Note: Descriptions are shown in the official language in which they were submitted.
CA 02637873 2008-07-16
HANDHELD ADHESIVE APPLICATOR
BACKGROUND OF THE INVENTION
[0001] Field of the Invention -- The present invention
relates generally to pressure-sensitive adhesives and
their application to desired surfaces, and more
specifically to a handheld adhesive segment application
apparatus.
[0002] 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.
[0003] 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.
[0004] 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
1
CA 02637873 2008-07-16
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 and is not limited to assembly line-like settings.
[0005] Increasingly, industry demands thermoplastic
adhesive application at on-site locations from portable,
simple-to-use, efficient, inexpensive, and safe dispensing
apparatuses. Additionally, such dispensing apparatuses
must be able to adhere thermoplastic adhesives to non-
planar, recessed, difficult to reach, or unstable
surfaces. Previously known apparatuses and methods have
failed to provide an adequate portable, simple-to-use,
efficient, inexpensive, and safe dispensing device and a
thermoplastic adhesive carrying medium capable of applying
thermoplastic adhesives to non-planar, recessed, difficult
to reach, or unstable surfaces.
[0006] In recent years, thermoplastic adhesive
applications have expanded from industrial use to home or
school use, such as in art projects or crafting.
Scrapbooking, rubber stamping, sewing, gift basket making,
and candlemaking are just a few examples of these newer
arts and crafts, pressure-sensitive, thermoplastic
adhesive uses. As these hobbies have developed over time,
the need for a simple, portable apparatus for dispensing
thermoplastic adhesives has become increasingly important.
[0007] Several different types of devices are available
for applying thermoplastic adhesives. For example, hot
glue guns dispense heated thermoplastic adhesive to an
item or surface, however, there are safety concerns when
using this type of applicator, especially in schools.
Additionally, such devices are inconvenient to use where
an electrical source is not readily available and they are
not readily portable, as a hot glue gun device must be
2
CA 02637873 2008-07-16
cooled before it can be transported and used in another
location.
[0008] Many adhesive applicator devices do not require
the use of heat or electricity, however, they can be bulky
and cumbersome to use when application of an adhesive
segment to a discrete location is required. Further,
conventional thermoplastic adhesive applicators are based
on the industrial designs, and as such, they can be
expensive to purchase, difficult to operate and heavy to
transport for regular or routine use.
SUMMARY OF THE INVENTION
[0009] With this invention, an adhesive segment
applicator apparatus is provided having an adhesive
dispensing wheel and a take-up core system within a
hosing. The configuration of the adhesive applicator of
the present invention allows the adhesive segments to be
dispensed from the tape using a single hand, and using a
single motion simultaneously dispense an adhesive segment
and advance the next adhesive segment to a dispensing
position.
[0010] The carrier release tape may be made from plain
stock carrier release tape, which can be cut into
individual tape strips either before or after the adhesive
segment application processes. The transverse width of
the preferred embodiment is approximately one inch
although the dimensions of the carrier release tape strips
may vary in accordance with the advancement mechanism
associated with the adhesive segment applicator apparatus
of the present invention with which it is used.
[0011] The second surface of the carrier release tape
has a coefficient of friction different from that of the
first so that adhesive segments do not adhere to the
second surface as strongly as they do to the first
surface. When the carrier release tape is wound into
3
CA 02637873 2008-07-16
rolls, the first surface, and thus, the adhesive segments
applied thereto, will be the external surface of the roll
of adhesive segment-laden carrier release tape.
[0012] In certain preferred embodiments of the present
invention, the adhesive segment applicator apparatus
includes a carrier tape dispensing system comprising a
supply wheel, a spent-tape take-up wheel and a roller are
each rotatably mounted inside the housing of the adhesive
segment applicator apparatus. A roll of adhesive segment-
laden carrier release tape is inserted onto the supply
wheel and engages the supply wheel in a secure fashion,
permitting the roll of adhesive segment-laden carrier
release tape to rotate when the supply wheel rotates. The
supply wheel includes a gear system or another mechanism
for engaging the take-up wheel.
