U.S. patent application number 11/135878 was filed with the patent office on 2005-12-01 for foam welding and profile manufacturing system.
Invention is credited to Henderson, Randal, Lauer, Eduardo, Stearly, Mark, Young, Julian.
Application Number | 20050263244 11/135878 |
Document ID | / |
Family ID | 35463404 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050263244 |
Kind Code |
A1 |
Henderson, Randal ; et
al. |
December 1, 2005 |
Foam welding and profile manufacturing system
Abstract
By providing a high speed welding system for fusing adjacent
foam profiles in a continuous manufacturing operation, a unique,
integrated, foam welding and profile manufacturing system is
attained which is capable of producing virtually any desired foam
product from foam extrusions without requiring the use of expensive
molds or forming components, and which significantly reduces
expensive scrap found in prior art construction systems. In
accordance with the teaching of the present invention, any desired
cross-sectional shape or configuration is capable of being
manufactured in fully automated, high-volume, rapid production
conditions, with virtual ease and simplicity. Furthermore, by
employing the present invention, foam profiles which previously
were unattainable due to their structural configurations, are
quickly and easily constructed in a mass production operation.
Inventors: |
Henderson, Randal;
(Franklinton, NC) ; Lauer, Eduardo; (Zebulon,
NC) ; Young, Julian; (Zebulon, NC) ; Stearly,
Mark; (Cary, NC) |
Correspondence
Address: |
Melvin I. Stoltz
51 Cherry Street
Milford
CT
06460
US
|
Family ID: |
35463404 |
Appl. No.: |
11/135878 |
Filed: |
May 24, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60574747 |
May 27, 2004 |
|
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|
Current U.S.
Class: |
156/304.6 ;
156/309.6 |
Current CPC
Class: |
B29C 48/001 20190201;
B29C 66/438 20130101; B29C 66/836 20130101; B29K 2105/04 20130101;
B29C 65/20 20130101; B29C 66/73921 20130101; B29D 24/001 20130101;
B29C 48/0012 20190201; B29C 66/52431 20130101; B29L 2031/003
20130101; B29C 66/8242 20130101; B29C 66/02241 20130101; B29C
66/843 20130101; B29C 65/2092 20130101; B29C 66/524 20130101; B29C
66/43421 20130101; B29C 65/14 20130101; B29C 2793/00 20130101; B29C
66/727 20130101; B29C 48/00 20190201; B29C 48/09 20190201; B29C
66/1142 20130101; Y10T 156/1082 20150115; B29C 66/1162 20130101;
B29C 2793/0036 20130101; B29C 65/103 20130101; B29C 48/11 20190201;
B29C 66/435 20130101; B29C 66/4722 20130101; B29L 2024/00 20130101;
B29C 48/12 20190201; B29C 66/5227 20130101; B29C 2793/0027
20130101; B29L 2031/772 20130101; B29C 2793/009 20130101; B29L
2023/225 20130101; B29C 48/0022 20190201; B29C 53/066 20130101;
B29C 66/02245 20130101; B29L 2024/006 20130101; B29C 2793/0054
20130101; B29C 66/474 20130101 |
Class at
Publication: |
156/304.6 ;
156/309.6 |
International
Class: |
B32B 031/20 |
Claims
Having described our invention, what we claim is new and desire to
secure by Letters Patent is:
1. A process for manufacturing panels of foam thermoplastic
material in a fully automated and high-volume production operation,
said process comprising the steps of: A. establishing a supply of
elongated sections of foam thermoplastic profiles or members each
having a desired cross-sectional shape and a longitudinally
extending, substantially continuous length; B. selecting a first
section and a second section from the supply of foam thermoplastic
profiles or members; C. positioning the first section of the foam
thermoplastic member into juxtaposed, parallel, adjacent, side to
side relationship with the second section of the foam thermoplastic
member; and D. advancing a welding member between adjacent sections
of the foam thermoplastic members for causing the sections to be
securely bonded to each other, thereby forming a fully integrated,
continuous panel comprising a plurality of sections of the foam
thermoplastic members securely bonded to each other:
2. The process defined in claim 1, wherein the welding step is
further defined as comprising the steps of: a) positioning the
welding member in cooperating relationship with the first two
adjacent edges of the two adjacent sections of foam thermoplastic
members, and b) advancing the welding member from a first end of
the first two adjacent edges to the opposed second end of the
adjacent edges of the foam thermoplastic members at a rate of speed
and temperature for causing the edges of the two adjacent sections
to be melted.
