US20110059282A1 - Adhesive Segment Indexing Method and Apparatus and Roll of Adhesive Segments for Use Therewith - Google Patents

Abstract

An automated system and method for applying thermoplastic adhesives to work pieces from a roll of adhesive segments applied to an adhesive segment-laden carrier release tape. The present invention may be implemented in a system that automatically advances the adhesive segment-laden carrier release tape to position an adhesive segment thereon in the apparatus for application thereof to a work piece. Accurate indexing and advancement of the adhesive segment-laden carrier release tape preferably is provided by optical indexing of the carrier release tape, e.g., by the optical detection of a transverse line or other index marking printed or otherwise provided on the adhesive segment carrier release along with the adhesive segments deposited thereon.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This patent application is a division of copending U.S. patent application Ser. No. 10/920,151, filed on Aug. 17, 2004, now U.S. Pat. No. 7,837,815, granted on Nov. 23, 2010, entitled “Adhesive Segment Indexing Method and Apparatus and Roll of Adhesive Segments for Use Therewith,” which patent application is assigned to the assignee of the present invention, which patent application in turn was a continuation-in-part of U.S. patent application Ser. No. 10/360,457, filed on Feb. 8, 2003, now abandoned, and a continuation-in-part of U.S. patent application Ser. No. 10/360,395, also filed on Feb. 8, 2003, also abandoned, both of which are continuations-in-part of U.S. patent application Ser. No. 10/125,012, filed on Apr. 18, 2002, now U.S. Pat. No. 6,686,016, granted on Feb. 3, 2004, and continuations-in-part of U.S. patent application Ser. No. 09/998,950, filed on Nov. 15, 2001, now U.S. Pat. No. 6,640,864, granted on Nov. 4, 2003. U.S. patent application Ser. No. 10/125,012, filed on Apr. 18, 2002, now U.S. Pat. No. 6,686,016, granted on Feb. 3, 2004, is itself a continuation of U.S. patent application Ser. No. 09/998,950, filed on Nov. 15, 2001, now U.S. Pat. No. 6,640,864, granted on Nov. 4, 2003, which is in turn a continuation of U.S. patent application Ser. No. 09/363,200, filed on Jul. 29, 1999, now U.S. Pat. No. 6,319,442, granted on Nov. 20, 2001, which is in turn a continuation-in-part of U.S. patent application Ser. No. 08/909,189, filed on Aug. 11, 1997, now U.S. Pat. No. 5,935,670, granted on Aug. 10, 2009, which in turn claimed the benefit of U.S. Provisional Patent Application No. 601036,896, filed on Feb. 6, 1997. All of the patents and patent applications mentioned in this paragraph are hereby incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention pertains generally to pressure-sensitive adhesives and their application to desired surfaces, and, more specifically, to applicator systems and methods for use in combination with rolls of indexed carrier release tape having pressure-sensitive adhesive segments attached thereto which may be individually dispensed using such applicator systems and methods.
• The term “adhesive” generically describes a class of “sticky” materials. Adhesives and adhesive applicators owe their innovation to the industrial revolution, which resulted in an explosion of technical and scientific breakthroughs. The breakthroughs of the industrial revolution included the introduction of new materials and ingredients for use in formulating market-specific and industry-specific adhesives. In creating novel adhesives, companies have diligently considered desirable qualities such as adhesive flexibility, toughness, minimum curing or setting time, and temperature and chemical resistance. Today, the technology and science of adhesives and apparatuses for their application is the foundation for a multi-billion dollar industry with over seven hundred companies competing for market share. More importantly, these companies strive to create and introduce novel adhesives as well as apparatuses and method for the simple, efficient, inexpensive, and safe application of adhesives.
• One of the most significant adhesive technical breakthroughs of the past century has been the introduction of pressure-sensitive thermoplastic adhesives. Thermoplastic adhesives have excellent adhering qualities; they can be softened by heating and firmed by cooling. These characteristics help thermoplastic adhesives produce waterproof, resilient, and long-lasting flexible bonds. Thermoplastic adhesives have what is known as a “plastic memory” meaning that each time a thermoplastic adhesive is heated, it can be molded into any desired form.
• Thermoplastic adhesives have significant applications in today's industry. For example, in the preparation of mass mailings, marketers often desire to attach a card, such as a credit card or the like, to a carrier document so that a consumer can peel the card easily from the carrier document. One method of making such an attachment involves the use of a pressure-sensitive, thermoplastic adhesive. For example, by using a heating container to melt the thermoplastic adhesive and a metering pump to dispense it during the printing or collating process, a portion of thermoplastic adhesive can be metered onto the carrier document and a credit card pressed against it.
• In addition to the uses for thermoplastic adhesives described above, industry is now finding additional uses for them. For example, thermoplastic adhesives are routinely used and applied as small bond points to eliminate the use of mechanical fasteners, such as staples, screws, rivets, clips, snaps, nails, and stitching. Thermoplastic adhesives are also extensively used in the packaging and manufacture of cartons, boxes, and corrugated boards, bags, envelopes, disposable products (diapers and other paper products), cigarettes, labels, and stamps. In fact, today's demand for thermoplastic adhesives extends to very broad fields of use.
• Increasingly, industry demands thermoplastic adhesive application at on-site locations from simple-to-use, efficient, and safe dispensing apparatuses. In providing thermoplastic adhesives for application to a surface, the previously known embodiments have contemplated all of the following thermoplastic adhesive carrying media and application methods: hot-melt “glue-gun” as adhesive dispensers; adhesive segment-laden carrier release tape for “by hand” adhesive application; use of a plunger-like dispensing system in combination with adhesive segment-laden carrier release tape; use of a cardboard box applicator system for use in combination with adhesive segment-laden carrier release tape; an electric automated dispensing system for use with adhesive segment-laden carrier release tape, which is activated by the pressing of a palm-sized push button; a hand-held mechanical adhesive segment applicator apparatus with a mechanical hand-operated trigger for advancing an adhesive segment-laden carrier release tape contained therein; and a stand for holding such a hand-held mechanical adhesive segment applicator with a powered system for activating the mechanical trigger automatically as a work piece is brought in contact with the adhesive segment applicator to apply an adhesive segment thereto.
• Using a “glue gun” device is an inefficient, difficult, and at times unsafe method of applying thermoplastic adhesives to a desired surface. First, the cost of using this equipment is relatively high. The apparatus and method are also inefficient consumers of both energy and glue. Specifically, the costs of the operation of such a dispenser (electrical usage, wasted glue from droppings) for only short periods of time outweigh any other potential advantages which may be realized. Safety is also an issue. Glue-gun devices are potentially unsafe because they include a heat source to heat a quantifiable supply of adhesive material to its melting point. A major drawback of using such an instrument is that the hot, molten thermoplastic adhesive can burn untrained users, and can also melt the substrate the user is applying the glue to. Finally, application of thermoplastic adhesives from a glue-gun does not enable the thermoplastic adhesive to withstand cold temperatures or to cool to a smooth surface, but instead will typically leave “spider webs” in the dried adhesive. In short, glue-gun applicators of the prior art are inefficient, difficult, and unsafe.
• Many of the shortcomings of the glue-gun applicators of the prior art were overcome by U.S. Pat. No. 5,935,670 to Downs (the “'670 Patent), which patent is hereby incorporated herein by reference. The '670 Patent discloses a method for presenting cold adhesive segments for application to a desired surface. The technology of the '670 Patent focuses mainly on the manufacture of a clean, unaltered carrier release tape having first and second release surfaces with different coefficients of friction, and the application thereto of adhesive segments at periodic intervals. The adhesive segment-laden carrier release tape is then wound into a roll. This embodiment allows a user to apply the adhesive segments from the carrier release tape by hand.