[0013] The take-up wheel is also rotatably mounted
inside the housing of the adhesive segment applicator
apparatus. The take-up wheel is operatively engaged to at
least a portion of the gear teeth or gear system of supply
wheel, permitting rotation of the supply wheel (and the
roll of adhesive segment-laden carrier release tape) to
drive rotation of the spent carrier tape take-up wheel.
An adhesive dispensing roller is also rotatably mounted to
the housing of the adhesive segment applicator apparatus
but is positioned so that a portion of the roller is
located outside the housing to provide an area of contact
for the roller to contact a surface or workpiece. The
adhesive segment applicator apparatus also may include a
cap mounted to or removable from the housing of the
adhesive segment applicator apparatus.
[0014] Preferably, the roll of adhesive segment-laden
carrier release tape and adhesive dispensing system
(including the supply wheel and the take-up wheel) are
substantially permanently enclosed within the housing of
the adhesive segment applicator apparatus, rendering the
4
CA 02637873 2008-07-16
applicator disposable. In particular, the housing
components are not separable once assembled so that once
the adhesive on the roll of adhesive segment-laden carrier
release tape is used, the roll is not replaceable. In
these embodiments, the applicator housing and each of the
components, including the supply wheel, take-up wheel and
roller are constructed of an easily disposable, and most
preferably recyclable, material.
[0015] The path of the adhesive segment-laden carrier
release tape within the applicator provides the applicator
with an automatic advancement function. Indeed, once
mounted the roll is mounted on to the supply wheel, the
carrier tape travels, with adhesive segments facing
outwardly, from the supply wheel, out of the housing and
over the roller at the point where an adhesive segment or
segments are dispensed to the desired object or surface.
The spent carrier tape then reenters the housing and
passes over the roll of adhesive segment-laden carrier
release tape where it is held in place within the housing
by the exposed adhesive on the remaining roll of adhesive
segment-laden carrier release tape on the supply wheel.
The free end of the roll of adhesive segment-laden carrier
release tape is mounted to the take-up wheel, and spent
carrier tape is wound thereon.
[0016] The adhesive segment applicator apparatus of the
present invention can be used to dispense adhesive to a
workpiece and automatically advance the carrier tape to
expose another adhesive segment to the workpiece. To
operate the adhesive segment applicator, the roller
containing an exposed adhesive segment, is placed in
contact with the intended workpiece or application
surface. The exposed adhesive segment is then applied to
the intended surface by contacting the adhesive segment to
the surface.
CA 02637873 2008-07-16
[0017] The carrier release tape is advanced by motion
of the application process. In particular, the adhesive
segment is applied to the surface by moving the adhesive
segment applicator apparatus across it in the operational
direction. This action causes the roller to rotate, and
simulataneous advancement of the adhesive segments on the
roll of carrier tape and winding of the spent carrier
tape. More specifically, by virtue of the second surface
of the spent carrier tape being held in place by the
adhesive segments on the roll of adhesive segment-laden
carrier release tape on the supply wheel, rotation of the
roller, drives the supply wheel, causing the spent carrier
tape to be drawn into the housing, thereby automatically
advancing the adhesive laden carrier tape. By nature of
the externally exposed adhesive segments on the roll of
adhesive segment-laden carrier release, tape, the second
surface of the spent carrier release tape adheres to the
adhesive segments on the wound roll of adhesive segment-
laden carrier release tape on the supply wheel and is held
in place. However, because the second surface of the
carrier release tape has a release property different from
that of the first surface the adhesive segments do not
adhere to it as strongly as they do to the first surface,
the carrier tape can be advanced across the wound roll of
adhesive segment-laden carrier release tape without
pulling off adhesive segments from the roll.
[0018] In turn, the supply wheel drives the take-up
wheel, thereby winding the spent carrier tape on to the
take-up spool. Thus, an adhesive segment applicator in
accordance with the present invention can be used easily
to deposit a series or row of adhesive segments along a
work piece surface and also wind spent carrier tape with a
single motion, and using a single hand.
[0019] It may seen that the compact, handheld adhesive
segment applicator apparatus of the present invention
6
CA 02637873 2008-07-16
includes a self-advancing adhesive dispensing system
including an adhesive supply wheel, take-up wheel and
roller that are each operatively engaged with eachother to
permits automatic advancement of the adhesive segment-
laden carrier release tape during application of an
adhesive segment to a surface. In addition, it may be
seen that the present invention provides a adhesive
segment applicator apparatus that automatically winds the
spent carrier release tape onto a roll - thereby reducing
the problem of scrap carrier tape interfering with the
adhesive application process.
