Product Driven In-Line Glue Dot Applicator And Method For Using Same

Abstract

A method and apparatus are provided, for transferring pressure-sensitive adhesive segments from a rolled flexible carrier release tape to a workpiece, by directing the flexible carrier release tape to a dispensing member attached to a pivotable arm, and pivoting the arm in such a manner that the dispensing member clamps the flexible carrier release tape against the workpiece. With the carrier release tape clamped against the workpiece, relative linear movement between the carrier release tape and the workpiece is initiated, in such a manner that the relative motion unrolls the flexible carrier tape and moves one or more pressure-sensitive adhesive segments into pressurized contact with the workpiece so that the one or more pressure-sensitive segments are transferred from the flexible carrier tape to the workpiece.

1 . A pressure-sensitive adhesive segment dispensing apparatus, for selectively attaching the pressure-sensitive adhesive segments to a workpiece surface, the dispensing apparatus comprising:
 a pivotable arm, defining first and second ends of the arm and an arm axis extending between the first and second ends of the arm, the arm also defining a pivot axis disposed between the first and second ends and extending substantially perpendicular to the arm axis, the arm being adapted for pivotable movement about the pivot axis;   an actuator arrangement operatively connected to the arm for causing the arm to pivot about the pivot axis substantially along a plane of arm movement extending orthogonally to the pivot axis, from an apply position of the arm to a retracted position of the arm;   a supply spool mounting arrangement, rotatably attached to the arm for rotation about a supply spool axis extending substantially parallel to the pivot axis of the arm, and adapted for holding a roll of flexible carrier release tape oriented to extend along a longitudinal path running substantially parallel to the plane of arm movement, with the flexible carrier release tape having a transverse width, opposed first and second release surfaces and a plurality of pressure-sensitive adhesive segments arrayed non-contiguously in a longitudinally spaced-apart progression along the first release surface of the carrier release tape; and   an adhesive dispensing roller rotatably mounted to the arm proximate the first end of the arm for rotation about a dispensing roller axis extending substantially parallel to the pivot axis;   the dispensing roller having a peripheral surface thereof adapted for bearing against the second release surface of the flexible carrier tape for guiding the flexible carrier tape along a portion of the longitudinally extending path of the tape;   the peripheral surface of the dispensing roller also being adapted for applying a clamping force directed substantially perpendicularly to the longitudinal path though the flexible carrier tape, and/or the pressure-sensitive adhesive segments attached to the carrier tape, such that the tape may be advanced by relative linear motion between the arm and workpiece for positioning the pressure-sensitive adhesive segments between the dispensing roller and the workpiece surface, when the arm is disposed in the apply position.   
   
   
       2 . The dispensing apparatus of  claim 1 , further comprising a take-up spool mounting arrangement, rotatably attached to the arm for rotation about a take-up spool axis extending substantially parallel to the pivot axis of the arm, and adapted for forming and holding a roll of the flexible carrier release tape received along the longitudinal path. 
   
   
       3 . The dispensing apparatus of  claim 2 , further comprising a pre-dispensing roller and a post-dispensing roller, wherein, the longitudinal path extends sequentially from a lower portion of the supply spool, over the pre-dispensing roller, around a portion or the periphery of the dispensing roller, around a portion of the periphery of the post-dispensing roller, and back over an upper portion of the supply spool, to the take-up spool. 
   
   
       4 . The dispensing apparatus of  claim 2 , further comprising a drive arrangement operatively connecting the supply spool mounting arrangement to the take-up spool mounting arrangement in such a manner that as the flexible carrier tape is pulled from the supply spool along the longitudinally directed path, and the supply spool is thereby rotated about the supply spool axis, rotation of the supply spool mounting arrangement is transmitted by the drive arrangement to the take-up spool mounting arrangement for rotating the take-up spool about the take-up spool axis. 
   
   
       5 . The dispensing apparatus of  claim 4 , wherein, the drive arrangement drives the take-up spool mounting arrangement at a higher rotational speed than the supply spool mounting arrangement. 
   