• Although the adhesive segment-laden carrier release tape taught in the '670 Patent provides a highly innovative and commercially successful product, application of the adhesive segments from the release tape onto a work piece in an efficient manner remains a challenge. Specifically, the coiled adhesive segment-laden carrier release tape must be unrolled to present an adhesive segment for application. After the adhesive segment has been applied to the desired surface, the tape must be unrolled an additional distance to ready the next adhesive segment for application. Advancing the carrier release tape manually in this manner is time-consuming, and the “spent” carrier release tape must be either torn off and disposed of or left intact and in the way. Finally, dropping or unintentional uncoiling of the unused roll of adhesive segment-laden carrier release tape may also be a problem.
• U.S. Pat. No. 6,319,442 to Downs (the “'442 Patent”) which patent is hereby incorporated herein by reference, further evolves the previously known adhesive segment-laden carrier release tape of the '670 Patent. Like the '670 Patent, the '442 Patent also contemplates a carrier release tape, which has first and second release surfaces with different coefficients of friction, and the application thereto of adhesive segments at periodic intervals. But, unlike the '670 Patent, the '442 Patent contemplates a thermoplastic adhesive carrier release tape having a transverse line of slits or perforations precut across its transverse width and between the adhesive segments. The precut tape of the '442 Patent thus allows individual portions of the carrier release tape and associated thermoplastic adhesives to be removed from the roll for manual application to a desired surface. While such an embodiment remedies the '670 Patent's problem of having a length of uncut spent carrier release tape, the carrier release tape of the '442 Patent (as well as of the '670 Patent) does not lend itself to use in combination with a more efficient dispenser for application of the adhesive segments.
• While the '670 and '442 Patents focus primarily on the creation of adhesive segment-laden carrier release tape, they also contemplate the use of the adhesive segment-laden carrier release tape in combination with numerous dispenser apparatuses. First, a plunger-like applicator, as detailed within both the '670 and '442 Patents, proves manageable, but is essentially a manually operated device for applying adhesive segments to a work piece from an adhesive segment-laden carrier release tape. Another previously known thermoplastic adhesive applicator is the so-called box applicator. The box applicator encases a roll of adhesive segment-laden carrier release tape as disclosed within the '670 and '442 Patents. The carrier release tape is advanced from the box applicator by hand. Exposed adhesive segments must be pressed between the surface to be glued and the top of the cardboard box applicator to ensure adherence. This application process exposes unspent adhesive segments to dust and other debris, which may cause the adhesive segments to lose their adhesive tack and damage or soil the desired surface. Furthermore, the box applicator is an entirely manually operated device.
• Not all previously known devices for applying thermoplastic adhesive from adhesive segment-laden carrier release tapes are entirely manual in operation. Previously known semi-automated methods dispose of the need to advance manually the carrier release tape. For example, the box applicator described above may be modified to include a motor for automatically advancing the adhesive segment-laden carrier release tape from the box either at a fixed rate, corresponding to the rate at which a worker may comfortably press a work piece against the adhesive segments as they are dispensed, or in response to the pressing of a push button to activate the motor to advance the adhesive segment-laden carrier release tape by a selected amount.
• A more advanced mechanical adhesive segment applicator apparatus and method is described in U.S. patent application Ser. Nos. 10/360,395 and 10/360,457, filed on Feb. 8, 2003, and U.S. patent application Ser. No. 10/368,231, filed on Feb. 18, 2003, all of which are assigned to the assignee of the present application and the disclosures of which are incorporated herein by reference. These patent applications describe a hand held mechanical device for applying adhesive segments to a work piece from a carrier release tape having pressure-sensitive adhesive segments attached thereto. An indexing mechanism is provided on the carrier release tape to facilitate the dispensing of individual adhesive segments. The indexing mechanism consists of a plurality of patterned scores, cuts, or indentations located in the surface of the carrier release tape. The hand held adhesive segment applicator apparatus includes a mechanism for engaging the carrier release tape by the indexing mechanism to advance the tape to expose a new adhesive segment to be disposed therefrom each time a trigger mechanism on the applicator is manually actuated. The hand held adhesive segment applicator may be mounted on a stand that holds the applicator in a desired adjustable position. A pneumatic actuator may be provided to engage the trigger of the applicator to advance the carrier release tape to expose a new adhesive segment to be dispensed from the applicator automatically. The actuator may be activated by a trigger mechanism that is mounted near where the adhesive segment is dispensed from the applicator, to be engaged by a work piece as an adhesive segment is dispensed therefrom. Alternatively, the actuator may be activated by a hand or foot operated switch.
• A limitation of previous systems and methods for applying thermoplastic adhesives to a work piece from an adhesive segment-laden carrier release tape is that operation of such systems and methods actually to apply the thermoplastic adhesive to a work piece is essentially manual. Even in systems that provide for the automatic or powered advancement of an adhesive segment-laden carrier release tape, the exposed adhesive segment must be applied to the work piece by either manually moving the applicator in contact with the work piece or manually moving the work piece in contact with the applicator. Such systems and methods for applying thermoplastic adhesives to work pieces from an adhesive segment-laden carrier release tape are thus not well suited to high speed high volume applications.
• What is desired, therefore, is a system and method for the automatic application of thermoplastic adhesives to work pieces from an adhesive segment-laden carrier release tape for use in high-speed high-volume assembly line-like applications. Such an adhesive segment applicator should provide for assured automatic release of the adhesive segments from the carrier release tape onto a work piece. Such a system should also provide accurate indexing and advancement of the carrier release tape to ensure proper operation and positioning of the adhesive segment in the applicator device and on a work piece.
SUMMARY OF THE INVENTION
• The present invention provides an automated system and method for applying thermoplastic adhesives to work pieces from a roll of adhesive segments applied to an adhesive segment-laden carrier release tape. The present invention may be implemented in a system that automatically advances the adhesive segment-laden carrier release tape to position an adhesive segment thereon in the apparatus for application thereof to a work piece. Accurate indexing and advancement of the adhesive segment-laden carrier release tape preferably is provided by optical indexing of the carrier release tape, e.g., by the optical detection of a transverse line or other index marking printed or otherwise provided on the adhesive segment carrier release along with the adhesive segments deposited thereon. The system may automatically apply the adhesive segment from the adhesive segment-laden carrier release tape onto a work piece by the use of an automatically actuated applicator head that contacts the surface of the adhesive segment-laden carrier release tape opposite the adhesive segment thereon to push the adhesive segment against the work piece to apply the adhesive segment to the work piece. In accordance with the present invention, the applicator head may include one or more sharp projections thereon that pierce through the carrier release tape, but not through the adhesive segment thereon, as the head presses the carrier release tape and adhesive segment against the work piece. It has been found that perforating the carrier release tape in this manner facilitates assured release of the adhesive segment from the carrier release tape and application of the adhesive segment to a work piece by the applicator head. Alternatively, the adhesive segment carrier release tape may be pre-perforated underneath each adhesive segment thereon, in which case the sharp projections need not be provided on the applicator head.
