U.S. patent application number 09/839053 was filed with the patent office on 2001-08-16 for flatbed lamination machine.
Invention is credited to Boyer, John James, Pourmand, Nasser.
Application Number | 20010013395 09/839053 |
Document ID | / |
Family ID | 23598764 |
Filed Date | 2001-08-16 |
United States Patent
Application |
20010013395 |
Kind Code |
A1 |
Pourmand, Nasser ; et
al. |
August 16, 2001 |
Flatbed lamination machine
Abstract
A lamination machine for adhesively heat laminating adjacent
surfaces of two lengths of material to each other. The machine
includes a flatbed pre-laminating station with upper and lower
pre-lamination conveyor belts and banks of heater components
immediately above and below. At least one pre-lamination belt is
vertically movable to establish and adjust a gap between belts
while its associated bank of heating elements is vertically
pressuredly movable to thereby tightly maintain proximity of heater
elements, belts, and laminate materials. Situated immediately
downstream is a pressure roller independently vertically movable to
establish and adjust laminate gap distance and, during lamination
operation, tensioned against a lower conveyor belt guide roller and
movable by a roller pressure driver toward the guide roller. A
flatbed cooling station is situated downstream from the pressure
roller and includes opposing cooling station conveyor belts
separate from those of the pre-laminating station to form a cooling
passage therebetween whose height is established and adjusted by
independent vertical movement of at least one belt, while its
associated bank of cooling elements is vertically pressuredly
movable to thereby tightly maintain proximity of cooling
components, belts, and laminate materials in the cooling station.
The pre-lamination and cooling station conveyor belts remain flat
during operation and thus do not experience air gap production
above and below heating and cooling components and consequent
production of temperature inconsistencies. Further, the pressure
roller position restricts air gap production on either side
thereof, thereby maximizing temperature consistency throughout
pre-lamination and cooling.
Inventors: |
Pourmand, Nasser; (Encino,
CA) ; Boyer, John James; (Yorba Linda, CA) |
Correspondence
Address: |
STETINA BRUNDA GARRED & BRUCKER
SUITE 250
75 ENTERPRISE
ALISO VIEJO
CA
92656
US
|
Family ID: |
23598764 |
Appl. No.: |
09/839053 |
Filed: |
April 20, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09839053 |
Apr 20, 2001 |
|
|
|
09404239 |
Sep 23, 1999 |
|
|
|
6227271 |
|
|
|
|
Current U.S.
Class: |
156/555 |
Current CPC
Class: |
B30B 15/34 20130101;
B32B 37/1027 20130101; Y10T 156/1741 20150115; B32B 2305/022
20130101; B30B 5/06 20130101; B32B 37/12 20130101; B32B 2305/18
20130101 |
Class at
Publication: |
156/555 |
International
Class: |
B31F 005/00 |
Claims
1. A lamination machine for adhesively heat laminating adjacent
surfaces of two lengths of material to each other, the machine
comprising: a) a flatbed pre-laminating station comprising upper
and lower continuous opposing pre-lamination conveyor belts
disposed one above the other to form a lamination passage
therebetween having an entrance through which two lengths of
material can enter for continued travel through the lamination
passage to a pre-laminating station exit, with at least one of said
belts independently vertically movable to establish and adjust
height of said lamination passage; b) a bank of upper heater
components positioned immediately above and in contact with the
upper pre-lamination conveyor belt and a bank of lower heater
components positioned immediately below and in contact with the
lower pre-lamination conveyor belt for heating heat-sensitive
adhesive disposed between two lengths of material when said lengths
travel through the pre-laminating station, with at least one of
said bank of upper heater components and said bank of lower heater
components pressuredly movable toward the pre-lamination conveyor
belts to thereby tightly maintain said belts spatially; c) a
lamination pressure roller situated immediately downstream from the
pre-laminating station exit and tensioned against a conveyor belt
guide roller situated beneath the lower conveyor belt and in
alignment with the lamination pressure roller, said pressure roller
pressuredly movable by a roller pressure driver toward the said
guide roller and independently vertically movable for establishing
and adjusting distance between the pressure roller and guide
roller; d) a flatbed cooling station situated immediately
downstream from the pressure roller and comprising upper and lower
continuous opposing cooling station conveyor belts disposed one
above the other to form a cooling passage therebetween having an
entrance through which a laminated product can travel after
emergence from beneath the pressure roller for continued travel
through the cooling passage to a cooling station exit, with at
least one of said belts independently vertically movable to
establish and adjust height of said lamination passage; and e) a
plurality of respective cooler components positioned immediately
above and immediately below the upper and lower cooling station
conveyor belts for cooling laminated product subsequent to
lamination thereof when said product travels through the cooling
zone.
