will be connected to the manifold in a direction opposite that of FIG. 2A. Thus, in this orientation, the lip 224 (rather than the lip 226) will interfit with a complementary projecting portion of the manifold to retain the module 202 on the manifold.

The top curved portion 240 and the bottom curved portion 242 may have the same or different radii of curvature. As shown in fig. 2A to 2C, the curved portions 240, 242 have different radii of curvature. Thus, a complementary projecting portion of a manifold (not shown) will have a complementary curved portion of appropriate shape. Because of this asymmetry, the module 202 will only properly mate with the manifold in one orientation. Thus, the recessed portion 212 of the module 202 can be considered "keyed" so that it serves to properly orient the module 202 and thereby prevent an operator from inadvertently reversing the module 202 when the module is attached to a manifold. The curved portions 240, 242 also serve to align the module 202 with the manifold. The curved shape forces the dispensing units to tend to be properly aligned side-by-side. Thus, the openings 204 and 206 will align with corresponding openings on the gun manifold. Also, the bolt holes 208, 210 will be properly aligned.

FIGS. 3A-3C illustrate an exemplary gun manifold constructed in accordance with the principles of the present invention for connection with the module of FIGS. 2A-2C. The manifold 302 differs from the manifold of FIG. 1 in that the opening 304 for the air passage is located at the top of the manifold 302. Also within the manifold is a region 318 for electrical devices (not shown) such as heating elements and control elements.

The manifold 302 includes a front face 308 that mates with the gun module, e.g., similar to the front face of FIG. 2A. A recess 308a may be provided to receive one or more screw heads 202a associated with the dispensing unit. The apertures 314 and 316 mate with apertures similarly provided on the gun module and allow bolts or other retaining devices to be used to secure the manifold 302 to the gun module. The front face 308 also includes an opening 310 to an air passage and an opening 312 to a liquid passage. Air and liquid are introduced into the connected spray gun dispensing unit through these openings 310, 312, respectively.

A portion 306 projects outwardly from the surface of the front face 308. The exemplary bulge 306 of fig. 3A has a narrower neck that curves outward to thicker wings on both sides. Thus, there is a top curved portion 340 and a bottom curved portion 342. These curved portions 340, 342 are shown as having different radii of curvature similar to the complementary portions of fig. 2A, however, alternative embodiments also contemplate that each curved portion 340, 342 has the same radius of curvature.

The side cross-sectional view of fig. 3B more clearly illustrates the shape of the projecting portion 306. This view also shows an opening 320 through which an adhesive or precursor liquid thereof, for example, is introduced into the manifold 302. Fig. 3C is an enlarged view of the encircled area showing that the projecting portion 306 includes an undercut portion 330 along its top edge and an undercut portion 332 along its bottom edge. Thus, these undercut portions 330, 332 form the raised portion 306 having a "T-shaped" profile 334.

Fig. 3D shows the module 202 and manifold 302 assembled together. Air connections are not shown; however, a cable 356 and fluid connection 354 are shown. Also shown is a cover 352 secured with bolts 350 that covers the area 318, and an exemplary spray gun mounting assembly 360. When the module 202 is placed on the manifold 302, its recessed portion 212 cooperates with the projecting portion 306 such that the module is retained by, or hangs from, the manifold 302. Also in this position, the operator can attach bolts 370 and 372 to more permanently secure the module 202 to the manifold 302.

FIGS. 4-11 illustrate variations of the rear face of the gun module which can be formed in various shapes to mate with a complementary front face of the manifold. Although the assemblies are referred to in this series of figures as examples of a module, these shapes can be used very easily as examples of a manifold or other liquid dispensing component. The present invention contemplates an interface between the module and the manifold that enables the module to be held by, or suspended from, the manifold. The exemplary shapes of FIGS. 4-11 allow for such suspension of the module, whether it be implemented on a manifold or on a module. Moreover, these figures do not clearly show the surfaces that interact complementarily with the illustrated examples, as one skilled in the art will recognize that any complementary surfaces will include appropriately shaped male portions corresponding to each of the illustrated female portions and appropriately shaped female portions corresponding to each of the male portions.