[0020] It may also be seen that the adhesive segment
applicator apparatus of the present invention may also be
configured to be compact and handheld - therefore,
rendering it easy to accurately dispense adhesive using a
single hand, allowing the user to stabilize the surface or
workpiece with another hand (if necessary) The present
invention can be disposable, such that the user may
dispose of or recycle the device, rather then take the
device apart for difficult or cumersome reloading thereof.
[0021] Each implementation of the adhesive segment
applicator apparatus of the present invention is of a
construction which is both durable and long lasting, and
will require little or no maintenance to be provided by
the user throughout its operating lifetime. The adhesive
segment applicator apparatuses of the present invention
are also of inexpensive construction to enhance their
market appeal and to thereby afford them the broadest
possible market. Finally, all of the aforesaid advantages
and objectives are achieved without incurring any
substantial relative disadvantage.
7
CA 02637873 2008-07-16
DESCRIPTION OF THE DRAWINGS
[0022] These and other advantages of the present
invention are best understood with reference to the
drawings, in which:
[0023] FIG. 1 is a perspective view of a handheld
adhesive segment applicator apparatus of the present
invention;
[0024] FIG. 2 is a side plan view of the handheld
adhesive segment applicator illustrated in FIG. 1,
including a manual advancement opening and a portion of an
advancement cap;
[0025] FIG. 3 is a side plan view of the handheld
adhesive segment applicator illustrated in FIGS. 1 and 2,
showing operational engagement of the supply and spent
tape take-up wheels;
[0026] FIG. 4 is an exploded view of the handheld
adhesive segment applicator illustrated in FIGS. 1 through
3;
[0027] FIG. 5 is a side plan view of an interior
surface of a front housing piece used to construct the
handheld adhesive segment applicator illustrated in FIGS.
1 through 4;
[0028] FIG. 6 is a back plan view of a tape supply gear
used to construct the handheld adhesive segment applicator
illustrated in FIGS. 1 through 5;
[0029] FIG. 7 is a front perspective view of an
advancement cap used to construct the handheld adhesive
segment applicator illustrated in FIGS. 1 through 6;
[0030] FIG. 8 is a side view of the advancement cap of
the supply wheel of the handheld adhesive segment
applicator illustrated in FIGS. 1 through 7;
[0031] FIG. 9 is a rear perspective view of a take-up
gear used to construct the handheld adhesive segment
applicator illustrated in FIGS. 1 through 8;
8
CA 02637873 2008-07-16
[0032] FIG. 10 is a front perspective view of a take-up
spool used to construct the handheld adhesive segment
applicator illustrated in FIGS. 1 through 10;
[0033] FIG. 11 is a side view of the handheld adhesive
segment applicator illustrated in FIGS. 1 through 10,
demonstrating the rolling operation of the application
while applying an adhesive segment to a surface;
[0034] FIG. 12 is a side view of the handheld adhesive
segment applicator illustrated in FIGS. 1 through 11,
demonstrating application of an adhesive segment to a
surface and automatic advancement of the roll of adhesive
segment laden carrier tape;
[0035] FIG. 13 is a side view of the handheld adhesive
segment applicator illustrated in FIGS. 1 through 12,
illustrating a detailed view of operation of the
applicator; and
[0036] FIG. 14 is a side view of the handheld adhesive
segment applicator illustrated in FIGS. 1 through 13,
illustrating manual advancement of the carrier tape using
a finger.
9
CA 02637873 2008-07-16 -
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] A preferred embodiment of an adhesive segment
applicator 50 of the present invention is illustrated
generally in FIG. 1, with an adhesive segment-laden
carrier release 52 tape including a plurality of adhesive
segments 54 used therein. It will be appreciated that the
applicator 50, and most preferably the applicator housing
and gear components, can be constructed of a variety of
substantially rigid materials. In particular, the
materials of construction can include a thermoplastic
material or thermoplastic composite material. It will
also be appreciated that the applicator 50 of the present
invention can come in a variety of colors or can be
transparent, including having individual components of
different colors and/or translucency, depending on the
desired end-look of the applicator.