2. A lamination machine as claimed in claim 1 wherein the bank of
upper heater components is movable and the bank of lower heater
components is stationary.
3. A lamination machine as claimed in claim 1 wherein the at least
one bank of heater components is pneumatically pressuredly movable
by at least one pneumatic cylinder.
4. A lamination machine as claimed in claim 1 wherein the roller
pressure driver is pneumatically powered.
5. A lamination machine as claimed in claim 1 additionally
comprising a pre-lamination preparation station disposed
substantially immediately upstream from said entrance to the
pre-laminating station, said preparation station comprising at
least one heat emitter for warming at least one length of material
prior to entry of said length into the lamination passage.
6. A lamination machine as claimed in claim 5 wherein the
preparation station additionally comprises an adhesive applicator
for applying lamination adhesive on a lower length of material
prior to an upper length of material covering said lower length.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] (Not Applicable)
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] (Not Applicable)
FIELD OF THE INVENTION
[0003] This invention relates in general to lamination equipment
for adhesively heat laminating two or more lengths of material to
each other to form a laminated product, and in particular, to a
flat-bed lamination machine having individual heating and cooling
zones each having dedicated tautly-maintained conveyor belt systems
for moving material and having disposed between the zones a
lamination pressure roller cooperatively aligned with a conveyor
belt guide roller for laminate production.
BACKGROUND OF THE INVENTION
[0004] Lamination is an extremely important process in the
production of a myriad of goods. Such lamination generally involves
the bonding of adjacent surfaces of two or more lengths of
different textile products to each other with heat-sensitive
adhesive. The two lengths typically are fed into a lamination
machine where both heat and physical pressure are applied to
consequently activate the adhesive and retain the lengths together
as a laminated product. Non-limiting examples of such laminated
products include garments with backings, wadding, or decorative
panels, carpets and draperies with backings and linings, furniture
upholstery and bedding covers, and scores of other domestic and
industrial commodities.
[0005] While lamination machines are known in the art, these
machines provide a single conveyor belt system of two opposing
rotating belts between which two lengths of material travel and are
laminated by opposing pressured rollers after the lengths of
material are heated during belt travel in a heating zone to a
lamination temperature. After such lamination, the resulting
laminated product is cooled and made available for final use.
Because of travel distance from initial entrance in the conveyor
belt system to final exit after cooling, the two opposing belts
thereof have a tendency to sag while moving fabric lengths and
resultantly cause air gaps between heating components and the
undersides of adjacent belt sites. These air gaps interfere with
heat delivery, and therefore heat regulation, in the heating zone
and can result in inferior lamination of two lengths of material.
It is therefore apparent that a need is present for a lamination
machine where heat delivery and regulation is controlled.
Accordingly, a primary object of the present invention is to
provide a lamination machine in which the spatial relation between
heating components and respectively adjacent conveyor belts is
maintained to deliver generally standardized heat quantities along
the entire length of a heating zone of the machine.
[0006] Another object of the present invention is to provide a
lamination machine where a bank of upper heater components are
positioned immediately above and in contact with the upper
pre-lamination conveyor belt while a bank of lower heater
components are positioned immediately below and in contact with the
lower pre-lamination conveyor belt, with at least one of the banks
being pneumatically pressure driven to be forced against the moving
belts for non-airgap belt position maintenance.
[0007] Still another object of the present invention is to provide
a lamination machine having a pre-laminating station and a cooling
station served by separate opposing upper and lower conveyor belts,
with the pre-laminating station having the banks of heater
components.