   
       6 . The dispensing apparatus of  claim 5 , wherein the drive arrangement is a belt and pulley arrangement having a drive pulley and driven pulley connected by a drive belt, with the drive pulley being larger than the driven pulley, the drive pulley being operatively attached to the supply spool mounting arrangement and the smaller pulley being operatively attached to the take-up spool mounting arrangement, and the belt being capable of a limited amount of slippage over one or both of the drive and driven pulleys. 
   
   
       7 . The dispensing apparatus of  claim 1 , wherein, the supply spool drive arrangement includes first and second supply spool drive arrangement side plates thereof, adapted for operatively clamping the supply spool therebetween, with the second drive spool side plate being selectively removable, for installation and removal of the supply spool. 
   
   
       8 . The dispensing apparatus of  claim 7 , wherein:
 the flexible carrier tape includes first and second longitudinally extending edges thereof spaced apart by the transverse width; and   the first supply spool drive arrangement side plate further comprises an inner surface thereof adapted for frictionally engaging one of the first and second longitudinally extending edges of the flexible carrier tape, when the supply spool is clamped between the first and second supply spool drive arrangement side plates, to thereby substantially preclude slippage of an outer layer of the roll of flexible carrier tape with respect to an inner layer of the flexible carrier tape as the tape is pulled from the supply spool along the longitudinally oriented path.   
   
   
       9 . The dispensing apparatus of  claim 7 , wherein, the second supply spool drive plate is constructed in a manner allowing the supply spool to be viewed through the second side plate, to thereby allow viewing of the amount of flexible carrier tape remaining on the supply spool. 
   
   
       10 . The dispensing apparatus of  claim 9 , wherein the second side plate is fabricated from a substantially opaque material having an opening therein through which the supply spool can be viewed. 
   
   
       11 . The dispensing apparatus of  claim 1 , further comprising:
 a pre-dispensing guide roller rotatably mounted to the arm along the longitudinal path between the supply spool and the adhesive dispensing roller for rotation about a pre-dispensing roller axis extending substantially parallel to the pivot axis;   the pre-dispensing roller having a peripheral surface thereof adapted for bearing against the first release surface of the flexible carrier tape or the pressure-sensitive adhesive segments attached to the first release surface for guiding the flexible carrier tape along a portion of the longitudinally extending path of the tape between the supply spool and the adhesive dispensing roller.   
   
   
       12 . The dispensing apparatus of  claim 11 , wherein, the peripheral surface of the pre-dispensing roller has a resistant to adhesion thereto of the pressure-sensitive adhesive segments. 
   
   
       13 . The dispensing apparatus of  claim 12 , wherein, the peripheral surface of the pre-dispensing roller includes grooves therein, for reducing contact of the peripheral surface of the pre-dispensing roller with the first release surface of the flexible carrier tape or the pressure-sensitive adhesive segments attached to the first release surface. 
   
   
       14 . The dispensing apparatus of  claim 12 , wherein, the peripheral surface of the pre-dispensing roller comprises a material having low adhesion to the pressure-sensitive adhesive segments attached to the first release surface. 
   
   
       15 . The dispensing apparatus of  claim 14 , wherein, the peripheral surface of the pre-dispensing roller includes grooves therein, for reducing contact of the peripheral surface of the pre-dispensing roller with the first release surface of the flexible carrier tape or the pressure-sensitive adhesive segments attached to the first release surface. 
   
   
       16 . The dispensing apparatus of  claim 1 , further comprising:
 a post-dispensing guide roller rotatably mounted to the arm along the longitudinal path, for receiving the flexible carrier tape from the adhesive dispensing roller, and for rotation about a post-dispensing roller axis extending substantially parallel to the pivot axis;   the post-dispensing roller having a peripheral surface thereof adapted for bearing against the second release surface of the flexible carrier tape for guiding the flexible carrier tape along a portion of the longitudinally extending path.   
   
   
       17 . The dispensing apparatus of  claim 1 , further including a position sensor, for monitoring a position of the flexible carrier tape along the longitudinally oriented path. 
   
   
       18 . The dispensing apparatus of  claim 17 , wherein, the sensor is located between dispensing roller and the post-dispensing roller. 
   
   
       19 . The dispensing apparatus of  claim 17 , wherein, the flexible carrier tape further comprises registration indicators detectable by the position sensor. 
   