3. The process defined in claim 2, wherein the welding step
comprises the further step of c) applying a force to the free edges
of both sections of the foam thermoplastic members for compressing
the melted edges of the sections into secure interengagement with
each other.
4. The process defined in claim 1, wherein the process further
comprises the steps of: E. selecting a third section from the
supply of foam thermoplastic members and positioning the third
section into juxtaposed, parallel, adjacent, side to side
relationship with the second section; and F. advancing the welding
member between the third section and the second section of foam
thermoplastic members for causing the sections to be securely
bonded to each other, thereby forming an enlarged fully integrated
continuous panel.
5. The process defined in claim 4, wherein the process further
comprises the steps of: G. repeatedly selecting additional sections
from the supply of foam thermoplastic members and positioning each
additional section into juxtaposed, parallel, adjacent, side to
side relationship with the previous section; and H. advancing the
welding member between the most recently selected adjacent sections
of foam thermoplastic members for causing the sections to be
securely bonded to each other, thereby further enlarging the fully
integrated, continuous panel.
6. The process defined in claim 5, wherein the section selecting
step and the welding step are repeated until a fully integrated,
continuous panel having a desired overall length has been
achieved.
7. The process defined in claim 1, wherein a plurality of sections
of foam thermoplastic members are simultaneously selected and
placed in juxtaposed, parallel, adjacent, side to side relationship
and the welding member is further defined as simultaneously
advancing through the plurality of sections of thermoplastic
members for forming an enlarged panel in a single welding
operation.
8. The process defined in claim 1, wherein each section of foam
thermoplastic member is further defined as comprising a
cross-sectional shape selected from the group consisting of
rectangles, squares, parallelograms, polygons, ellipses, circles,
ovals, combinations thereof, and portions thereof.
9. The process defined in claim 8, wherein the cross-sectional
shape of the foam thermoplastic member is further defined as
comprising a combination of separate and distinct cross-sectional
shapes integrally formed as a single component.
10. The process defined in claim 9, wherein the cross-sectional
shape of the foam thermoplastic members is further defined as
comprising one selected from the group consisting of configurations
having a T-shape, an H-shape, a W-shape, an E-shape, a Y-shape, a
D-shape, an F-shape, a V-shape, a B-shape, a Z-shape, and the
like.
11. The process defined in claim 10, wherein the cross-section of
each section of foam thermoplastic members is further defined as
being solid.
12. The process defined in claim 8, wherein the cross-section of
each section of foam thermoplastic members is further defined as
comprising at least one aperture longitudinally extending through
substantially the entire length thereof.
13. The process is defined in claim 1, when the welding member is
further defined as comprising one selected from the group
consisting of heated wires, hot metal surfaces, and nozzles
providing hot air.
14. The process defined in claim 1, comprising the additional step
of: E. forming elongated strips of foam thermoplastic material
having a unique configuration by longitudinally cutting a plurality
of strips from the formed panel member with each of said strips
having a desired size and shape.
15. The process defined in claim 14, wherein each of the elongated
strips is further defined as being formed by cutting the formed
panel member along a cut line which extends substantially
perpendicularly to the longitudinal axis formed by the bonding of
adjacent sections of foam thermoplastic members.
16. The process of defined in claim 1, comprising the additional
step of: E. cutting portions of the foamed panel member in a
plurality of desired positions for producing a panel member having
a unique configuration incapable of being produced by direct
extrusion.
17. A process for manufacturing panels of foam thermoplastic
material in a fully automated and high-volume production operation,
said process comprising the steps of: A. continuously extruding a
foam thermoplastic member in an elongated, longitudinally
extending, substantially continuous length having a desired
cross-sectional shape; B. cutting the elongated foam thermoplastic
member into sections having a desired overall length; C.
positioning a first section of the foam thermoplastic member into
juxtaposed, parallel, side to side, adjacent relationship with a
second section of the foam thermoplastic member; D. advancing a
welding member between adjacent sections of the foam thermoplastic
member for causing the sections to be securely bonded to each
other, thereby forming a fully integrated, continuous panel
consisting of a plurality of sections of the foam thermoplastic
member securely bonded to each other.
18. The process defined in claim 17, wherein a plurality of
sections of foam thermoplastic members are placed in juxtaposed,
parallel, adjacent, side to side relationship and the welding
member is further defined as simultaneously advancing through the
plurality of sections of thermoplastic members for forming an
enlarged panel in a single welding operation.