Similar to the exemplary distribution unit described above, the distribution unit 402 of FIG. 4 includes air openings 204 and liquid openings 206 along with bolt holes 208 and 210. Indeed, all of the various dispensing units described below include these features even if not explicitly described. The portion 412 surrounding the air opening 204 is sized to fit an O-ring or other gasket (not shown). Similarly, the area 408 surrounding the liquid opening 206 is also sized to fit an O-ring (not shown). However, region 408 includes an annular protrusion 410 immediately surrounding opening 206. In some examples, liquid passing through the opening 206 may adhere to the O-ring and unseat the O-ring or push it into the opening 206. The annular protrusion 210 separates the liquid from the O-ring and thus ensures that the O-ring remains in place. The recessed portions 412 and 408 can be formed to a depth that is substantially non-conducive to retaining the module on a manifold (not shown), or they can be cut into the module 402 to a depth that will not interact with a corresponding annular ridge on the manifold to provide additional resting surfaces thereon for hanging the module 402. The recessed portion 404 of FIG. 4 resembles the bow-tie shape 212 of FIG. 2A, which helps properly align the openings 204, 206 on the module 402. As previously explained, the recessed portion 404 can also be "keyed" to prevent the module 402 from being improperly positioned on the gun manifold (not shown). The recessed portion 404 of the module 402 of fig. 4 and other alternative embodiments of fig. 5-24 may include a lip (as shown in fig. 2C) or may have a smooth shape.

The module 502 of fig. 5 shows a recessed portion 504 that is a horizontally extending region having substantially the same width 506 along its entire length. In fig. 6, the module 602 includes a recessed portion along substantially the entire top half thereof, and as a result, an angled surface 608 protrudes from the module 602. If the module 602 is placed in a direction such that it dispenses upwardly, the angled surface 608 will effectively interact with a corresponding projection on the manifold. The annular portion 606 provides a mating surface between the module 602 and a manifold (not shown). When bolted into an assembly, surface 606 will form a seal with the manifold.

The module 702 of fig. 7 includes a bow-tie like recess. However, instead of a smooth curved portion, the recessed portion 704 is formed by angled portions 710 and 712. As before, these angled portions 710, 712 may be shaped differently from one another to provide a "keyed" dispensing unit. The module 802 of fig. 8 has a recess 804 in which the curved portions 808, 810 are more rounded than the bow tie recesses previously described. The dispensing unit 902 of fig. 9 is similar to the horizontally-extending portion 504 of fig. 5, but includes additional features 908 and 910. These features 908 and 910 have relatively small grooves into the recess 904. As a result, the module 902 will automatically be pushed into alignment when it is placed on a complementary manifold (not shown). In FIG. 10, an exemplary module 1002 includes side-by-side recessed portions 1004 and 1006 that flare outwardly toward the sides of the module.

The dispensing unit of fig. 11 is substantially identical to the dispensing unit of fig. 5, except for the location of the respective liquid openings. The liquid opening 508 of the dispensing unit 502 (fig. 5) is eccentrically located in the annular region 510, similar to the opening 206 in the annular region 410 shown in fig. 4. In contrast, however, in fig. 11, the liquid opening 1204 is centered in a surrounding annular region 1206.

In many of the configurations shown herein, the manifold will include a complementary shaped projecting portion. This projection separates the air port and the liquid port when the manifold and the module are coupled together. More specifically, the projections and recesses form a dam-like structure between the two ports. Thus, even if the O-ring fails or liquid leaks from the manifold, the dam will help prevent adhesive from reaching the air port and damaging the module. In addition, the recess may be shaped to provide an exit path for any liquid that may escape from the liquid port. In particular, since the recesses are sloped downwardly from their centers, any liquid entering the trough will be diverted outwardly to the edges of the dispensing unit rather than toward the air ports.

One embodiment of the present invention is directed to a module that can still interact with a conventional or legacy gun manifold. These manifolds typically have a smoothly machined front surface that mates with a smoothly machined rear surface of the module. While modules having a hanging configuration are becoming more common, there is still a need for these new types of modules to interact with older types of manifolds.