[0008] Yet another object of the present invention is to provide a
lamination machine wherein a pressure drivable lamination roller
resides between the pre-laminating station and the cooling station
and is pressured against a guide roller serving the lower conveyor
belt of the lamination station.
[0009] These and other objects of the present invention will become
apparent throughout the description thereof which now follows.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention is a lamination machine for adhesively
heat laminating adjacent surfaces of two lengths of material to
each other. The machine comprises, first of all, a flatbed
pre-laminating station comprising upper and lower continuous
opposing pre-lamination conveyor belts disposed one above the other
to form a lamination passage therebetween having an entrance
through which two lengths of material can enter for continued
travel through the lamination passage to a pre-laminating station
exit. The upper conveyor belt of the pre-laminating station is
independently vertically movable to thereby establish and adjust
the height of gap between the upper and lower conveyor belts such
that a wide range of thicknesses of materials to be laminated can
be accommodated. A bank of upper heater components is positioned
immediately above and in contact with the upper pre-lamination
conveyor belt and a bank of lower heater components is positioned
immediately below and in contact with the lower pre-lamination
conveyor belt. The banks of heater components function to heat
heat-sensitive adhesive disposed between two lengths of material
when the lengths travel through the pre-laminating station, with at
least one of the banks being pressuredly movable by a bank pressure
driver toward the pre-lamination conveyor belts to thereby tightly
maintain the belts spatially.
[0011] Situated immediately downstream from the pre-laminating
station exit is a lamination pressure roller tensionable against a
conveyor belt guide roller situated beneath the lower conveyor belt
and in alignment with the lamination pressure roller. As with the
upper conveyor belt of the pre-laminating station, the pressure
roller is independently vertically movable to likewise adjust the
height of the gap between it and the guide roller. The lamination
pressure roller is also pressuredly movable against the guide
roller to thereby accomplish lamination pressure on lengths of
material traveling between the pressure and guide rollers. A
flatbed cooling station is situated immediately downstream from the
pressure roller and comprises upper and lower continuous opposing
cooling station conveyor belts separate from those of the
pre-laminating station and disposed one above the other to form a
cooling passage therebetween having an entrance through which a
laminated product can travel after emergence from beneath the
pressure roller for continued travel to a cooling station exit. As
with the upper conveyor belt of the pre-laminating station, the
upper conveyor belt of the cooling station is likewise
independently vertically movable to thereby establish and adjust
the height of the gap between the upper and lower cooling station
conveyor belts. Two respective banks of cooler components are
positioned immediately above and immediately below the upper and
lower cooling station conveyor belts for cooling a laminated
product subsequent to lamination thereof when the product travels
through the cooling zone. As with the heater component banks
described above, at least one of the cooler component banks
likewise is pressuredly movable toward the conveyor belts to
thereby maintain a tight spatial relationship between the two
opposing belts.
[0012] As is thus apparent, two types of vertical movement are
provided to components of each of the pre-laminating station, the
lamination pressure roller, and the cooling station. Specifically,
the belts and roller are vertically movable first to establish and
adjust gap height for layers of material to pass, and second to
provide pressure against the layers during pre-lamination heating,
lamination adhesion, and post-lamination cooling. Because the banks
of heater components are pressure driven as described, the
pre-lamination conveyor belts remain in a substantially flat
position during belt operation and thereby do not experience air
gap production and consequent production of temperature
inconsistencies within the pre-laminating station. Further, because
the lamination pressure roller is tensioned against an aligned
conveyor belt guide roller situated beneath the lower conveyor
belt, no air gap production occurs immediately preceding the
interface of the rollers between which lamination fabric travels
since pressure of the pressure roller becomes one with pressure of
guide roller of the lower conveyor belt. Finally, because the
cooling station is separate, travel between its opposing cooling
station conveyor belts is relatively short and consequently
promotes taut contact with cooler components and consequent
maximization of cooler component capability in readying
newly-produced laminated product.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0013] An illustrative and presently preferred embodiment of the
invention is shown in the accompanying drawings in which:
[0014] FIG. 1 is a side elevation schematic view of a prior art
lamination machine;
[0015] FIG. 2 is a side elevation schematic view of a lamination
machine according to the present invention
[0016] FIG. 3 is a side elevation schematic view in enhanced detail
of the lamination machine of FIG. 2; and
[0017] FIG. 4 is an end elevation schematic view in enhanced detail
of the lamination machine of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring first to FIG. 1, a schematic illustration of a
prior art lamination machine 10 is illustrated. As there shown, the
prior art machine 10 includes a heating zone 12, a pair of opposing
lamination rollers 14, 16, and a laminated-product cooling zone 18.