19. The process defined in claim 17, wherein the welding member is
further defined as being repeatedly advanced through two adjacent
sections of the thermoplastic member, thereby forming the enlarged
panel by repeatedly bonding a single section of the foam
thermoplastic member to the previously formed assembly of bonded
foam thermoplastic sections.
20. The process defined in claim 19, wherein a panel having any
desired size and shape is formed by cutting each section of the
foam thermoplastic member into the precisely desired length
segments and advancing additional segments into bonding engagement
with the previously formed and bonded sections until a panel having
the overall desired dimensions has been realized.
21. The process defined in claim 17, wherein the foam thermoplastic
member is continuously formed using an extruder constructed for
producing the foam thermoplastic member in any desired
cross-sectional configuration.
22. The process defined in claim 21, wherein said process comprises
the additional step of: E. advancing the elongated, longitudinally
extending foam thermoplastic member exiting the extruder into
association with a puller member constructed for continuously
drawing the foam thermoplastic member from the extruder and feeding
the foam thermoplastic member to a support plate constructed for
retaining the foam thermoplastic member and cooperating with the
cutting member for enabling the foam thermoplastic member to be cut
in the desired segment lengths.
23. The process defined in claim 22, wherein the welding member is
further defined as being repeatedly advanced through two adjacent
sections of the thermoplastic member, thereby forming an enlarged
panel by repeatedly bonding a single section of the foam
thermoplastic member to the previously formed assembly of bonded
foam thermoplastic sections.
24. The process defined in claim 23, wherein a panel of infinite
length is continuously formed by repeatedly bonding additional
sections of the foam thermoplastic member to the previously formed
assembly of bonded foam thermoplastic sections, with panels of any
desired size being constructed by cutting panel sections of a
desired dimension from the continuously formed panel member.
25. The process defined in claim 1, wherein the continuously
extruded foam thermoplastic member is further defined as comprising
a cross-sectional shape selected from the group consisting of
rectangles, squares, parallelograms, polygons, ellipses, circles,
ovals, and portions thereof.
26. The process defined in claim 25, wherein the cross-sectional
shape of the foam thermoplastic member is further defined as
comprising a combination of separate and distinct cross-sectional
shapes integrally formed as a single component.
27. The process defined in claim 26, wherein the cross-sectional
shape comprises one selected from the group consisting of
configurations having a T-shape, an H-shape, a W-shape, an E-shape,
a Y-shape, a D-shape, an F-shape, a V-shape, a B-shape, a Z-shape,
and the like.
28. The process defined in claim 25, wherein the cross-section of
the foam thermoplastic member is further defined as being
solid.
29. The process defined in claim 25, wherein the cross-section of
the foam thermoplastic member is further defined as comprising at
least one aperture longitudinally extending through substantially
the entire length thereof.
30. The process defined in claim 1, comprising the additional step
of; E. forming elongated strips of foam thermoplastic material
having a unique configuration by longitudinally cutting the strip
from the formed panel member with the desired size and shape,
whereby the elongated strips produced represents a configuration
which is incapable of being produced by direct extrusion.
31. The process defined in claim 30, wherein the elongated strip is
further defined as being formed by cutting the formed panel member
along a cut line which extends substantially perpendicularly to the
longitudinal axis formed by the bonding of adjacent sections of
foam thermoplastic.
32. The process defined in claim 1, comprising the additional step
of E. cutting the portions of the formed panel member in a
plurality of desired positions for producing a panel member having
any unique configuration incapable of being produced by direct
extrusion.
33. A process for manufacturing enlarged panels of foam
thermoplastic in a fully automated and high-volume production
operation, said process comprising the steps of: A. continuously
extruding a foam thermoplastic member in an elongated,
longitudinally extending, substantially continuous length having a
desired cross-sectional shape; B. cutting the elongated foam
thermoplastic member into sections having a desired overall length;
C. positioning each section of the foam thermoplastic member into
juxtaposed, parallel, side to side relationship with each adjacent
section of the foam thermoplastic member; D. advancing a welding
member between adjacent sections of the foam thermoplastic member
for causing the sections to be securely bonded to each other,
thereby forming a fully integrated, continuous panel consisting of
a plurality of sections of the foam thermoplastic member securely
bonded to each other; and E. forming elongated strips of foam
thermoplastic material having a unique configuration by
longitudinally cutting the strip from the formed panel member with
the desired size and shape, whereby the elongated strips produced
represents a configuration which is incapable of being produced by
direct extrusion.