• An automated adhesive segment indexing and applicator method and apparatus in accordance with the present invention employs a roll of adhesive segments provided on a differential carrier release strip or tape. A first surface of the carrier release tape has a coefficient of friction higher than the coefficient of friction of the second side of the carrier release tape, so that the first surface of the carrier release tape provides less release than does the second surface of the carrier release tape. Adhesive segments are deposited on the first, higher friction, surface of the carrier release tape, such that the adhesive segment-laden carrier release tape may be unwound with the adhesive segments remaining only on one surface of the carrier release tape.
• In accordance with the present invention, the adhesive segment-laden carrier release tape includes optically detectable index markings thereon. Such index markings may include lines, e.g., black lines extending transversely across the carrier release tape, e.g., between the thermoplastic adhesive segments deposited thereon. Other optically detectable index markings may be printed on or otherwise applied to either one or both surfaces of the adhesive segment-laden carrier release tape. Such optically detectable markings may include physical perforations through the adhesive segment-laden carrier release tape. The index markings may be provided on the adhesive segment-laden carrier release tape as part of the process of depositing thermoplastic adhesive segments thereon, or may be provided by the manufacturer of the carrier release tape. In any case, the index markings must be accurately spaced along one or both surfaces of the differential release carrier release tape. During the application of the thermoplastic adhesive to the differential release carrier release tape the thermoplastic adhesive material is deposited thereon accurately in position relative to the index markings, e.g., by using optical detection of the index markings during the application process.
• As will be discussed in more detail below, it has been found that, in an automatic adhesive segment applicator system in accordance with the present invention, an adhesive segment may be more assuredly removed from the adhesive segment-laden carrier release tape and applied to a work piece by an applicator head, if one or more holes or apertures are pierced through the adhesive segment-laden carrier release tape underneath the thermoplastic adhesive segments thereon. These perforations through the adhesive segment-laden carrier release tape may be formed during the process of forming a roll of adhesive segment-laden carrier release tape. This may be achieved, for example, by, after the thermoplastic adhesive segment has been applied onto the carrier release tape, and at least partially cooled, piercing the one or more perforations through the side of the carrier release tape opposite the adhesive segments. These perforations may be provided using an appropriate die, e.g., a rotary die with the appropriate sharp projections to pierce through the side of the carrier release tape opposite the adhesive segments and into, but preferably not through, the adhesive segment applied to the carrier release tape. As will be discussed in more detail below, such perforations through the carrier release tape may also be formed during the process of applying an adhesive segment from the tape onto a work piece by an adhesive segment applicator in accordance with the present invention.
• An automatic adhesive segment applicator in accordance with the present invention preferably includes several components, all of which are mounted on a movable support structure. The components mounted on the movable support structure may include a supply spool, including a roll of adhesive segment-laden carrier release tape in accordance with the present invention, a tape guide, a take-up spool, a take-up spool drive motor, a tape clamp, an applicator head, pneumatic or other appropriate actuator mechanisms for the tape clamp and the applicator head, and an optical index detector. The applicator head may extend through a central aperture or bore formed through the tape guide and may have one or more sharp projections formed on the end thereof to pierce or otherwise provide perforations through the adhesive segment-laden carrier release tape on the side thereof opposite the adhesive segment during application thereof to a work piece to assure release of the adhesive segment from the release tape and application thereof to the work piece. The entire support structure on which these components are mounted, preferably is, in turn, mounted on a support base for movement with respect thereto toward and away from a work piece to which an adhesive segment from the adhesive segment-laden carrier release tape is to be applied. A pneumatic or other appropriate mechanism preferably is provided to move the support structure toward and away from the work piece by moving the support structure with respect to the support structure base. An appropriate controller preferably is provided to monitor and control system operation to apply automatically adhesive segments from the adhesive segment-laden carrier release tape onto a series of work pieces in a manner that assures release of the adhesive segments from the carrier release tape onto the work piece.
• In operation, a roll of adhesive segment-laden carrier release tape, with optically detectable index markings formed thereon, as described above, is placed on the supply spool. The adhesive segment-laden carrier release tape is strung through the clamp and tape guide and onto the take-up spool. The take-up spool will accumulate the release tape after adhesive segments have been removed therefrom. The optical sensor is used to detect the index markings on the adhesive segment-laden carrier release tape to provide a signal to the system controller to indicate to the system controller the position of the tape, and, therefore, the position of the thermoplastic adhesive segments thereon, with respect to the tape guide and applicator head. Using this indexing information, the system controller may operate the motor driving the take-up spool to pull the adhesive segment-laden carrier release tape from the supply reel to position an adhesive segment on the release tape with respect to the applicator head for application thereby to a work piece. At this point, the one or more tape clamps may be closed and the entire support structure moved with respect to the support base to bring the thermoplastic adhesive segment adjacent to the work piece to which it is to be applied. The operation of the one or more tape clamps (e.g., either alone or in combination with pinch rollers) prevents undesirable movement of the release tape in the area of the adhesive segment to be applied to a work piece during the application process. The applicator head is then moved rapidly against the side of the adhesive segment-laden carrier release tape opposite the adhesive segment to push the adhesive segment against the surface of the work piece to which it is to be applied. Preferably the adhesive segment applicator head includes one or more sharp projections thereon which pierce through the surface of the adhesive segment-laden carrier release tape and into, but not through, the adhesive segment on the opposite side thereof. It is believed that the providing of these perforations through the release tape prevents air pressure between the adhesive segment and the release tape that might cause the adhesive segment not to be released from the tape onto the work piece in some cases as the applicator head is retracted. Preferably the extension and retraction of the applicator head to press the adhesive segment against the work piece, while providing perforations through the carrier release tape, may be performed twice in rapid succession to ensure release of the adhesive segment from the carrier release tape onto the work piece. After the adhesive segment is applied to the work piece in this manner the entire system support structure may be moved away from the work piece and the tape clamp released to allow free movement of the adhesive segment-laden carrier release tape supply spool. The controller may then operate the motor driving the take up spool to pull adhesive segment-laden carrier release tape from the supply spool to position the next adhesive segment on the carrier release tape in the proper position on the tape guide in front of the applicator head in preparation for the application thereof to the next work piece. The optical sensor is used to detect the index markings on the tape to provide feedback to the controller to ensure that the adhesive segment-laden carrier release tape is thus properly positioned for the next application.
• This entire automatic application operation may be triggered manually by an operator, e.g., each time the operator presents a work piece to which a thermoplastic adhesive segment is to be applied by the device. Alternatively, the application operation, may be triggered automatically as part of an assembly line system, e.g., each time a work piece is detected to be in position for a thermoplastic adhesive segment to be applied thereto by the system.