The conventional manifold 2502 shown in FIG. 12A has a smooth front face 2516 with no projecting portions. Such a manifold 2502 includes an air supply connector 2512 and a liquid supply connector 2514 as well as many other features not shown. The dispensing unit 2504 includes a rear face having a recessed portion 2518 and a dispensing nozzle 2510. This recessed portion 2518 need not interfere with the module 2504, which is fixedly secured to the manifold 2502. The module 2504 can be mounted directly to the manifold 2502 with one or more bolts 2508 so that smooth contact surfaces and O-rings (if any) sealingly connect the module 2504 to the manifold 2502. However, this arrangement does not provide the advantages of a retaining or hanging structure provided by the module 2504.

Thus, the adapter 2506 can be used between the manifold 2502 and the module 2504. The adaptor 2506 is attached to the manifold 2502 and is provided with a projecting portion 2519 on which to suspend or at least partially support one or more modules 2504. Typically, the adapter 2506 will be coupled to the manifold 2502 using bolts 2520 and one or more existing mounting holes 2521. For example, the adapter 2506 can use the original holes for mounting the dispensing units while providing additional holes that the dispensing units can use. One of ordinary skill in the art can envision many alternative ways to connect one or more of the module 2504, adapter 2506 and manifold 2502, including the use of long bolts 2508 through at least one of the original holes 2521. Similar to the configuration of FIG. 1, the recessed portion 2518 is shaped to complement the projecting portion 2519 and enable the module 2504 to hang from the manifold 2502. In this manner, the new module 2504 can work with an older manifold 2502. Fig. 12B shows an exploded view of the assembly of fig. 12A.

As an alternative to the adapter 2506 of FIG. 12A, the adapter 2606 of FIG. 13A may be used to enable the new manifold 2602 to be used with an older module 2604. The old version of the dispensing unit 2604 includes a dispensing nozzle 2610 and a smooth rear face 2616 without a recessed region. In this example, the adapter 2606 includes a recessed portion 2618 that mates with a projecting portion 2619 on the front face of the manifold 2602. As seen previously, the recessed portion 2618 enables the module 2604 to be temporarily held or suspended by the manifold 2602. In operation, for example, the module 2604 is coupled to the adapter 2606 by one or more bolts 2608. The module 2604 and the adaptor 2606 are then hung from the projecting portion 2619 so that the bolt 2608 can be fully tightened within the channel or mounting hole 2621. Thus, in this manner, old style modules 2604 can be changed to work with new style manifolds 2602. Alternatively, the original bolts that connect with the module 2604 may be replaced with long bolts, and the components 2602, 2604, and 2606 may be overlapped or assembled as shown in fig. 13A and may be connected together with new longer bolts. Fig. 13B shows an exploded view of the assembly of fig. 13A.

The adapters 2506 and 2606 of fig. 12A and 13A can be shaped to conform to any of the recessed shapes (or complementary projecting portions) shown herein for supporting components such as a module, manifold, adapter, or any similar component. Thus, conventional apparatus can be adapted to provide a dam-like structure to prevent contamination of the air channels with liquid, a wedge-shaped structure to prevent mis-orientation of the module on the manifold, and a self-aligning structure to align the manifold and the corresponding channels of the module, by using appropriate adapters. Furthermore, the use of adapters constructed in accordance with the present invention allows multiple units connected to a single adapter to be easily replaced with other distribution units of different numbers and spaces.

In the foregoing embodiments, the recessed portions of the various dispensing units are positioned between the air ports and the liquid ports. However, other embodiments of the invention also provide for positioning the recessed area at other portions of the dispensing unit near the rear. For example, the dispensing unit 2702 of fig. 14 includes a recessed portion 2704 located near the top of the dispensing unit 2702. As before, the dispensing unit 2702 includes an air port 2708, a liquid port 2710 and bolt holes 2712, 2714. However, in this example, the recessed portion 2704 is not located between the ports 2708 and 2710, which enables the module 2702 to be held or hung from a manifold when the recessed portion 2704 is mated with a complementary projecting portion (not shown) of the manifold. The recess 2704 is contoured to resemble a dovetail with edges that flare away from each other; however, alternative embodiments may include recesses having edges that are substantially parallel to each other. Fig. 15 shows a module 2802 having a recessed portion 2804 that has a shape similar to the recessed portion 2704, but is located near the bottom of the module 2802 rather than at the top. Fig. 16 shows a module 2902 having recessed portions 2904 and 2906 at opposite ends of the module 2902. The profiles of the recessed portions 2904 and 2906 may be the same or different to prevent mis-orientation of the module 2902.