   
       20 . The dispensing apparatus of  claim 18 , wherein, the registration indicators are optically detectable, and the position sensor comprises an optical sensor adapted for detecting the registration indicators. 
   
   
       21 . The dispensing apparatus of  claim 1 , further comprising an arm support member, having the arm pivotably connected thereto along the pivot axis. 
   
   
       22 . The dispensing apparatus of  claim 20 , wherein, the actuator arrangement is operatively connected between the arm and the arm support member, for pivoting the arm with respect to the arm support member. 
   
   
       23 . The dispensing apparatus of  claim 21 , wherein, the arm support member is stationary and the workpiece is movable linearly relative to the arm support member for transferring one or more adhesive segments from the flexible carrier tape to the workpiece. 
   
   
       24 . The dispensing arrangement of  claim 21 , wherein the workpiece is stationary, and the arm support member is movable linearly relative to the workpiece for transferring one or more adhesive segments from the flexible carrier tape to the workpiece. 
   
   
       25 . A method for transferring pressure sensitive adhesive segments from a rolled flexible carrier release tape to a workpiece, the method comprising:
 directing the flexible carrier tape to a dispensing member attached to a pivotable arm, and pivoting the arm in such a manner that the dispensing member clamps the flexible carrier release tape against the workpiece; and   initiating relative linear motion between the carrier release tape and the workpiece, whereby the relative motion unrolls the flexible carrier tape and moves one or more pressure sensitive adhesive segments into pressurized contact with the workpiece in such a manner that the one or more pressure-sensitive segments are transferred from the flexible carrier tape to the workpiece.   
   
   
       26 . The method of  claim 24 , further comprising, monitoring a position of the flexible carrier as it is unrolled by the relative motion, and pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired length of the release tape has been unrolled. 
   
   
       27 . The method of  claim 24 , further comprising, monitoring a position of the flexible carrier as it is unrolled by the relative motion, and pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired number of pressure sensitive adhesive segments have been brought into clamped contact with the workpiece. 
   
   
       28 . The method of  claim 24 , wherein, the relative motion is generated by moving the workpiece linearly relative to the pivotable arm. 
   
   
       29 . The method of  claim 24 , wherein, the relative motion is generated by moving the pivotable arm linearly relative to the workpiece. 
   
   
       30 . An apparatus for transferring pressure sensitive adhesive segments from a rolled flexible carrier release tape to a workpiece, the apparatus comprising:
 a pivotable arm, pivotably mounted for selective movement from a first to a second angular position; and   a dispensing member attached to the pivotable arm;   the dispensing member also being operatively connected to the rolled flexible carrier tape in such a manner that when the arm is pivoted to the first angular position the dispensing member clamps the flexible carrier release tape against the workpiece, such that relative linear motion between the carrier release tape and the workpiece unrolls the flexible carrier tape and moves one or more pressure sensitive adhesive segments into pressurized contact with the workpiece in such a manner that the one or more pressure sensitive segments are transferred from the flexible carrier tape to the workpiece.   
   
   
       31 . The apparatus of  claim 29 , further comprising, an instrumentality for generating relative linear motion between the arm and the workpiece. 
   
   
       32 . The apparatus of  claim 30 , wherein, the instrumentality generates the relative motion by moving the workpiece linearly relative to the pivotable arm. 
   
   
       33 . The apparatus of  claim 30 , wherein, the instrumentality generates the relative motion by moving the pivotable arm linearly relative to the workpiece. 
   
   
       34 . The apparatus of  claim 29 , further comprising, a position sensing and control arrangement for monitoring a position of the flexible carrier tape as it is unrolled by the relative motion, and pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired length of the release tape has been unrolled. 
   
   
       35 . The apparatus of  claim 29 , further comprising, a position sensing and control arrangement for monitoring a position of the flexible carrier as it is unrolled by the relative motion, and pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired number of pressure sensitive adhesive segments have been brought into clamped contact with the workpiece. 
   