• Further objects, features, and advantages of the present invention will be apparent from the following detailed description thereof taken in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
• These and other advantages of the present invention are best understood with reference to the drawings, in which:
• FIG. 1 is a schematic depiction of the manufacturing process for creating rolls of optically indexed adhesive segment-laden carrier release tape;
• FIG. 2 is a perspective view of a section of a strip of the indexed adhesive segment-laden carrier release tape having optically detectable index marking lines extending transversely across the tape between thermoplastic adhesive segments thereon and an optical detector for detecting the index markings;
• FIG. 3 is a figure similar to that ofFIG. 2 showing other exemplary index markings on the adhesive segment-laden carrier release tape that may be used in accordance with the present invention;
• FIG. 4 is a detailed schematic cross sectional side view of an exemplary method for providing perforations through a surface of the adhesive segment carrier release tape opposite thermoplastic adhesive segments thereon during the manufacturing process thereof;
• FIG. 5 is an isometric view of a roll of indexed adhesive segment-laden carrier release tape manufactured by the process illustrated inFIG. 1;
• FIG. 6 is a front plan view of an exemplary automated adhesive segment applicator apparatus in accordance with the present invention;
• FIG. 7 is a side view of the exemplary automatic adhesive segment applicator apparatus ofFIG. 6 as taken along line7-7 thereof;
• FIG. 8 is a more detailed view of a tape guide, tape clamp, and applicator head of an exemplary adhesive segment applicator apparatus in accordance with the present invention as taken generally along line8-8 ofFIG. 6;
• FIG. 9 is a schematic block diagram of an exemplary control system for an automatic adhesive segment applicator apparatus in accordance with the present invention;
• FIG. 10 is a flow chart diagram illustrating an exemplary method for applying a thermoplastic adhesive segment from an adhesive segment-laden carrier release tape onto a work piece using an adhesive segment indexing apparatus in accordance with the present invention; and
• FIGS. 11-14 illustrate schematically a portion of an exemplary adhesive segment applicator apparatus in accordance with the present invention showing various positions thereof during use of the apparatus to apply an adhesive segment from an adhesive segment-laden carrier release tape onto a work piece.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT
• The present invention provides a system and method for applying automatically adhesive segments from an adhesive segment-laden carrier release tape onto a work piece or series of work pieces, in a rapid and effective manner. The present invention may employ optical index markings on the carrier release tape to assure accurate positioning of the carrier release tape within the apparatus. The system also employs an automatic applicator method that ensures full and sure release of adhesive segments from the carrier release tape onto a work piece during the application process. Both the structure and operation of an exemplary applicator apparatus and method in accordance with the present invention, as well as the optically indexed carrier release tape used therein, and the manufacturer of such an adhesive segment-laden carrier release tape will now be described in detail herein.
• An exemplary process for manufacturing an adhesive segment-laden carrier release tape for use with an automatic adhesive segment applicator method and apparatus in accordance with the present invention will first be described with reference toFIG. 1. Asystem20 for manufacturing an adhesive segment-laden carrier release tape in accordance with the present invention provides a back tensionedreel22 holding a stock roll of differential releasecarrier release strip24, having afirst surface26 and asecond surface28 opposite the first surface. Thecarrier release strip24 may be made of paper that has a silicone release material on the first26 and second28 surfaces. Thefirst surface26 of thecarrier release strip24 has a coefficient of friction higher than the coefficient of friction of thesecond surface28 of thecarrier release strip24, so that the first surface of thecarrier release strip26 provides less release than does the second surface of thecarrier release strip24.
• Thecarrier release strip24 is dispensed from the tensionedreel22 with thefirst surface26 facing upward to move beneath a pair of thermoplastic glue metering nozzles30 (only one of which is visible inFIG. 1) supplied with thermoplastic adhesive by a metering pump (not shown) to dispense side-by-sideadhesive segments32 onto thefirst surface26 as thefirst surface26 moves past thenozzles30.Air jets34 directed on thefirst surface26 then cool theadhesive segments32 which are also cooled by natural convection as thecarrier strip24 moves along.
• A slittingknife36 divides thecarrier strip24 into multiple strips, each of which are then wound intocoils40 on take-upreels38 under controlled tensioning. Capstan and idler wheels may also be provided so that the tension onreels38 may be controlled independently of the tension provided by thesupply reel22.
• Theadhesive segments32 are initially mounded high on thefirst surface26 of thecarrier strip26, but as they are wound about thereel38, eachadhesive segment32 is compressed beneath thesecond surface28 of thecarrier strip24 of the next succeeding layer of thecarrier strip24 and thesurface26 of the layer of thecarrier strip24 on which it was deposited so as to flatten the adhesive segments into circular disks. Alternatively, a cooled drum having a non-stick surface may be used to flatten theadhesive segments32 prior to winding onreel38.
• The differential release properties ofsurfaces26 and28, the fact that theadhesive segments32 were initially applied in a hot state to surface26 to cause better adherence, and the fact there is some cooling and hence “skinning over” of theadhesive segments32 prior to winding onreel38, all ensure that theadhesive segments32 remain adhered to thefirst surface26 as thecoil40 is unwound.
• It should be noted that although theadhesive segments32 described and illustrated herein are generally circular in shape, the present invention may be applied to and employ adhesive segments on the carrier release tape which have any other generally two dimensional shape. The shape of the adhesive segments may determined in general by the shape or other characteristics of the thermoplasticglue metering nozzles30 used to apply the thermoplastic adhesive to thecarrier strip24.
• In accordance with the present invention, the adhesive segment-ladencarrier release tape24 has a series of optically detectable index markings formed thereon. As will be described in more detail below, these optically detectable index markings are employed by an automatic adhesive segment applicator system in accordance with the present invention accurately to position adhesive segments for application by the applicator. As illustrated, for example, inFIG. 2, the optically detectable index markings may take the form oflines42 formed on thecarrier release tape24 and extending transversely across thetape24 between theadhesive segments32 thereon. It should be understood that various different types of optically detectable index markings on the adhesive segment-ladencarrier release tape24 may be employed. For example, as illustrated inFIG. 3,printer registration marks44 may be placed in regular positions along thecarrier strip24.
• Whateverindex markings42,44 are employed, theindex markings42,44 may be formed on either or bothsurfaces26,28 of thecarrier release tape24. Besides being formed on one or bothsurfaces26,28 of thecarrier release tape24, the index markings may also be formed as perforations or other cuts or holes formed into thecarrier release tape24 that may be detected by an optical detector. As also illustrated inFIG. 3, the opticallydetectable index markings44 may be positioned on thesurfaces26,28 of thecarrier release tape24 not only between theadhesive segments32 thereon, but also at different positions on thesurfaces26,28 of thetape24 with respect to theadhesive segments32. For example, theadhesive segments32 on thecarrier release tape24 may be made of a transparent thermoplastic material, in which case theindex markings44 may be positioned partially or entirely beneath theadhesive segments32 on thecarrier release tape24 and still be detectable by an optical detector.