The module of fig. 17 to 19 includes a recess having a "half-trough shape". The module 3002 of FIG. 17 includes a half-trough edge portion 3004 along its top edge, while the module 3102 of FIG. 18 includes a half-trough edge portion 3104 along its bottom edge. The module 3202 of fig. 19 includes one half-channel 3204 along its top edge and another half-channel 3206 along its bottom edge. These half-trough edge portions are configured to receive a complementary shaped projection on a manifold (not shown) in accordance with the principles of the present invention.

Fig. 20 to 22 show an exemplary allocation unit according to another embodiment of the present invention. The following description of the module 3302 focuses on its rear face 3301, and specifically the recessed structure 3312, that mates with a gun manifold (not shown). However, it should be understood that the gun dispensing unit 3302 may include all of the internal and external features typically found in hot melt pneumatic or electric adhesive guns.

The module 3302 includes screw holes 3308, 3310 to enable the module 3302 to be attached to a gun manifold. The rear face 3301 of the exemplary dispensing unit 3302 includes a port 3304 to the air passageway and a port 3301 to the liquid passageway. In this particular example, each port 3304, 3306 has a surrounding indentation 3314, 3316, respectively, that receives an O-ring (not shown) between the module 3302 and the manifold.

A recessed portion 3312 is provided between the air port 3304 and the liquid port 3306. In this exemplary embodiment, the recessed portion 3312 resembles a "bow tie" in that it has a narrower central region that flares outward on both sides. Thus, there is a top curved portion 3340 and a bottom curved portion 3342. The side view of fig. 21 focuses on the shape of the recessed portion 3312, and fig. 22 is an enlarged view of the recessed portion 3312. Specifically, the top curved portion 3340 includes a recessed area 3320 that extends to form a lip 3326, while the bottom curved portion 3342 includes its own recessed portion 3322 that extends to form a lip 3324. The lip 3326 allows the module 3302 to be self-supporting in a vertical orientation as shown in FIGS. 20-22 when the module is placed on a gun manifold (not shown) having a complementary projecting portion. Thus, the module 3302 will be temporarily held or hung from the manifold until bolts or other retainers can be inserted into the openings 3308 and 3310.

The module 3302 is substantially similar to the module 202 of fig. 2A-2C, except for the lips 3326 and 3324. Referring to fig. 2A-2C, similar lips 3326 and 3324 are angled away from the rear face 201. The module 3302 has lips 3326 and 3324 that are substantially perpendicular to the face 3301 of the module 3302. If used with a manifold having a complementary shaped projecting portion, the relatively flat surfaces of the lips 3326 and 3324 provide more surface area than the angled lips 224 and 226 to frictionally engage the manifold.

In those instances where the module may be configured to dispense in an upward direction, it will be connected to the manifold in a direction opposite to that of FIG. 20. Thus, in such an orientation, the lip 3324 (and not the lip 3326) will interact with a complementary projecting portion of the manifold to retain the module 3302 on the manifold.

The simultaneous curved portion 3340 and the bottom curved portion 3342 may have the same or different radii of curvature, as shown in fig. 20-22, with curved portions 3340 and 3342 having different radii of curvature. Thus, the complementary projecting portion of the manifold (not shown) will have a complementary curved portion of suitable shape. Because of this asymmetry, the module 3302 will only properly mate with the manifold in one direction. Thus, the recessed portion 3312 of the module 3302 can be considered "keyed" so that it serves to properly orient the module 3302 and, thus, prevent an operator from inadvertently inverting the module 3302 when the module 3302 is coupled to a manifold. The curved portions 3340, 3342 also serve to properly align the module 3302 with the gun manifold. Due to the curved shape, the dispensing units are pushed into proper side-by-side alignment. Thus, the openings 3304 and 3306 will be aligned with their corresponding openings on the gun manifold. Similarly, holes 3308, 3310 will also be properly aligned.