A single pair of opposing upper and lower conveyor belts 20, 22
move lengths 24, 26 of material through the heating zone 12,
between the lamination rollers 14, 16, and through the cooling zone
18 for final departure from the machine exit 28. Because of the
length of the belts 20, 22 and the variation of thicknesses of
materials that must be accommodated as occasioned by the lamination
rollers 14, 16, an air gap 30 can develop between the lower
conveyor belt 22 and heating and cooling elements 32, 34
immediately before and after the lamination rollers 14, 16. This
air gap 30 creates an untoward distance between the heating and
cooling elements 32, 34 and the material riding on the lower belt
22 which can result in temperature inconsistencies and temperature
control difficulties. This undesirable non-precise control of
temperature can adversely affect laminar adhesion and thus result
in the production of a sub-standard laminated end product.
[0019] The lamination machine 40 of the present invention, as shown
in FIGS. 2-4, overcomes such temperature variations. As
illustrated, the lamination machine 40 provides a flatbed
pre-lamination station 42 where two lengths 44, 46 of material,
here non-limitedly exemplified as fabric and foam, respectively,
are fed for lamination preparation. In particular, the
pre-laminating station 42 has upper and lower continuous opposing
pre-lamination conveyor belts 48, 50 disposed one above the other
to form a lamination passage 52 therebetween having an entrance 54
through which the two lengths 44, 46 of material can travel to a
pre-laminating station exit 56. As described later, height of the
lamination passage 52 (the gap between the upper and lower conveyor
belts 48, 50) is established and adjusted by vertical movement of
the upper belt 48 in relation to the lower belt 50.
[0020] A bank 58 of upper heating components 60 are positioned
immediately above the upper conveyor belt 48, while a bank 62 of
lower heating components 64 are positioned immediately below the
lower conveyor belt 50. These heating components 60, 64 function to
heat heat-sensitive adhesive disposed between the two lengths 44,
46 of material as these lengths travel through the pre-lamination
station 42. As illustrated, the lower conveyor belt 50 rides
directly upon the lower heating components 64, while the bank 58 of
upper heating components 60 is vertically movable as illustrated by
arrows 66 to create pressure against the inside of the upper
conveyor belt 48 and consequent pressure against layers of material
passing within the pre-lamination station 42. As shown in FIG. 2,
vertical movement of the bank 58 of upper heating components 60 is
accomplished by standard heating-component pneumatic cylinders 72,
but can also be accomplished hydraulically or mechanically, as with
a scissor jack, as would be recognized. In addition to vertical
movement of the bank 58, the entire assembly 59 encompassed by the
upper conveyor belt 48 is vertically movable to thereby establish
and adjust the height of the gap 61 of the pre-lamination station
42 between the upper and lower conveyor belts 48, 50. As shown in
FIG. 3, standard pneumatic cylinders 68 separate from the heating
component pneumatic cylinders 72 function to raise and lower the
assembly 59 to thereby adjust the gap 61 in accord with the
thickness of layers of material passing within the pre-lamination
station 42. Once again, it is to be understood, of course, that
pneumatically driven movement as described throughout can be
replaced by mechanically driven or hydraulically driven movement as
would be apparent to the ordinary-skilled artisan. Belt-driven
motor 70 functions to conventionally move all conveyor belts.