• Preferably, theindex markings42,44 may be pre-printed or otherwise formed on or in thecarrier strip24 before theadhesive segments32 are deposited thereon. Alternatively, theindex markings42,44 may be printed or otherwise formed on or in thecarrier strip24 as part of the process of or by thesystem20 for depositing theadhesive segments32 on thecarrier strip24. In such a case, for example, aprinter46, such as a laser printer or similar device, may be incorporated as part of thesystem20 for creating the adhesive segment-laden carrier release tape, as illustrated inFIG. 1. In such a case, theprinter46, or other device, is used to place theindex markings42 and44 on one or both surfaces of thecarrier release tape24 before theadhesive segments32 are deposited thereon. Note that if the index markings to be used are physical indentations, punctures, or perforations in or through thecarrier tape24, a device other than theprinter46, such as a rotary die with a plurality of die blades attached around its outer circumference, may be used to form the index markings in thecarrier release tape24. In any case, whether printed or formed on thecarrier release tape24 by the manufacturer thereof or during the process of applyingadhesive segments32 to thecarrier release tape24, the optically detectable index markings preferably are formed on thecarrier release tape24 in a uniformly spaced apart longitudinal progression along the length of thecarrier release tape24.
• During application of theadhesive segments32 to thecarrier release tape24 it is important that theadhesive segments32 be deposited on thecarrier release tape24 along the length of thecarrier release tape24 in a consistent relative position to the index markings formed on thecarrier release tape24. In order to achieve this precise control for the depositing of theadhesive segments32 on thecarrier release tape24 anoptical sensor48, as illustrated inFIG. 2, or the like may be used to coordinate operation of the dispensingnozzles30 so that theadhesive segments32 are correctly placed with respect to the index markings on thecarrier release tape24.
• It should be noted that, in some cases, theadhesive segments32 deposited on thecarrier strip24 may be detectable, or made detectable, by an optical detector. Therefore, theadhesive segments32 may themselves be used as index markings. For example, thermoplastic adhesives used to form theadhesive segments32 may be formulated for varying properties such as degrees of tack, etc. Thethermoplastic adhesives32 may also be formulated for optical detectability, e.g., by compounding the thermoplastic adhesive with colors or other optically detectable characteristics. For example, luminescence under ultra-violet is a natural characteristic of some thermoplastic adhesives and this fact may be used to employadhesive segments32 formed of such thermoplastic adhesives as index markings themselves.
• Throughout the remainder of this patent application the index markings printed, or otherwise formed in or on thecarrier release tape24 will be referred to with reference to the exemplaryline index markings42 described and illustrated with reference toFIG. 2. However, it should be understood, that the term “index markings” and “optically detectable indices” and any similar terms as used throughout this application, including in the claims, also refers to other type of index markings, whether printed on or formed in thecarrier release tape24 including optical detectableadhesive segments32 deposited on thecarrier release tape24.
• As will be discussed in more detail below, it has been found that for the application ofadhesive segments32 from an adhesive segmentcarrier release tape24 onto a work piece using an automatic adhesive segment applicator in accordance with the present invention, release of theadhesive segment32 from thecarrier release tape24 onto the work piece can better be assured if a portion of thecarrier release tape24 lying underneath or behind theadhesive segment32 is punctured or perforated by one or more perforations. As will be described in more detail below, this perforating of thecarrier release tape24 behind anadhesive segment32 may be performed by an automatic adhesive segment applicator in accordance with the present invention during the process of applying theadhesive segment32 onto a work piece. Alternatively, one or more perforations may be formed in thecarrier release tape24 behind theadhesive segments32 deposited thereon during the process of fabricating the adhesive segment-laden carrier release tape. For example, theadhesive segments32 may be deposited upon acarrier release tape24 in which such perforations have already been formed. However, since theadhesive segments32 are deposited on thecarrier release tape24 in liquid form it is possible that the deposited liquid thermoplastic adhesive may seep through such preformed perforations in thecarrier release tape24 resulting in thermoplastic adhesive on both opposedsurfaces26 and28 of thecarrier release tape24. Obviously this is unacceptable.
• Alternatively, and preferably, if perforations are to be made through thecarrier release tape24 behind theadhesive segments32 deposited thereon, such perforations are preferably formed through thecarrier release tape24 after the thermoplasticadhesive segments32 have been deposited thereon and, at least partially, cooled and solidified. An exemplary system and method for forming such perforations in thecarrier release tape24 is illustrated schematically at50 inFIGS. 1 and 4. In this case, arotary die52 and correspondingrotary anvil member54 cooperate to perforate thecarrier release tape24 behind eachadhesive segment32 deposited on thecarrier release tape24. The rotary die52 is typically drum-shaped with a plurality of blades orprojections56 formed around its outer circumference. Therotary anvil member54 has correspondingrecesses58 formed therein. Thecarrier release tape24 is effectively pinched between therotary die52 and therotary anvil member54. As thecarrier release tape24 passes between therotary die52 and therotary anvil member54 theprojections56 on the rotary die punch one or more holes in thecarrier release tape24 through thesurface28 of thecarrier release tape24 opposite thesurface26 on which theadhesive segment32 is deposited. Theprojections56 formed on the rotary die52 preferably are long enough to penetrate through thecarrier release tape24 without penetrating entirely through theadhesive segment32 deposited thereon. The notchedrotary anvil member54 provides support for thecarrier release tape24 as therelease tape24 is punctured by the rotary die52. Therecesses58 on therotating anvil member54 are sized and shape such that, as the adhesive segment-ladencarrier release tape24 passes between theanvil member54 and the rotary die52. Theadhesive segments32 on thecarrier release tape24 are positioned within therecesses58 such that theanvil member54 provides support to thecarrier release tape24 around theadhesive segments32 without actually contacting or crushing theadhesive segments32 on thecarrier release tape24. It should be understood that although the embodiment illustrated and described herein shows perforating thecarrier release tape24 only at positions thereon which correspond toadhesive segments32 deposited thereon, the perforations may, alternatively, be formed along the entire length of thecarrier release tape24, so long as at least one such perforation is made in thecarrier release tape24 at each location at which anadhesive segment32 is deposited thereon.
• Referring now toFIG. 5, atape roll60 of the indexed adhesive segment-ladencarrier release tape24 is illustrated with a plurality of dispensableadhesive segments32 contained thereon. It may be seen that the indexed adhesive segment-ladencarrier release tape24 is wound onto a hollowcylindrical core62, which may be, for example, made of cardboard, plastic, or the like. The inside of thecore62 has two identically-shapedorientation facilitating segments64 and66 mounted or formed therein. Theorientation facilitating segments64 and66 will be used to facilitate the installation of thetape roll60 onto a supply spool (to be discussed in detail below) in the proper orientation. Due to the presence and configuration of theorientation facilitating segments64 and66 on the inside of the core62, it will be impossible to place thetape roll60 onto the supply spool backwards.
• An automatic adhesivesegment applicator apparatus70 in accordance with the present invention will now be described in detail first with reference toFIGS. 6 and 7. The various components that form an automatic adhesivesegment applicator apparatus70 in accordance with the present invention are mounted on amovable support structure72. Themovable support structure72 may be implemented, for example, as a plate shaped structure made of steel, aluminum, or some other appropriate ridged and sturdy material. Thesupport structure72 is movably mounted with respect to asupport structure base74. For example, thesupport structure72 may be movably mounted via anappropriate mounting structure76 to supportrod bearings78 that are fixedly attached to thesupport structure base74. A supportstructure actuation device79, such as, for example, a pneumatic air cylinder, or similar device is employed to move thesupport structure72, in this case, up and down on thesupport rod bearings78 with respect to thesupport structure base74.