FIG. 23 illustrates an exemplary module according to another embodiment of the present invention. This module 3602 is similar in many respects to the module 3302 of FIG. 20; therefore, most features of the module 3602 will be described only briefly. The rear face 3601 of the exemplary module 3602 includes an opening 3604 to one air channel and an opening 3605 to another air channel. In some dispensing units, the piston is driven by compressed air to move the piston in one direction. Movement of the piston is translated into movement of a needle within the dispensing unit to control dispensing of liquid from the dispensing unit. In such dispensing units, a spring is usually provided which urges the piston in the opposite direction. Alternatively, the dispensing unit may comprise a piston without a spring, instead moving the piston in both the up and down direction by means of separately applied air. The dispensing unit 3602 is an example of the latter type of dispensing unit, and thus, includes an opening 3604 that supplies air to move the piston downward and an opening 3605 that supplies air to move the piston upward. As with the previous embodiments, an opening 3306 to the liquid passage is included. In this particular example, each opening 3604, 3605, 3606 has a surrounding recess that receives an O-ring (not shown) between the module 3602 and the manifold, respectively.

A recessed portion 3612 is disposed between the air ports 3604, 3605 and the liquid port 3606. The recessed portion 3612 is substantially similar to the previously described "bow tie" portion. Thus, there is a top curved portion 3640 and a bottom curved portion 3642. Specifically, the top curved portion 3640 includes an undercut portion 3620 that extends to form a top lip, while the bottom curved portion 3642 includes its own undercut portion 3622 that extends to form a bottom lip. Similar to the lips 3324, 3326 of fig. 22, the top and bottom lips of the module 3602 are substantially perpendicular to the face 3601, as shown in fig. 24. It has also been proposed to use lips similar to the angled lips 224, 226.

FIG. 25 illustrates a manifold 4002 that is adapted for use with a plurality of modules. An exemplary use of the manifold 4002 is in the production of nonwoven materials, such as for the manufacture of diapers. The manifold 4002 includes five portions (a, b, c, d, e, and f) that may be substantially identical. One of ordinary skill in the art will recognize that fewer or more sections may be used to accommodate a plurality of different dispensing units. The features of part a are described clearly below. But each of the other sections b-f also has similar characteristics. An opening or port 4004 is provided for receiving pressurized air and providing it to the dispensing unit through opening 4006 in a controlled manner. Port 4010 is a liquid port that supplies a liquid, such as hot melt adhesive, to the dispensing unit. Port 4012 also supplies air to the dispensing unit. However, such air is not typically used to drive the liquid dispensing, but rather to influence the characteristics of the liquid being dispensed, such as vortex air. Those of ordinary skill in the art will recognize that the described ports for liquid and air are exemplary in nature and that different configurations known in the art may be used without departing from the scope of the present invention. For example, additional ports may be included to enable recirculation of liquid from the dispensing unit.

Attachment holes 4008, 4009 are included on the manifold 4002, which enable the module to be bolted or otherwise attached to the manifold 4002. Further, a protruding portion 4005 is provided that engages with a complementary shaped recessed portion of the dispensing unit. In this manner, the projecting portion 4005 supports the module in a vertical orientation even before the module is bolted to the manifold 4002.

Fig. 26 is an enlarged view of the projecting portion 4005 and illustrates that the projecting portion 4005 has the bow tie shape previously described having a different radius of curvature to provide a "keyed" operation. FIG. 25 shows five such projecting portions 4005, thus enabling five different dispensing modules to be connected to the manifold 4002.

Fig. 27 shows a cross-sectional view of the manifold 4002. In this cross-sectional view, the passages to the different ports are shown. For example, passage 4020 communicates with port 4006, passage 4022 communicates with port 4010, and passage 4024 communicates with port 4012. The projection 4005 has a profile as shown in fig. 27 and includes an upper surface 4030 and a lower surface 4032 extending outwardly and substantially parallel from the face 4001 of the manifold 4002.

The exemplary manifolds and modules described herein can be manufactured in a variety of ways. For example, a manifold such as that of FIG. 3A may be initially formed with rectangular-shaped side projections extending from face 308. Subsequently, the face 308 is machined in a separate manufacturing step to sealingly mate with the dispensing unit within tolerances, and the raised portion is machined to form the profile of the raised portion 306 as shown in FIG. 3C.