34. The process defined in claim 33, wherein the elongated strip is
further defined as being formed by cutting the formed panel member
along a cut line which extends substantially perpendicularly to the
longitudinal axis formed by the bonding of adjacent sections of
foam thermoplastic.
Description
RELATED APPLICATIONS
[0001] This application is related to U.S. Provisional Patent
Application Ser. No. 60/574,747, filed May 27, 2004 entitled FOAM
WELDING AND PROFILE MANUFACTURING SYSTEM.
TECHNICAL FIELD
[0002] This invention relates to the production of foam
thermoplastic profiles or members and, in particular, to an
automated system for welding foam thermoplastic profiles/members to
each other to form enlarged panels and complex geometric
shapes.
BACKGROUND ART
[0003] During the last decade, substantial attention has been
devoted to the production of products from foam thermoplastic
materials for enhancing products and improving the construction and
the manufacturing expenses incurred for such products. In view of
the highly competitive manufacturing costs that have been obtained
from the use of foam plastic materials, the demand for foam plastic
materials has increased, with substantial commercial pressure being
created for improved and enhanced profile shapes and
configurations.
[0004] In this regard, as the desire and demand continues to
increase for incorporating thermoplastic foam profiles in a wide
variety of diverse products, the shape and configuration required
for the thermoplastic foam profiles becomes increasingly varied and
diverse. However, due to the construction methods which exist for
creating thermoplastic foam profiles in the most efficient and cost
effective manner, limitations exist on the profile constructions
and/or configurations which are capable of being achieved. As a
result, various products where thermoplastic foam profiles are
desired are incapable of being satisfied, due to the inability of
thermoplastic foam profiles to be produced for such products in an
economical, cost-effective manner.
[0005] Typically, thermoplastic foam profiles or elongated members
are constructed by a continuous extrusion process. In this process,
the elongated foam profile or member produced incorporates a
single, pre-determined cross-sectional shape or configuration.
Although the cross-sectional shape or configuration can be widely
varied by incorporating various production techniques, the foam
profile or member produced must incorporate the same
cross-sectional shape or configuration throughout the entire length
of the profile/member. Although this process accommodates the
production of thermoplastic foam profiles/members which can be
employed in numerous products and industries, other industries and
products are incapable of enjoying the benefits of the
thermoplastic foam profiles/members which are produced in a high
volume and/or fully automated production operation, due to
requirements for products which cannot employ a profile having a
uniform, longitudinally extending, cross-sectional shape or
configuration.
[0006] In order to accommodate the various products and industries
which require specialized thermoplastic foam product
configurations, special molds must be created for enabling a
precisely constructed foam profile or configuration to be achieved.
Typically, these operations are batch operations, requiring more
labor, production costs, as well as investment for molds and other
equipment required to produce the desired product. In addition,
these prior art production methods typically produce excessive
scrap material, causing substantially increased expenses to be
realized from these prior art methods.
[0007] Consequently, it is a principal object of the present
invention to provide a method for producing uniquely constructed
thermoplastic foam profile configurations in a fully automated and
high volume production operation wherein the foam profile
configurations are incapable of being directly produced by
extrusion.
[0008] Another object of the present invention is to provide a
method for producing uniquely constructed thermoplastic foam
profile configurations, having the characteristic features
described above, which is adaptable for enabling virtually any
desired configuration to be achieved.
[0009] Another object of the present invention is to provide a
method for producing uniquely constructed thermoplastic foam
profile configurations, having the characteristic features
described above, which is capable of operating in a highly
efficient and cost effective process.
[0010] Another object of the present invention is to provide a
method for producing uniquely constructed thermoplastic foam
profile configurations, having the characteristic features
described above, which is capable of operating with a minimum of
scrap material being produced.
[0011] Another object to the present invention is to provide a
method for producing uniquely constructed thermoplastic foam
profile configurations, having the characteristic features
described above, which is capable of operating on a continuous,
high-volume production operation.
[0012] Other and more specific objects will in part be obvious and
will in part to appear hereinafter.