• The main components of the automatic adhesivesegment applicator apparatus70 in accordance with the present invention that are mounted on thesupport structure72 include asupply spool80, atape guide82, atape clamp84, an applicator head86 (disposed within thetape guide82 and illustrated inFIG. 8), a spent tape take upspool88 and an opticalindex marking detector90. Also attached to thesupport structure72 are appropriate actuators including, e.g., anair cylinder actuator92 for actuating thetape clamp84, anair cylinder actuator94 for operating theapplicator head86, and amotor96 for driving the take upspool88.
• Thesupply spool80 may be mounted via anextension arm98 to thesupport structure72. Theextension arm98 may be fixedly attached to thesupport structure72 in any conventional and convenient manner. Thesupply spool80 may be implemented in any conventional manner to support atape roll60 of indexed adhesive segment-ladencarrier release tape24, as described above. Thesupply spool80 preferably includesorientation facilitating segments100 and102 which are sized, shaped, and positioned to engage the correspondingorientation facilitating segments64 and66 on thetape roll60 to ensure that thetape roll60 can only be mounted on thesupply spool80 in the correct orientation, i.e., the orientation whereby thesurface26 of thecarrier release tape24 havingadhesive segments32 thereon is directed through the adhesive segmentindexing applicator apparatus70 for application to a work piece. Thesupply spool80 preferably is implemented to allow rotation of thespool80 such that the adhesive segment-ladencarrier release tape24 may be unwound from thetape roll60 as tape is pulled from theroll60 during normal operation of the adhesivesegment applicator apparatus70. However, preferably enough resistance to rotation is provided, in any conventional manner, to prevent free rotation of thesupply spool80 in other situations, thereby to prevent unintended unwinding of thetape roll60 mounted on thesupply spool80.
• Thetape guide82 is elongated, having two opposedelongated sides104 and106 along which the adhesive segment-ladencarrier release tape24 is strung during operation of theadhesive segment applicator70. Thesides104 and106 of thetape guide82 are preferably designed to facilitate such guiding of thecarrier release tape24 around thetape guide82 past theapplicator head86, which is disposed within thetape guide82 and which, during operation, extends from anend108 of thetape guide82. To facilitate such guidance of thecarrier release tape24 around thetape guide82, thesides104 and106 of thetape guide82 may be provided withrails110, or other similar structures, which are spaced apart along thesides104 and106 of thetape guide82 at a distance slightly larger than the width of the adhesive segment-ladencarrier release tape24.Such rails110 or other structures help to prevent the adhesive segment-ladencarrier release tape24 from slipping off thecarrier guide82 as the adhesive segment-ladencarrier release tape24 is moved through theadhesive segment applicator70 during operation thereof. Thetransition112 between thesides104 and106 and end108 of thetape guide82 preferably is rounded and smooth to facilitate movement of the adhesive segment-ladencarrier release tape24 aroundtape guide82 without causing damage to thetape24 or unintended peeling of theadhesive segments32 therefrom.
• Thetape clamp84 is designed to hold the adhesive segment-ladencarrier release tape24 tightly in position against thetape guide82 during application of anadhesive segment32 from thecarrier release tape24 onto a work piece. As illustrated inFIG. 8, thetape clamp84 preferably includesprojections114 extending therefrom in the direction of aside104 of thetape guide82. When thetape clamp84 is moved in the direction of thetape guide82, by operation of thetape clamp actuator92, thetape clamp projections114 pinch the adhesive segment-ladencarrier release tape24 between theprojections114 and theside104 of thetape guide82, thereby preventing movement of the adhesive segment-ladencarrier release tape24. Theprojections114 are separated from each other by a distance such that agap116 is created between them such that when theclamp84 is closed against thetape guide82 the body of theclamp84 other than theprojections114 remains spaced apart from thetape guide82, thereby to prevent thetape clamp84 from contacting theadhesive segments32 deposited on the adhesive segment-ladencarrier release tape24 passed in between thetape clamp84 and thetape guide82. Note that thetape clamp actuator92 may be implemented in any conventional manner, e.g., using a pneumatic air cylinder with pneumatic and/or spring return.
• Note that during operation of theadhesive segment applicator70 it is important that the adhesive segment-ladencarrier release tape24 be held firmly in position with respect to theapplicator head86 during operation of theapplicator head86 to apply anadhesive segment32 onto a work piece. This may be achieved, for example, by providing atape clamp84 on bothsides104 and106 of thetape guide82. Alternatively, asingle tape clamp84 may be employed, as illustrated inFIG. 6, wherein apinch roller system118 is provided on the opposite side of thetape guide82 from thetape clamp84. A conventionalpinch roller system118 may be employed through which the spentcarrier release tape24, withadhesive segments32 removed therefrom, is strung and which allows movement of the carrier release tape in only one direction through thecontroller system118 onto the take upspool88.
• Theapplicator head86 preferably is mounted for axial movement in abore120 formed through thetape guide82 such that theapplicator head86 may be moved in and out of thetape guide82 to extend from thebore120 at theend108 of thetape guide82. The size and shape of theapplicator head86 preferably corresponds generally to the size of theadhesive segments32 that are to be applied to the work piece by thehead86. Theapplicator head86 preferably includes at least one, and preferably a plurality, ofsharp projections122 extending therefrom. As will be described in more detail below, during operation of theadhesive segment applicator70 theapplicator head actuator94 is operated to move theapplicator head86 outward from the end of108 of the tape guide, to contact theside28 of thecarrier release tape24 opposite anadhesive segment32 to press theadhesive segment32 against a work piece to apply theadhesive segment32 to the work piece. Theprojections122 are sized, and the movement of theapplicator head82 is coordinated, to pierce through thecarrier release tape24 behind theadhesive segment32, preferably without piercing entirely through theadhesive segment32 into the work piece upon which theadhesive segment32 is being deposited. The forming of apertures through therelease tape24 in this manner during the application procedure facilitates release of theadhesive segment32 from thecarrier release tape24 onto the work piece to provide assured application of theadhesive segment32 to the work piece during the rapid automatic application ofadhesive segments32 to a work piece using theadhesive segment application70 in accordance with the present invention.
• The take upspool88 may be implemented as a conventional rotatable spool onto which thecarrier release tape24 is wound after theadhesive segments32 have been removed therefrom. The take upspool88 may preferably be driven by amotor96, such as a stepper or servo motor. As illustrated, the take upspool motor96 may be mounted on thesupport structure plate72 on the side thereof opposite the take upspool88. A drive axle may extend from themotor96 through thesupport structure72 directly to engage and drive thepinch roller system118. A drive belt126 connected between thepinch roller system118 and the take upspool88 couples the take upspool88 to themotor96. In operation, themotor96 is operated to rotated thepinch roller system118 and take upspool88 to pull thecarrier release tape24, which is strung around thetape guide82, from thetape roll60 mounted on thesupply spool80.
• In accordance with the present invention, an opticalindex marking detector90 is employed to detect theindex markings42 formed on the adhesive segment-ladencarrier release tape24. Theoptical detector90 may be implemented in any conventional manner, and specifically is selected and implemented to detect the particular type of index marking formed on or in thecarrier release tape24. The opticalindex marking detector90 may be mounted in any appropriate and convenient place on thesupport structure72 to detect theindex markings42.
• Anexemplary control system130 for an adhesive segment applicator in accordance with the present invention will now be described in more detail with reference toFIG. 9. Thesystem controller132 may be implemented in a conventional manner to perform the functions described herein. For example, thecontroller132 may be implemented in whole or in part using a microprocessor or other programmable device and/or using in a combination of discreet digital and/or analog circuitry. Thecontroller132 may, but need not, be mounted to the adhesive segmentapplicator support structure72.