[0021] Immediately downstream from the exit 56 of the
pre-lamination station 42 is a lamination pressure roller 74
tensioned against a conveyor belt guide roller 76 situated beneath
the lower conveyor belt 50 and in vertical alignment with the
pressure roller 74. The entire pressure roller 74 is movable
vertically via a pneumatic cylinder 75 to establish and adjust the
gap between it and the guide roller 76, while a conventional
pneumatic cylinder 78 functions as a roller pressure driver to
tension the pressure roller 74 against the guide roller 76 to
accomplish laminar bonding. In order to assure unimpeded travel of
laminate material into the cooling station 80, a plenum 47 can be
situated immediately beyond the roller 74. The plenum 47 has a
series of apertures immediately below a laminated layered product
90 passing there over and from which pressurized air generated by a
standard air compressor 49 is directed after delivery thereto
through a conduit 51 to maintain the product 90 in a direct path
into a cooling station 80. In a like manner as with the
pre-lamination station 42, the lower conveyor belt 84 of the
flatbed cooling station 80 rides directly upon the lower cooler
components 94, while the bank 91 of upper cooler components 97 is
vertically movable as illustrated by arrows 66 to be movable to a
position to create pressure against the inside of the upper
conveyor belt 82 and consequent pressure against layers of material
passing within the cooling passage 86. As shown in FIG. 2, vertical
movement of the bank 95 of upper cooler components 97 is
accomplished by standard cooler-component pneumatic cylinders 75.
In addition to vertical movement of the bank 95, the entire
assembly 79 encompassed by the upper conveyor belt 82 is vertically
movable to thereby establish and adjust the height of the gap 63 of
the cooling passage 86 between the upper and lower conveyor belts
82, 84. As shown in FIG. 4, standard pneumatic cylinders 89
separate from the cooler-component pneumatic cylinders 75 function
to raise and lower the assembly 79 to thereby adjust the gap 63 in
accord with the thickness of layers of material passing within the
cooling passage 86. Cooling of a laminated layered product 90 prior
to its discharge through the exit 92 is thereby accomplished. A
standard support structure 95 can be integral with the machine 40
to thereby maintain an appropriately situated work level.
[0022] FIG. 2 additionally shows a preparation station 100
immediately upstream from the entrance 54 to the pre-lamination
station 42. The preparation station 100 can include an adhesive
applicator 102 such as an electrostatic distribution unit 104 for
applying lamination adhesive on a lower length of material 46 fed
from a roll 106 prior to its coverage by a cooperating upper length
44 likewise fed from a roll 108. One or more heat emitters 110, 112
such as infrared ovens can be provided to for warming of lengths
44, 46 of material prior to entry into the lamination passage 52.
As appropriate, a standard support conveyor belt 114 can be
included with the preparation station 100 to aid in material
movement.
[0023] In use, lengths 44, 46 are fed as shown through the
preparation station 100 for adhesive application and then into the
lamination passage 52 of the pre-lamination station 42 wherein
fixed, quantifiable pressure is applied. The two lengths 44, 46 are
slowly moved by the upper and lower conveyor belts 48, 50 through
the pre-lamination station 42 while being heated by the upper and
lower heating components 60, 64. Adequate heat is applied to assure
activation of lamination adhesive. The lengths 44, 46 eventually
emerge from the exit 56 of the pre-lamination station 42 for
immediate movement beneath the pressure roller 74 where actual
laminar bonding occurs. Thereafter, the now laminated product 90
enters the flatbed cooling station 80 for cooling and final exit
from the exit 92 as a finished end product. As is evident from FIG.
2, the cooperative pressure engagement of the pressure roller 74
with the vertically aligned conveyor belt guide roller 76
accomplishes maintenance of the upper and lower pre-lamination
conveyor belts 48, 50 in contact with the upper and lower heating
components 60, 64, while the pneumatically controlled upper bank 58
pressured against the upper conveyor belt 48 assures contact of the
heating components 60 with the belt 48. The independent upper and
lower cooling station conveyor belts 82, 84 of the cooling station
80 cooperate with each other as shown in FIG. 2 to likewise
maintain a flatbed configuration. As is therefore evident, both
heating and cooling components remain in contact with respective
conveyor belts and thus prohibit air gap production therebetween,
resulting, of course, in efficient maintenance of desired
temperature values throughout both the pre-lamination station 42
and the cooling station 80.
[0024] While an illustrative and presently preferred embodiment of
the invention has been described in detail herein, it is to be
understood that the inventive concepts may be otherwise variously
embodied and employed and that the appended claims are intended to
be construed to include such variations except insofar as limited
by the prior art.
* * * * *