   
       36 . A pressure-sensitive adhesive segment dispensing apparatus, for selectively attaching the pressure-sensitive adhesive segments to a workpiece surface, the dispensing apparatus comprising:
 a pivotable arm, defining first and second ends of the arm and an arm axis extending between the first and second ends of the arm, the arm also defining a pivot axis disposed between the first and second ends and extending substantially perpendicular to the arm axis, the arm being adapted for pivotable movement about the pivot axis;   an actuator arrangement operatively connected to the arm for causing the arm to pivot about the pivot axis substantially along a plane of arm movement extending orthogonally to the pivot axis, from an apply position of the arm to a retracted position of the arm;   a supply spool mounting arrangement, rotatably attached to the arm for rotation about a supply spool axis extending substantially parallel to the pivot axis of the arm, and adapted for holding a roll of flexible carrier release tape oriented to extend along a longitudinal path running substantially parallel to the plane of arm movement, with the flexible carrier release tape having a transverse width, opposed first and second release surfaces and a plurality of pressure-sensitive adhesive segments arrayed non-contiguously in a longitudinally spaced-apart progression along the first release surface of the carrier release tape;   an adhesive dispensing roller rotatably mounted to the arm proximate the first end of the arm for rotation about a dispensing roller axis extending substantially parallel to the pivot axis;   the dispensing roller having a peripheral surface thereof adapted for bearing against the second release surface of the flexible carrier tape for guiding the flexible carrier tape along a portion of the longitudinally extending path of the tape;   the peripheral surface of the dispensing roller also being adapted for applying a clamping force directed substantially perpendicularly to the longitudinal path though the flexible carrier tape, and/or the pressure-sensitive adhesive segments attached to the carrier tape, such that the tape may be advanced by relative linear motion between the arm and workpiece for positioning the pressure-sensitive adhesive segments between the dispensing roller and the workpiece surface, when the arm is disposed in the apply position;   a take-up spool mounting arrangement, rotatably attached to the arm for rotation about a take-up spool axis extending substantially parallel to the pivot axis of the arm, and adapted for forming and holding a roll of the flexible carrier release tape received along the longitudinal path;   a drive arrangement operatively connecting the supply spool mounting arrangement to the take-up spool mounting arrangement in such a manner that as the flexible carrier tape is pulled from the supply spool along the longitudinally directed path, and the supply spool is thereby rotated about the supply spool axis, rotation of the supply spool mounting arrangement is transmitted by the drive arrangement to the take-up spool mounting arrangement for rotating the take-up spool about the take-up spool axis;   the drive arrangement being configured for driving the take-up spool mounting arrangement at a higher rotational speed than the supply spool mounting arrangement;   the drive arrangement including a belt and pulley arrangement having a drive pulley and driven pulley connected by a drive belt, with the drive pulley being larger than the driven pulley, the drive pulley being operatively attached to the supply spool mounting arrangement and the smaller pulley being operatively attached to the take-up spool mounting arrangement, and the belt being capable of a limited amount of slippage over one or both of the drive and driven pulley;   a pre-dispensing guide roller rotatably mounted to the arm along the longitudinal path between the supply spool and the adhesive dispensing roller for rotation about a pre-dispensing roller axis extending substantially parallel to the pivot axis;   the pre-dispensing roller having a peripheral surface thereof adapted for bearing against the first release surface of the flexible carrier tape or the pressure-sensitive adhesive segments attached to the first release surface for guiding the flexible carrier tape along a portion of the longitudinally extending path of the tape between the supply spool and the adhesive dispensing roller;   the peripheral surface of the pre-dispensing roller including a material that is resistant to adhesion thereto of the pressure-sensitive adhesive segment;   the peripheral surface of the pre-dispensing roller includes grooves therein, for reducing contact of the peripheral surface of the pre-dispensing roller with the first release surface of the flexible carrier tape or the pressure-sensitive adhesive segments attached to the first release surface; and   a post-dispensing guide roller rotatably mounted to the arm along the longitudinal path, for receiving the flexible carrier tape from the adhesive dispensing roller, and for rotation about a post-dispensing roller axis extending substantially parallel to the pivot axis;   the post-dispensing roller having a peripheral surface thereof adapted for bearing against the second release surface of the flexible carrier tape for guiding the flexible carrier tape along a portion of the longitudinally extending path;   the longitudinal path extending sequentially from a lower portion of the supply spool, over the pre-dispensing roller, around a portion or the periphery of the dispensing roller, around a portion of the periphery of the post-dispensing roller, and back over an upper portion of the supply spool, to the take-up spool.   
   