[0038] It will be further appreciated that any type of
adhesive segment-laden carrier release tape can be used in
the applicator 50 of the present invention and is not
limited to those shown in the figures. Carrier tapes of
different widths and sizes can be used. In addition, the
adhesive segments may be of any size, shape or color
(including transparent), depending on the desired end-use
of the applicator product. Further, it will be
appreciated that the roll of adhesive segment-laden
carrier release tape can be configured to dispense a
single, or multiple adhesive segments at a given time,
also depending on the end-use application of the
applicator 50.
[0039] Preferably, however, the adhesive segment-laden
carrier release tape will be of the type that includes two
surfaces, a first surface 51 and a second surface 53,
wherein the second surface 53 of the carrier release tape
has a coefficient of friction different from that of the
first surface 51 so that adhesive segments do not adhere
CA 02637873 2008-07-16
to the second surface as strongly as they do to the first
surface 51. When the carrier release tape is wound into
rolls, the first surface, and thus, the adhesive segments
applied thereto, will be on the external surface of the
roll of adhesive segment-laden carrier release tape 52.
[0040] Referring first to FIGS. 1 through 3, the
adhesive segment applicator 50, in its simplest form,
includes an adhesive tape supply wheel, indicated
generally at 56, a spent tape, take-up wheel, indicated
generally at 58, and an applicator tip or roller 60, which
are each rotatably secured within an applicator housing 62
by any means known to those skilled in the art. The
applicator housing 62 is preferably formed in two pieces,
including a front housing portion 64 and a rear housing
portion 66, as described in more detail below.
[0041] As best illustrated in FIG. 4, the rear housing
portion 66 has a side wall 68 having interior and exterior
surfaces 70 and 72, respectively, and a side edge 73
encompassing substantially the entire perimeter of the
side wall 68. An opening or space 75 is provided in the
side edge 73 for accommodating the roller 60 and the
adhesive segment-laden carrier release tape 52.
[0042] The interior surface 70 of the rear housing
portion 66 includes a plurality of outwardly projecting
teeth 74 and a supply wheel mounting shaft 76 for
operatively engaging the supply wheel 56. The interior
surface 70 also includes a take-up wheel mounting shaft 78
for operatively engaging the take-up wheel 58, and a
roller mounting shaft 80 for operatively engaging the
roller 60. When the applicator 50 is assembled, each of
the mounting shafts 76, 78 and 80 are configured to extend
from the rear housing portion 66 to the front housing
portion 64.
[0043] A plurality of locking pins 82 also project from
the interior surface 70 of the side wall 68 of the rear
11
CA 02637873 2008-07-16
housing portion 66. The locking pins 82 are configured to
engage corresponding locking pins within the front housing
portion 64 of the applicator 50 in order to retain the
front and rear applicator housing portions 64 and 66,
respectively, together.
[0044] Preferably, the teeth 70, each of the mounting
shafts 76, 78 and 80 and the locking pins 82 are
integrally formed within the interior surface 70 of the
side wall 68 of the rear housing portion 66. However, the
rear housing portion 66 may be constructed so that the
mounting shafts 76, 78 and 80 and the locking pins 82 are
secured to the inside surface 70 after it is formed. It
will also be appreciated that the outside surface 72 of
the rear housing portion 66 can be texturized or include
gripping portions to facilitate a user's ability to grasp
the applicator 50 with a single hand.
[0045] Turning now to FIG. 5, in addition to FIG. 4,
the front housing portion 64 has a side wall 84 having
interior and exterior surfaces 86 and 88, respectively,
and a side edge 89 encompassing substantially the entire
perimeter of the side wall 84. An opening or space 91 is
provided in the side edge 89 for accommodating the roller
60 and the adhesive segment-laden carrier release tape 52.