• The opticalindex marking detector90 operates as a tape position sensor which provides an input to thesystem controller132 relative to the detected position of theindex markings42 on thecarrier release tape24. Thecontroller132 processes the signal received from thetape position sensor90 to determine, in a conventional manner, the position of the adhesive segment-ladencarrier release tape24. Before controlling theapplicator70 to apply anadhesive segment32 from thecarrier release tape24 onto a work piece, thecontroller132 determines, based on the signal received from thetape position sensor90, whether the adhesive segment-ladencarrier release tape24 is positioned such that anadhesive segment32 is positioned at theend108 of thetape guide82 to be applied to a work piece by theapplicator head86. If anadhesive segment32 is not in the desired position thecontroller132 sends a control signal to thetape advance motor96, via an appropriateconventional motor controller134, to rotate thepinch roller system118 and take upspool88 to advance the adhesive segment-ladencarrier release tape24 from thesupply roll60 until the signal from thetape position sensor90 indicates that anadhesive segment32 is in the desired position. (Preferably amanual calibration input136 is provided to provide an input to thecontroller132 if it is determined by observation that the controller is not properly positioning in adhesive segment in the desired position for application to a work piece.)
• Once the adhesive segment-ladencarrier release tape24 is positioned such that anadhesive segment32 is positioned in an appropriate position at theend108 of thetape guide82, the controller sends appropriate control signals to thesupport structure actuator79, thetape clamp actuator92, and theapplicator head actuator94 to control operation thereof in sequence automatically to apply the adhesive segment to a work piece, in a manner to be described in more detail below. This application process may be initiated manually, e.g., by amanual trigger138 that provides a trigger signal to thecontroller132. Themanual trigger138 may be implemented, for example, as a hand or foot operated switch that provides a trigger signal to the controller to initiate the adhesive segment application process when an operator has positioned a work piece in a desired position or notes that a work piece is in the desired position for the application for anadhesive segment32 thereto. Alternatively, the adhesive segment application process may be initiated automatically by a conveyor or other work piece relatedtrigger system140. For example, such awork piece trigger140 may provide a trigger signal to initiate the application of anadhesive segment32 onto a work piece using a conventional system for detecting the presence of a work piece in the appropriate position relative to theadhesive segment applicator70. Such an automaticwork piece trigger140 may, particularly, be employed in an assembly line like setting.
• As described previously, asupport structure actuator79,tape clamp actuator92, andapplicator head actuator94 may be implemented using pneumatic air cylinder type actuators. In such a case, the control signals provided to operate such actuators are provided by thecontroller132 to appropriatecorresponding switching devices142,144, and146 to direct compressed air, from acompressed air supply148, to the appropriateair cylinder actuators79,92, and94 to operate the actuators at the desired time and in the desired manner. Note that preferably a singlecompressed air supply148 may be used to provide operation of all of theair cylinder actuators79,92, and94 employed in theapplicator apparatus70.
• An exemplary process for operating an adhesive segment applicator system in accordance with the present invention to apply anadhesive segment32 from an adhesive segment-ladencarrier release tape24 onto awork piece152 now will be described with reference to the exemplary flow chart diagram of FIG.10 andFIGS. 11-14.FIGS. 11-14 illustrate, schematically, relative positions of the adhesive segment-ladencarrier release tape24,tape guide82,tape clamp84,applicator head86, andwork piece152 at various points during the adhesive segment applicator operation.
• Thesystem controller132 first employs the signal provided from thetape position sensor90 to determine154 the position of thetape24 in the adhesivesegment applicator apparatus70. Specifically, the controller employs the tapeposition sensor signal90 to determine if the tape is in aposition156 such that anadhesive segment32 is positioned at theend108 of thetape guide82, in front of the opening of thebore120 in which theapplicator head86 is positioned. If the adhesive segment-ladencarrier release tape24 is not in the desired position, the controller sends the appropriate signals to thetape advance motor96 to advance thetape158 until the signal from thetape position sensor90 indicates that the tape is in the desired position.
• Thecontroller132 then waits for atrigger signal160. As discussed above, the trigger signal may be provided manually by an operator or automatically by a work piece positioning or detection system when thework piece152 is in the desired position for application of adhesive segment thereto. While the controller awaits for the trigger signal with the adhesive segment-laden carrier release tape positioned with anadhesive segment32 ready for application to thework piece152 the apparatus components are in the position illustrated inFIG. 11.
• After receiving a trigger signal, indicating that a work piece is in position for an adhesive segment to be applied thereto, thecontroller132 sends a signal to the tape clamp actuator92 to actuate thetape clamp84 thereby to clamp162 the adhesive segment-ladencarrier release tape24 position such that thetape24 in the area of theadhesive segment32 to be applied to the work piece does not move.
• With the tape clamped, thecontroller132 sends a signal to thesupport structure actuator79 to lower thesupport structure72 to bring theadhesive segment32 to be applied to thework piece152 in contact with thework piece152. After clamping162 the tape and lowering164 thesupport structure72 the apparatus is in the position illustrated inFIG. 12.
• Thecontroller132 then provides a signal to theapplicator head actuator94 to lower166 theactuator head86 rapidly against the side of thecarrier release tape24 opposite theadhesive segment32. This operation, illustrated inFIG. 13, presses theadhesive segment32 against thework piece152, thereby to apply theadhesive segment32 onto thework piece152. Simultaneously, thesharp projections122 provide one or more perforations through therelease tape24, preferably without piercing through theadhesive segment32 into thework piece152. Thecontroller132 may then send the appropriate signal to theapplicator head actuator94 to retract168 the applicator head back into thetape guide82. It is believed that the piercing of holes or apertures through therelease tape24 behind theadhesive segment32 prevents air pressure behind theadhesive segment32 as theapplicator head86 is retracted from tending to pulladhesive segment32 back off of thework piece152 to which it has been applied. Thus, providing one or more perforations through thecarrier release tape24 behind theadhesive segment32 assures removal of theadhesive segment32 from therelease tape24 and complete application thereof to thework piece152.
• Preferably the step of extending166 and retracting168 theapplicator head86 may be repeated170 rapidly at least once for eachadhesive segment32 to be applied to a work piece. This further assures release of theadhesive segment32 from thecarrier release tape24 onto thework piece152.
• After theapplicator head86 has been operated to apply theadhesive segment32 onto thework piece152, thecontroller132 may send a control signal to thesupport structure actuator79 to raise thesupport structure72 back to its starting position and may send a signal to the tape clamp actuator92 to release174 thetape clamp92 to allow movement of the adhesive segment-ladencarrier release tape24. Having applied anadhesive segment32 onto thework piece152, thecontroller132 may then send a control signal to thetape advance motor96 to advance the adhesive segment-ladencarrier release tape24 to position the next adhesive segment on the carrier release tape in the proper position for application to a work piece, as illustrated inFIG. 14. As discussed above, the, e.g., opticaltape position sensor90 may be employed to detect theindex markings42 on thecarrier release tape24 to ensure that the nextadhesive segment32 on thecarrier release tape24 is in the proper position.
• It should be understood that the present invention is not limited to the particular exemplary applications and embodiments illustrated and described herein. In particular, although the exemplary adhesivesegment applicator apparatus70 illustrated and described herein moves in a generally vertical, up and down, direction with respect to awork piece152 position below theapplicator70, an adhesive segment applicator apparatus in accordance with the present invention may be positioned in any direction with respect to a work piece and oriented and operated with respect thereto to apply an adhesive segment from an adhesive segment carrier release tape onto the work piece in accordance with the present invention.
• Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims (20)