   
       37 . The apparatus of  claim 36 , further comprising, a position sensing and control arrangement for monitoring a position of the flexible carrier tape as it is unrolled by the relative motion, and pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired length of the release tape has been unrolled. 
   
   
       38 . The apparatus of  claim 36 , further comprising, a position sensing and control arrangement for monitoring a position of the flexible carrier as it is unrolled by the relative motion, and pivoting the arm in such a manner that the dispensing member unclamps the flexible carrier release tape after a desired number of pressure sensitive adhesive segments have been brought into clamped contact with the workpiece. 
   
   
       39 . The dispensing apparatus of  claim 36 , further comprising an arm support member, having the arm pivotably connected thereto along the pivot axis, with the actuator arrangement being operatively connected between the arm and the arm support member, for pivoting the arm with respect to the arm support member. 
   
   
       40 . The dispensing apparatus of  claim 36 , wherein:
 the supply spool drive arrangement includes first and second supply spool drive arrangement side plates thereof, adapted for operatively clamping the supply spool therebetween, with the second drive spool side plate being selectively removable, for installation and removal of the supply spool;   the flexible carrier tape includes first and second longitudinally extending edges thereof spaced apart by the transverse width; and   the first supply spool drive arrangement side plate further comprises a cushioned inner surface thereof adapted for frictionally engaging one of the first and second longitudinally extending edges of the flexible carrier tape, when the supply spool is clamped between the first and second supply spool drive arrangement side plates, to thereby substantially preclude slippage of an outer layer of the roll of flexible carrier tape with respect to an inner layer of the flexible carrier tape as the tape is pulled from the supply spool along the longitudinally oriented path.   
   
   
       41 . The dispensing apparatus of  claim 2 , further comprising a drive arrangement operatively connecting the supply spool mounting arrangement to the take-up spool mounting arrangement in such a manner that as the flexible carrier tape is pulled from the supply spool along the longitudinally directed path, and the supply spool is thereby rotated about the supply spool axis, the drive arrangement rotates the take-up spool about the take-up spool axis. 
   
   
       42 . The dispensing apparatus of  claim 41 , wherein, the drive arrangement comprises, a motor operatively connected to the take-up spool mounting arrangement for rotating the take-up spool as the flexible carrier tape is pulled from the supply spool. 
   
   
       43 . The dispensing apparatus of  claim 42 , wherein:
 the drive arrangement further comprises, a clutch operatively connecting the motor to the take-up spool mounting arrangement in such a manner that the clutch applies a torque to the take-up spool mounting arrangement for urging the take-up spool mounting arrangement to rotate the take-up spool for winding the flexible carrier tape onto the take-up spool; and   the clutch is configured to slip when the flexible carrier tape is not being pulled from the supply spool.   
   
   
       44 . The dispensing apparatus of  claim 43 , wherein, the drive arrangement drives the take-up spool mounting arrangement at a higher rotational speed than the supply spool mounting arrangement. 
   
   
       45 . The dispensing apparatus of  claim 43 , further comprising, a braking arrangement operatively connected for resisting rotation of the supply-spool mounting arrangement, when the flexible carrier tape is not being pulled from the supply spool along the longitudinally directed path. 
   
   
       46 . The dispensing apparatus of  claim 44 , wherein, the braking arrangement is configured for resisting rotation of the supply-spool when the arm is not in the retracted position. 
   
   
       47 . The dispensing apparatus of  claim 45 , wherein, the braking arrangement includes a brake actuator which is activated and deactivated in correspondence to movement of the arm between the retracted and apply positions of the arm. 
   
   
       48 . The dispensing apparatus of  claim 46 , wherein, the braking apparatus further comprises a brake shoe having a braking surface and operatively connected to the arm and the brake actuator for movement by the brake actuator from an engaged position, whereat the braking surface bears against a portion of the supply-spool mounting arrangement, for resisting rotation of the supply spool, and a disengaged position, whereat the braking surface does not bear against the supply-spool mounting arrangement.