[0046] The interior surface 86 includes a first tubular
projection or prong 90 configured to interfit and/or
engage the mounting shaft 76, permitting the supply wheel
56 to be rotatably secured within the housing 62. A
second tubular projection or prong 92 extending from the
inside surface 86 of the front housing portion 64 is
configured to interfit and/or engage take-up wheel
mounting shaft 78, permitting the take-up wheel 58 to be
rotatably secured within the housing 62. Likewise, a
third tubular projection or prong 94 extending from the
inside surface 86 is configured to interfit and/or engage
12
CA 02637873 2008-07-16
the roller mounting shaft 80, permitting the roller 60 to
be rotatably secured within the housing 62.
[0047] A plurality of locking pins 98 also project from
the interior surface 86 of the front housing portion 64.
The locking pins 98 are located within the side wall 84 so
that they are aligned with and engage the locking pins 82
in the rear housing portion 66. In certain preferred
embodiments of the present invention, the locking pins 98
and 82, respectively, are tubular and are configured so
that they interfit with each other and lock together, so
that the front and rear housing portions 64 and 66 cannot
be easily separated once assembled.
[0048] The front and rear applicator housing portions
64 and 66 can be held together by any means known to those
skilled in the art; however, it is preferable that once
the front and rear housing portions 64 and 66 are
assembled, the housing 62 will be difficult, if not
impossible to separate, preventing the adhesive segment-
laden carrier release tape 52 from becoming unthreaded
within or removed from the applicator 50. In certain
other preferred embodiments, the locking pins 98 and 82
are configured so that they interfit with each other but
are easily separated as well, permitting the front and
rear housing portions 64 and 66 to be separated from each
other for re-loading the applicator 50 with adhesive tape
52 and reassembling it.
[0049] Preferably, each of prongs 90, 92 and 94 and the
locking pins 98 are integrally formed within the interior
surface 86 of the side wall 84 of the front housing
portion 64. However, the front housing portion 64 may be
constructed so that the prongs 90, 92 and 94 and the
locking pins 98 are secured to the inside surface 86 after
it is formed.
[0050] As best illustrated in FIGS. 1, 5 and 14, the
front housing portion 64 includes an arcuate aperture 100
13
CA 02637873 2008-07-16
positioned within the side wall 84 in a location that will
be close to the location of the adhesive tape supply wheel
56 when the applicator 50 is assembled. This aperture 100
will permit the user to manually advance the adhesive
segment-laden carrier release tape 52 if required, as will
be described in more detail below with respect to FIG. 14.
Further, it will also be appreciated that the outside
surface 88 of the front housing portion 64 can be
texturized or include gripping portions to facilitate a
user's ability to grasp the applicator 50 with a single
hand.
[0051] Turning next to FIGS. 6 through 8, in addition
to FIGS. 3 and 4, the adhesive tape supply wheel 56 is
illustrated. The adhesive tape supply wheel 56 is
configured to rotatably mount on to the supply wheel
mounting shaft 76 and comprises a supply gear 104 and a
supply advancement cap 106. The supply gear 104 and the
advancement cap are configured to hold the roll of
adhesive segment-laden carrier release tape 52
therebetween.
[0052] Accordingly, the supply gear 104 includes a
circular base 108 having several openings or cut-outs 116
formed therein. In between each opening 116, extension
arms 117 are included, adding rigidity to the base portion
108 of the supply gear 104. The supply gear 104 further
includes front and back surfaces 108 and 110,
respectively, and a plurality of gear teeth 112 formed
around an edge 114 thereof. The front surface 108 of the
supply gear 104 includes a tubular shaft 118 with a
plurality of elongated ribs 120 formed therein for
securely receiving the roll of adhesive segment-laden
carrier release tape 52. It will be recognized by those
skilled in the art that the tubular shaft 118 can be
configured in any manner that permits the supply roll of
adhesive tape to be received thereon, e.g. depending on
14
CA 02637873 2008-07-16
the size and shape of the core onto which the adhesive
laden carrier tape 52 is wound.
[0053] As best illustrated in FIG. 6, the supply gear
104 is formed so that the back surface 110 includes at
least one arcuate arm 126 extending outwardly from at
least one of the extension arms 117. The arcuate arms 126
include an outwardly projecting tang 122 configured to
engage at least one of the teeth 74 formed in the rear
housing portion 66. During use of the adhesive applicator
50, the tangs 122 prevent rotation of the supply wheel 56
in a direction opposite the dispensing direction, and
thus, prevent the carrier release tape 52 from coming
loose within the applicator housing 62.