FIG. 28 illustrates a manifold having a projecting portion manufactured according to another method of manufacture. In particular, manifold 4102 initially includes a face 4104 having a substantially planar surface. During the manufacturing process, material is machined away from the face 4104 to form an upper recessed region 4106 and a lower recessed region 4108. These zones 4106, 4108 correspond to the surfaces that will mate with the dispensing unit. The removal of material effectively forms a raised portion 4114 having an upper lip 4110 and a lower lip 4112. During removal, the upper lip 4110 and lower lip 4112 may also be contoured to form features described herein, such as those described with respect to fig. 3C. As a result, the manufacturing process for forming the projecting portion of the manifold is simplified, improved, and more economical.

Further, as shown in FIGS. 3A, 25 and 26, a machined portion 4025 on the manifold is formed according to the method for forming the recessed portion (308 of FIG. 3A and 4001 of FIG. 38) within tolerance. But when another machining method and/or cutting tool is used, portion 4025 is not formed, as shown in fig. 28.

While the present invention has been illustrated by a description of various preferred embodiments and while these preferred embodiments have been described in some detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily occur to those skilled in the art. The various features of the present invention may be used alone or in various combinations depending on the needs and preferences of the user. As is now known, the present invention has been described in conjunction with the preferred methods of practicing the present invention.

Claims (39)

1. An apparatus for dispensing liquid thermoplastic material comprising

A first component comprising a first side and at least one channel for receiving the liquid thermoplastic material, said channel comprising an opening on said first side, and said first component further comprising a first interaction surface on said first side, said first interaction surface being configured as one of: a recess extending only partially into the first part or a protrusion extending only partially into a second part, the first interacting surface being adapted to cooperate with a second interacting surface on the second part, thereby enabling either at least partial support of the first part on the second part or at least partial support of the second part on the first part.

2. The apparatus of claim 1, wherein said first component is a gun manifold configured to support a dispensing module on said first side.

3. The apparatus of claim 2, further comprising said second component, wherein said second component is a module including a second interactive surface complementary to said first interactive surface and configured to mate said first interactive surface and said second interactive surface to at least partially support said module on said gun manifold.

4. The apparatus of claim 1, wherein the first component is a dispensing unit including a valve for selectively dispensing the liquid thermoplastic material.

5. The apparatus of claim 1, wherein said first interactive surface is asymmetrically shaped such that when said first member is oriented in a first direction, the first and second interactive surfaces cooperate to self-support one of said first and second members on the other of said first and second members, and when said first member is oriented in a second direction opposite said first direction, said first and second interactive surfaces do not cooperate and do not self-support one of said first and second members on the other of said first and second members.

6. The apparatus of claim 1, further comprising the second component having a second interactive surface, and wherein the first interactive surface and the second interactive surface cooperate to self-support the first component on the second component.

7. The apparatus of claim 6, wherein:

the first component further includes a first air port, an

The second component further comprises a second air port;

wherein the first air port is in communication with the second air port when the first and second interacting surfaces are mated.

8. The apparatus of claim 7, wherein:

the first interaction surface includes asymmetrically curved surfaces such that the first and second interaction surfaces mate only when the first air port is aligned with the second air port.

9. The apparatus of claim 7, wherein:

the asymmetrically curved surface further includes a plurality of opposing curved surfaces having different radii of curvature.

10. The apparatus of claim 7, wherein said first and second interacting surfaces further cooperate to align said first and second air ports.

11. The apparatus of claim 1, wherein said first component is an adapter configured to be positioned generally between a dispensing module and a manifold.

12. The apparatus of claim 1, wherein the first interactive surface further comprises opposing curvilinear surfaces defining a concave space therebetween for receiving a convex portion at least partially defined by the second interactive surface.

13. The device of claim 1, wherein the first interactive surface further comprises opposing curvilinear surfaces defining a convex portion therebetween, the convex portion configured to be received in a concave space at least partially defined by the second interactive surface.

14. The device of claim 1, wherein said recessed portion and said protruding portion are each generally bow tie shaped.

15. The device of claim 1, wherein the recessed portion and the protruding portion have a shape selected from the group consisting of:

(a) the shape of the rectangle is that of the rectangle,

(b) a plurality of angled surface portions of the plurality of angled surface portions,

(c) a generally rectangular shape having opposed curved portions, an

(d) A dovetail shape.

16. The apparatus of claim 1, wherein the interaction surface further comprises a protruding portion having a first undercut portion forming a first lip.

