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A thermoplastic material processing method and system including an integrated melting, pressurizing and dispensing unit and a regulated feed supply system to improve overall performance by only heating the amount of material needed and minimizing the time it is at raised temperatures. The system inc

A thermoplastic material processing method and system including an integrated melting, pressurizing and dispensing unit and a regulated feed supply system to improve overall performance by only heating the amount of material needed and minimizing the time it is at raised temperatures. The system includes a compact heat exchanger consisting of a plurality of thin heater plates arranged primarily parallel and spaced closely together to form small spaces therebetween. This puts all thermoplastic material in close proximity with the heated surfaces thus improving the overall melting process. The heat exchanger can include heater plates arranged in a radial or fan orientation and a grid of thin heated fins set within a heated enclosure.

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What is claimed is: 1. An apparatus for melting solid particulate material to melted material having a final application temperature suitable for immediate dispensing at an application site, comprising: a. a housing; b. an inlet associated with said housing for receiving material to be melted; c. a

What is claimed is: 1. An apparatus for melting solid particulate material to melted material having a final application temperature suitable for immediate dispensing at an application site, comprising: a. a housing; b. an inlet associated with said housing for receiving material to be melted; c. a plurality of heater plates spaced closely together generally within said housing, each heater plate comprising i. an upper portion, ii. a lower portion, iii. at least one first layer comprising a thermally conductive and electrically insulative material, iv. at least one electrical resistance heater element operatively associated with said conductive material, said heater element extends substantially the length and width of said heater plate and maintains substantially the entire exterior surface of said heater plate at substantially the same temperature while either said solid particulate material, said melted material, partially melted material or a mixture of solid, partially melted and melted material passes from said upper portion to said lower portion at a wide range of flow rate and targeted application temperature conditions, and v. at least one second layer comprising a thermally conductive and electrically insulative material, whereby said at least one electrical resistance heater element is substantially disposed between said first and second layers of thermally conductive and electrically insulative material, whereby said heater plates raise the temperature of said melted material to a final recommended temperature suitable for immediate dispensing at said application site. 2. The apparatus of claim 1, further comprising an outlet for dispensing melted material proximate to said application site. 3. The apparatus of claim 1, wherein said first and second layers of said heater plate are generally flat and are substantially parallel to each other. 4. The heater element of claim 1, wherein said heater plate further comprises a layer of thermally conductive material laminated to both sides of said electrically insulating material. 5. The apparatus of claim 1, wherein said heater plate is coated with a nonstick coating. 6. The apparatus of claim 1, wherein each said heater plate further comprises a means for attaching said plate to said housing. 7. The apparatus of claim 6, wherein said attaching means comprises at least one slot associated with said housing into which said plate can be inserted and maintained. 8. The apparatus of claim 1, wherein the space between two adjacent heater plates is between about 0.1 and 0.4 inches. 9. The apparatus of claim 1, wherein said plurality of heater plates are arranged in a generally parallel orientation. 10. The apparatus of claim 1, wherein each said heater plate has a first face and a second face, said first and second faces being substantially parallel to each other and wherein said plurality of heater plates have a top end and a bottom end and are arranged in a generally radial fan orientation wherein the spacing between said heater plates decreases in the direction of flow of said material from said top end of said heater plate toward said bottom end of said heater plate. 11. The apparatus of claim 1, wherein each of said heater plates has a first outer surface and a second outer surface which are substantially parallel to each other. 12. The apparatus of claim 1, wherein said plurality of heater plates consist of two sets of intersecting sets of plates arranged in two directions so as to form a grid pattern. 13. The apparatus of claim 1, wherein each said heater plate has a thickness of less than or equal to about 0.2 inches. 14. The apparatus of claim 1, wherein each said heater plate has a thickness of about 0.04 inches. 15. The apparatus of claim 1, wherein each said heater plate has a wattage density which varies commensurate with the heat transfer demand load based on the temperature differential of said material flowing through said heater plate. 16. The apparatus of claim 1, further comprising at least one temperature sensor associated with each of said plurality of heater plates and responsive to material load conditions so as to send a signal to a heater element control to adjust wattage as necessary to maintain the surface of said heater plate at a substantially constant temperature while said material flows within said heater plate. 17. The apparatus of claim 1, wherein said at least one heater element is divided into at least two temperature control zones. 18. The apparatus of claim 1, further comprising a sensor for detecting the presence and/or quantity of unmelted material proximate to said inlet. 19. The apparatus of claim 18, wherein sensor comprises a presence-sensing device. 20. The apparatus of claim 1, wherein said at least one heater element is divided into at least one temperature control zone. 21. The apparatus of claim 20, wherein said at least one heater element wattage density varies with the heat transfer demand load along the direction of flow of said material from said upper portion to said lower portion. 22. The apparatus of claim 20, wherein the relationship between the wattage densities versus the distance along said plate is non-linear along the direction of flow of said material from said upper portion to said lower portion. 23. The apparatus of claim 22, wherein said relationship between the wattage densities versus the distance along said plate in the direction of said material flow follows the formula C(1-e-t/τ), where C is a constant, t is time (proportional to the distance along the plate path) and τ is a time constant. 24. The apparatus of claim 20, wherein said wattage density varies in a generally smooth gradient along said heater plate in the direction of said material flow. 25. The apparatus of claim 20, wherein said wattage density varies as a generally step function along said heater plate in the direction of said material flow. 26. The apparatus of claim 1, wherein said outlet includes a bottom having slope to promote drainage of said flowable thermoplastic material. 27. The apparatus of claim 1, further comprising a pump and a nozzle, whereby said plurality of heater plates raise the temperature of said melted material to a final recommended temperature to be used at said application site and said pump increases the pressure of said melted material and said nozzle delivers melted material proximate to said application site. 28. The apparatus of claim 27, further comprising a valve disposed between said pump and said nozzle.