[0054] As best illustrated in FIGS. 7 and 8, the
advancement cap 106 is substantially circular including a
base 128 having front and back surfaces 130 and 132,
respectively. The base 128 includes an opening 134 formed
therein and arcuate extensions 136 projecting from the
back surface 132 thereof. The arcuate extensions 136 are
laterally spaced apart and sized to fit within the tubular
shaft 118 of the supply gear 104. As will be appreciated,
when the applicator 50 is assembled, arcuate extensions
136 are inserted into the tubular shaft 118 securing the
supply gear 104 and advancement cap 106 together with the
roll of adhesive segment-laden carrier release tape 52
securely positioned therebetween. The front surface 130
of the advancement cap 106 includes a plurality of spaced-
apart ridges 138 that permit the supply wheel 56 to be
manually advanced if desired.
[0055] Preferably, each of the supply gear 104 and the
advancement cap 106 are constructed of a single piece of
material; however, they may be constructed of multiple
pieces and assembled together, as will be well known to
those skilled in the art.
CA 02637873 2008-07-16
[0056] Turning, next to FIGS. 9 and 10, in addition to
FIGS. 1 through 4, the take-up wheel 58 is illustrated.
The take-up wheel 58 comprises a take-up gear 140 and a
take-up spool 142. The take-up gear 140 includes a
circular base 144 having a circular opening 146 formed
therein for accommodating the take-up wheel mounting shaft
78, and further includes front and back surfaces 148 and
150, respectively. The back surface 150 of the take-up
gear 140 includes a plurality of gear teeth 152 configured
to operatively interfit with the plurality of gear teeth
112 formed around the edge 114 of the supply gear 104 of
the supply wheel 56, in order to provide an adhesive
applicator 50 with automatic advancement of the carrier
tape as well as simultaneous winding of spent carrier
tape.
[0057] The front surface 148 of the take-up gear 140
includes a tubular shaft 156 with a plurality of
elongated, space-apart ribs 158 extending radially
therefrom. The take-up gear 140 also includes a plurality
of fingers 160 extending outwardly from the front surface
148 of the base 144. Each finger 160 is formed between
two of the ribs located on the tubular shaft 156, and are
sized to provide a friction fit with the take-up spool
142. It will be recognized by those skilled in the art
that the tubular shaft 156, ribs 158 and fingers 160 can
be configured in any manner the permits the take-up spool
142 to be securely but removably secured to the take-up
gear 140.
[0058] The take-up spool 142 is substantially circular
including a base 164 having front and back surfaces 166
and 168, respectively. The base 164 includes an opening
170 formed therein for accommodating the take-up wheel
mounting shaft 78. A tubular shaft 174 having ribs 176
formed therein extends from front surface 166 of the base
164. The diameter of the tubular shaft 174 is sized to
16
CA 02637873 2008-07-16
fit around the tubular shaft 156 and ribs 158 on the take-
up gear 140 thereby securing the take-up spool 142 to the
take-up gear 140. The take-up spool 142 further includes
at least one slot 178, located between at least one of the
ribs 176 on the tubular shaft 174 for securing a free end
of the roll of adhesive segment-laden carrier release tape
52.
[0059] Preferably, each of the take-up gear 140 and the
take-up spool are constructed of a single piece of
material; however, they may be constructed of multiple
pieces and assembled together, as will be well known to
those skilled in the art.
[0060] As best illustrated in FIGS. 1 through 4, the
roller 60 is rotatably secured within the housing 62 using
hub elements 180 and 182. In use, the roller 60 is the
point of application for the adhesive segments 54 as they
are dispensed on to a surface. The hub elements 180 and
182 are substantially identical to each other and are
configured to fit over the roller mounting shaft 80, while
rotatably securing the roller 60 therebetween. It will be
appreciated that the roller 60 may be rotatably secured
within the housing 62 by any means known to those skilled
in the art.