17. The apparatus of claim 16, further comprising a second undercut portion forming a second lip opposite said first lip.

18. The apparatus of claim 17, wherein the first and second lips have opposing, chamfered surfaces.

19. An apparatus for dispensing liquid thermoplastic material comprising

A first component comprising a first face comprising a first interaction surface and a first liquid port, the first interaction surface being formed as a recess extending only partially into the first component, and

a second component comprising a second face, the second face comprising a second interaction surface complementary to the first interaction surface and a second liquid port, the second interaction surface formed as a projection, wherein the recess and the projection cooperate to align the first and second liquid ports and at least partially support one of the first and second components on the other of the first and second components.

20. The apparatus of claim 19, wherein said first component is a gun manifold.

21. The apparatus of claim 19, wherein the second component is a dispensing unit.

22. The apparatus of claim 19, wherein the first component is a dispensing unit.

23. The apparatus of claim 19, wherein said second component is a gun manifold.

24. The apparatus of claim 19, wherein the first and second interactive surfaces are asymmetrically shaped such that when the first member is oriented in a first direction, the first and second interactive surfaces cooperate to self-support one of the first and second members on the other of the first and second members, and when the first member is oriented in a second direction opposite the first direction, the first and second interactive surfaces do not cooperate and do not self-support one of the first and second members on the other of the first and second members.

25. The apparatus of claim 19, wherein the first interactive surface and the second interactive surface cooperate to allow the first component to self-support on the second component.

26. The apparatus of claim 19, wherein:

the first component further comprising a first air port and the second component further comprising a second air port,

wherein the first air port communicates with the second air port when the first and second interacting surfaces are mated.

27. The apparatus of claim 26, wherein:

the first interaction surface is asymmetrically shaped such that the first and second interaction surfaces mate only when the first air port is aligned with the second air port.

28. The apparatus of claim 19, wherein one of said first and second components is an adapter configured to be positioned generally between a module and a manifold.

29. The apparatus of claim 19, wherein:

the recesses are formed between a first set of curvilinear surfaces,

the projections are formed between a second set of curvilinear surfaces.

30. The apparatus of claim 19, wherein:

the recessed portion and the protruding portion are both substantially bow-tie shaped.

31. The device of claim 19, wherein the recessed portion and the protruding portion have a shape selected from the group consisting of:

(a) the shape of the rectangle is that of the rectangle,

(b) a plurality of angled surface portions of the plurality of angled surface portions,

(c) a generally rectangular shape having opposed curved portions, an

(d) A dovetail shape.

32. The apparatus of claim 19, wherein said recessed portion and said projecting portion include cooperating undercut portions and associated lips for self-supporting one of said first and second members on the other of said first and second members.

33. The apparatus of claim 32, wherein said lip has opposed, chamfered surfaces.

34. A method of connecting a first component of a liquid thermoplastic material dispenser to a second component of the liquid thermoplastic material dispenser, the first component including a first face having a recessed portion extending only partially into the first component, the second component including a second face having a protruding portion complementary to the recessed portion and configured to mate the recessed portion and the protruding portion, and the first and second faces also having respective first and second liquid ports therein, respectively, the method comprising:

at least partially supporting one of the first and second components on the other of the first and second components by engaging the recessed portion of the first component with the protruding portion of the second component;

aligning the first and second fluid ports in fluid communication with each other; and

the first component is secured to the second component with a separate fastener.

35. The method of claim 34, wherein the step of at least partially supporting one of the first and second members on the other of the first and second members further comprises the step of suspending one of the first and second members from the other of the first and second members.

36. The method of claim 34, wherein at least partially supporting one of the first and second components on the other of the first and second components further comprises fully self-supporting one of the first and second components on the other of the first and second components.

37. The method of claim 34, wherein the first face further comprises a first air port and the second face further comprises a second air port, and the method further comprises:

the first and second air ports are aligned in fluid communication with one another.

38. The method of claim 34, wherein the step of engaging the recessed portion of the first component with the protruding portion of the second component further comprises:

a first curvilinear surface is joined to a second complementary curvilinear surface.

39. The method of claim 34, wherein the first and second components are two different components selected from the group consisting of: a module, a manifold, and an adapter for connecting the module to the manifold.