What is claimed is:

1. An adhesive segment dispensing tape, comprising:

(a) a flexible carrier release tape extending longitudinally and having a transverse width, said flexible carrier release tape also having opposed first and second release surfaces;

(b) a plurality of adhesive segments arrayed non-contiguously in a longitudinally spaced-apart progression along the first release surface of the carrier release tape, consecutive ones of the adhesive segments being spaced longitudinally apart by a predetermined and substantially uniform distance on the first release surface of the carrier release tape, wherein each of the adhesive segments is configured to adhere to a surface after release from the carrier release tape and to support an object attached to the adhesive segment; and

(c) a plurality of detectable indices on at least one of the first and second release surfaces of the carrier release tape and in a uniformly spaced apart longitudinal progression on the carrier release tape, wherein each of the detectable indices is in the same relative position on the carrier release tape with respect to at least one corresponding adhesive segment but wherein each of the optically detectable indices does not contact the at least one corresponding adhesive segment.

2. The adhesive segment dispensing tape ofclaim 2, wherein the adhesive segment dispensing tape is arranged and configured to have the adhesive segments be dispensed by an adhesive segment dispensing apparatus, the adhesive segment dispensing apparatus comprising:

a dispensing location for receiving the dispensing tape with the plurality of adhesive segments arrayed thereon, wherefrom adhesive segments are applied directly from the dispensing tape onto a work piece; and

a single optical detector mounted on the adhesive segment dispensing apparatus in a fixed relationship to the dispensing tape, at least a one of the detectable indices on the at least one of the first and second release surfaces of the carrier release tape being automatically detected and the adhesive segment dispensing tape being automatically moved to position an adhesive segment on the dispensing tape at the dispensing location on the adhesive dispensing tape apparatus using the detected at least one of the detectable indices, whereupon the adhesive segment dispensing apparatus applies the adhesive segment at the dispensing location onto a work piece.

3. The adhesive segment dispensing tape ofclaim 1, wherein the plurality of detectable indices on the first release surface of the carrier release tape comprise:

optically detectable indices.

4. The adhesive segment dispensing tape ofclaim 1, wherein the plurality of detectable indices on the first release surface of the carrier release tape comprise:

optically detectable indices printed onto the carrier release tape.

5. The adhesive segment dispensing tape ofclaim 4, wherein the plurality of optically detectable indices comprise:

visible lines printed on the carrier release tape and extending transversely across the carrier release tape.

6. The adhesive segment dispensing tape ofclaim 1, wherein the plurality of detectable indices are positioned on the carrier release tape such that each of the detectable indices is positioned in between adjacent adhesive segments on the carrier release tape.

7. The adhesive segment dispensing tape ofclaim 1, wherein the plurality of detectable indices comprise:

perforations formed extending through the carrier release tape.

8. The adhesive segment dispensing tape ofclaim 1. additionally comprising:

a plurality of perforations extending through the carrier release tape and positioned in a longitudinally spaced-apart progression along the length thereof in positions thereon to coincide with the positions of the adhesive segments thereon.

9. An adhesive segment dispensing tape, comprising:

(a) a flexible carrier release tape extending longitudinally and having a transverse width, said flexible carrier release tape also having opposed first and second release surfaces;

(b) a plurality of adhesive segments, each segment having first and second tacky surfaces, arrayed non-contiguously in a longitudinally spaced-apart progression along the first release surface of the carrier release tape, consecutive ones of the adhesive segments being spaced longitudinally apart by a predetermined and substantially uniform distance on the first release surface of the carrier release tape, wherein each of the adhesive segments is configured to adhere with the first tacky surface to a work piece and support an object attached to the second tacky surface; and

(c) a plurality of optically detectable visible lines printed so as to extend transversely across the carrier release tape on at least one of the first and second release surfaces of the carrier release tape and in a uniformly spaced apart longitudinal progression on the carrier release tape such that each of the visible lines is positioned between adjacent adhesive segments on the carrier release tape, wherein each of the visible lines is in the same relative position on the carrier release tape with respect to at least one corresponding adhesive segment;

wherein the adhesive segment dispensing tape is arranged and configured to have the adhesive segments dispensed directly from the dispensing tape onto a work piece by an adhesive segment dispensing apparatus having a dispensing location accommodating the carrier tape with the plurality of adhesive segments arrayed thereon, wherein a single optical detector mounted on the adhesive segment dispensing apparatus in a fixed relationship to the dispensing tape automatically detects a position of at least one of the adhesive segments on the adhesive segment dispensing tape and automatically moves the adhesive segment dispensing tape to position an adhesive segment on the dispensing tape at the dispensing location on the adhesive dispensing tape apparatus using the detected position of the at least one of the adhesive segments, whereupon the adhesive segment dispensing apparatus applies the adhesive segment at the dispensing location onto a work piece.

10. The adhesive segment dispensing tape ofclaim 9, wherein each of the optically detectable visible lines does not contact the at least one corresponding adhesive segment.

11. The adhesive segment dispensing tape ofclaim 9, wherein the plurality of optically detectable visible lines are printed on the first release surface of the carrier release tape.

12. The adhesive segment dispensing tape ofclaim 9, wherein the plurality of optically detectable visible lines are black in color and the flexible carrier release tape is light in color.

13. The adhesive segment dispensing tape ofclaim 9, additionally comprising:

a plurality of perforations extending through the carrier release tape and positioned in a longitudinally spaced-apart progression along the length thereof in positions thereon to coincide with the positions of the adhesive segments thereon.

14. An adhesive segment dispensing tape, comprising:

(a) a flexible carrier release tape extending longitudinally and having a transverse width, said flexible carrier release tape also having opposed first and second release surfaces;

(b) a plurality of adhesive segments, each segment having first and second tacky surfaces, arrayed non-contiguously in a longitudinally spaced-apart progression along the first release surface of the carrier release tape, consecutive ones of the adhesive segments being spaced longitudinally apart by a predetermined and substantially uniform distance on the first release surface of the carrier release tape, wherein each of the adhesive segments is configured to adhere with the first tacky surface to a work piece and support an object attached to the second tacky surface; and

(c) a plurality of detectable indices on at least one of the first and second release surfaces of the carrier release tape and in a uniformly spaced apart longitudinal progression on the carrier release tape, wherein each of the detectable indices is in the same relative position on the carrier release tape with respect to at least one corresponding adhesive segment.

15. The adhesive segment dispensing tape ofclaim 14, wherein the plurality of detectable indices on the first release surface of the carrier release tape comprise:

optically detectable indices printed onto the carrier release tape.

16. The adhesive segment dispensing tape ofclaim 15, wherein the plurality of optically detectable indices comprise:

optically detectable visible lines printed on the carrier release tape and extending transversely across the carrier release tape.

17. The adhesive segment dispensing tape ofclaim 16, wherein each of the optically detectable visible lines does not contact the at least one corresponding adhesive segment.

18. The adhesive segment dispensing tape ofclaim 16, wherein the optically detectable visible lines are positioned on the carrier release tape such that each of the optically detectable visible lines is positioned in between adjacent adhesive segments on the carrier release tape.

19. The adhesive segment dispensing tape ofclaim 16, wherein the plurality of optically detectable visible lines are black in color and the flexible carrier release tape is light in color.

20. The adhesive segment dispensing tape ofclaim 14, wherein the plurality of detectable indices comprise:

perforations formed extending through the carrier release tape and positioned in a longitudinally spaced-apart progression along the length thereof in positions thereon to coincide with the positions of the adhesive segments thereon.

Images