[0061] The roller 60 may be constructed of a silicone
or rubber material to provide the appropriate coefficient
of friction between the roller 60 and the carrier tape to
prevent slipping or unwanted movement of the carrier tape
with respect to the roller 60. Preferably, the roller 60
may be formed of or contain a soft overmolded cushion or
resilient cushion around its external circumference to
permit the roller 60 of the adhesive segment applicator
apparatus 50 to engage non-flat, recessed, difficult to
reach, or unstable surfaces.
[0062] The adhesive segment applicator apparatus 50 may
also include a cover or cap 190 that is hingedly attached
17
CA 02637873 2008-07-16
to the housing 62 with a fastener 192 and/or a cap can be
removably mounted or snapped on to the applicator housing
62 in order to cover the adhesive segments on the carrier
tape and also to protect the roller 60.
[0063] Turning next to FIGS. 11 through 14, in addition
to FIGS. 1 through 4, assembly and operation of the
adhesive applicator 50 of the present invention is
illustrated. The supply wheel 56 is rotatably mounted
within the rear housing portion 66 by inserting the supply
gear 104 on to the supply wheel mounting shaft 76, loading
and securely mounting a roll of adhesive segment-laden
carrier release tape 52 thereto and securing it in place
using the advancement cap 106. As illustrated in the
FIGS., the roll of adhesive segment-laden carrier release
tape 52 is loaded on to the supply wheel 56 with the
adhesive segments 54 disposed on the outside or exposed
surface of the carrier tape.
[0064] Likewise, the take-up wheel 58 is rotatably
mounted within the rear housing portion 66 by inserting
the take-up gear 140 on to the take-up wheel mounting
shaft 78, securely mounting the free end of the roll of
adhesive segment-laden carrier release tape 52 within one
of the slots 178 on the take-up spool 142 and securing it
into place on the take-up gear 140.
[0065] As illustrated in FIGS. 3, 13 and 14, once
installed on the take-up gear mounting shaft 78, it can be
seen that a portion of the gear teeth 152 on the take-up
gear 140 functionally engage a portion of the gear teeth
112 on the edge 114 of the supply gear 104 of the supply
gear 104. Clearly, as the supply wheel 56 rotates (e.g.
is automatically or manually driven in the dispensing
direction of the applicator 50), the operational
interaction of the gear teeth 112 of the supply gear 104
and the gear teeth 152 on the take-up gear 140 causes the
18
CA 02637873 2008-07-16
take-up spool to also rotate. (The take-up gear 140 is
the driven gear).
[0066] Accordingly, FIG. 13 best illustrates the path
of the adhesive segment-laden carrier release tape 52
within the applicator 50. Once mounted on to the supply
wheel 56, the carrier tape travels, with adhesive segments
facing out, from the supply wheel 56, out of the housing
62 and over the roller 60 at the point where an adhesive
segment(s) is dispensed to a surface 200 The spent
carrier tape then continues over the roller 60, enters the
housing 60 and passes over the roll of adhesive segment-
laden carrier release tape 52 where it is held in place
within the housing 60 by the exposed adhesive 54 on the
remaining roll of adhesive segment-laden carrier release
tape 52. The free end of the roll of adhesive segment-
laden carrier release tape 52 is mounted to the take-up
wheel, and spent carrier tape is wound thereon. It will
be appreciated that due to the respective sizes of the
supply wheel 56 and the take-up wheel 58, a limited amount
of slip or slack in the carrier tape is permitted inside
the housing 62.
[0067] Finally, after the roll of adhesive segment-
laden carrier release tape 52 is properly threaded, the
housing 62 is secured together by aligning the locking
pins 82 and side edge opening 75 in the rear housing
portion 66 with the locking pins 98 and side edge opening
91 in the front housing portion 64. In this way, each of
the mounting shafts 76, 78 and 80 in the rear housing
portion 66 will be aligned and engaged with each of the
first, second and third prongs 90, 92 and 94 in the front
housing portion 64. The front and rear housing portions
64 and 66 are then secured together and locked into
position by pushing the housing components together. Once
assembled, it can be seen that a portion of the roller 60
19
CA 02637873 2008-07-16
is outside of the housing 62 to facilitate application of
the adhesive to a work-piece or surface.
[0068] In certain preferred embodiments of the present
invention, the applicator 50 is configured to be
disposable, i.e. the housing components are not separable
once assembled so that once the adhesive on the roll of
adhesive segment-laden carrier release tape is used, the
roll is not replaceable. In these embodiments, the
applicator housing 62 and each of the components,
including the supply wheel, take-up wheel and roller are
constructed of an easily disposable, and most preferably
recyclable, material.
[0069] However, consistent with the broader aspects of
the invention, and as well known to those skilled in the
art, the adhesive applicator 50 can be designed to be
reusable, including the ability to easily separate the
housing components 64 and 66 and replace an empty roll of
adhesive segment-laden carrier release tape with a new
roll of adhesive segment-laden carrier release tape.
[0070] As illustrated in FIGS. 11 through 14, the
adhesive segment applicator apparatus 50 of the present
invention can be used to dispense adhesive to a workpiece
and automatically advance the carrier tape to expose
another adhesive segment to the workpiece. To operate the
adhesive segment applicator 50 of the present invention,
the adhesive segment-laden carrier release tape 52 is
installed as described above, and an adhesive segment 54
is exposed at the roller 60 of the adhesive segment
applicator 50. As illustrated in FIG. 11, the roller 60,
containing the adhesive segment 54, is placed in contact
with the intended workpiece or application surface 200.
Then, as illustrated in FIG. 12, the adhesive segment 54
is then applied to the intended surface 200 by contacting
the adhesive segment 54 to the surface 200.
CA 02637873 2008-07-16
[0071] The carrier release tape is advanced by motion
of the application process. In particular, as the
adhesive segment 54 is applied to a surface 200, e.g., by
moving the adhesive segment applicator apparatus 50 across
the surface 200 in the direction 210, the roller 60
rotates in the direction 212.
[0072] By virtue of the second surface 53 of the spent
carrier tape being held in place by the adhesive segments
54 on the roll of adhesive segment-laden carrier release
tape 52 on the supply wheel 56, rotation of the roller 60,
drives the supply wheel 56 in direction 216, causing the
spent carrier tape to be drawn into the housing 62 in the
direction 214 and advances the adhesive laden carrier tape
in the direction 220. By nature of the externally exposed
adhesive segments 54 on the roll of adhesive segment-laden
carrier release tape 52, the second surface 53 of the
spent carrier release tape adheres to the adhesive
segments 54 on the wound roll of adhesive segment-laden
carrier release tape 54 on the supply wheel 56 and is held
in place. However, because the second surface 53 of the
carrier release tape has a release property different from
that of the first surface 51 the adhesive segments 54 do
not adhere to it as strongly as they do to the first
surface 51, the carrier tape can be advanced across the
wound roll of adhesive segment-laden carrier release tape
52 without pulling off adhesive segments 54 from the roll.
[0073] In turn, the supply wheel 56 drives the take-up
wheel 58 in the direction 218, thereby winding the spent
carrier tape on to the take-up spool 142. Thus, an
adhesive segment applicator apparatus 50 in accordance
with the present invention and can be used easily to
deposit a series or row of adhesive segments 53 along a
work piece surface 200 and also wind spent carrier tape
with a single motion, and using a single hand.
21
CA 02637873 2008-07-16
[0074] Turning for the moment to FIG. 14, it can be
seen that the opening 100 provides the applicator 50 with
a manual advancement mechanism. In particular, if the
roll of adhesive segment-laden carrier release tape 52
comes loose within the housing 62 and/or the automatic
advancement feature of the applicator 50 is not working
properly, the adhesive segments can be advanced manually.
Using a finger or thumb, the user can rotate the supply
wheel by gripping or moving the ribs 138 in the
operational direction 216. As will be appreciated, even
if the supply wheel, and thus they adhesive segments, are
manually rotated, this motion will still cause
simultaneous winding of the spent carrier tape on to the
take-up wheel as described above.
[0075] Although an exemplary embodiment of the adhesive
segment applicator apparatus of the present invention has
been shown and described with reference to particular
embodiments and applications thereof, it will be apparent
to those having ordinary skill in the art that a number of
changes, modifications, or alterations to the invention as
described herein may be made, none of which depart from
the spirit or scope of the present invention. All such
changes, modifications, and alterations should therefore
be seen as being within the scope of the present
invention.
22