SUMMARY OF THE INVENTION
[0013] By employing the teaching of the present invention, all of
the difficulties, drawbacks, and inabilities or prior art
construction systems have been overcome, and a new, unique, and
fully integrated foam welding and profile manufacturing system is
attained which is capable of producing virtually any desired foam
product from foam extrusions without requiring the use of expensive
molds or forming components, and which significantly reduces
expensive scrap found in prior art construction systems. In
accordance with the teaching of the present invention, any desired
cross-sectional shape or configuration is capable of being
manufactured in fully automated, high-volume, rapid production
conditions, with virtual ease and simplicity.
[0014] In one embodiment of the present invention, the fully
integrated, foam welding and profile manufacturing system of the
present invention employs a unique profile welding operation which
enables adjacent, elongated, foam profile sections to be quickly
and easily integrally welded to each other on a continuing, repeat
basis, in order to form enlarged panels of the elongated foam
profiles in any particular desired overall size and/or shape. In
this regard, each of the elongated, foam profile sections typically
comprise longitudinally extending, foam profiles which have been
previously manufactured with a desired cross-sectional shape or
configuration and have been cut to a desired overall length. By
continuously welding sections of the elongated foam profiles to the
previously welded sections, an enlarged panel having any desired
configuration is quickly and easily attained.
[0015] In addition, in a further aspect of the present invention,
elongated strips are cut from the welded panels in order to attain
an elongated foam profile with a cross-sectional geometry or
profile which would otherwise be incapable of being manufactured
using normal extrusion methods. Furthermore, by repeatedly cutting
the panel into the desired elongated strips, the desired
configuration is capable of being achieved in a high volume, mass
production.
[0016] By employing the present invention, foam profiles which
previously were unattainable due to their structural
configurations, are quickly and easily constructed in a mass
production operation, thereby obtaining these foam profiles in any
desired quantity and with highly competitive pricing. In addition,
the foam profiles are produced with a structural integrity which is
equivalent to or greater than the structural integrity inherent in
such products.
[0017] In addition, the present invention enables complex geometric
thermoplastic foam shapes of any desired three-dimensional
configuration to be produced with the resulting product comprising
either a specific polymer material or a composite of two or more
materials. Furthermore, these products are produced in a continuous
process using rapid, mass production techniques.
[0018] In an alternate embodiment of the present invention, a fully
integrated, foam welding and profile manufacturing system is
realized by incorporating foam extrusion components which produce
an elongated foam profile on a continuous basis with the foam
profile having the desired cross-sectional shape or configuration
for the resulting panel and/or the component strips. By employing
this additional feature of the present invention, the extrusion
system continuously produces the desired elongated, foam profile
which is cut subsequent to its formation into precisely desired
lengths, each of which is then delivered to the welding system for
welding each elongated section to the previously welded sections to
form the desired panel. Thereafter, if desired, the panel is cut
into a plurality of strips having the final configuration
desired.
[0019] As is evident from the foregoing detailed discussion, the
first step in employing the present invention is the production of
an elongated, longitudinally extending, thermoplastic foam profile
which incorporates a precisely desired cross-sectional
configuration. Once the elongated foam profile is formed, the
elongated, longitudinally extending profile is cut into precisely
desired lengths which are either stored for subsequent use or are
delivered directly to the welding system of the present invention.
In those instances where the foam profile sections are stored, the
sections are subsequently delivered to the welding system for the
production of the enlarged panels and/or the uniquely configured
strips formed from the panels.
[0020] During the panel formation process, each section of the
thermoplastic foam profile is positioned in juxtaposed,
longitudinally extending, adjacent, side to side relationship with
another foam profile, and once in position, welding means
longitudinally travel along the entire length of the adjacent
profiles, causing the profiles to be welded into a single
component. By continuously repeating this welding step, enlarged
panels of fully welded foam profiles are achieved.
[0021] Once the enlarged panels of a desired configuration have
been obtained, the panels are automatically advanced through a
contouring station that is setup to cut any desired secondary
cross-sectional shape, which is cut perpendicular to the
longitudinal direction of the extruded profile panels, wherein the
final, desired cutting operation is achieved. In this cutting
operation, the panels are cut into sections in order to form the
precisely desired thermoplastic foam product. In one typical
operation, the panels are cut at an angle which is perpendicular to
the longitudinally extended weld line of each foam profile. In this
way, the resulting product is a complex geometric thermoplastic
foam component which is completely different from the original
configuration and is typically a configuration which is
unattainable from an extruder directly.
[0022] In addition to cross-cutting the welded panels in a
perpendicular direction relative to the longitudinal axis of each
foam profile, the panels may be cut at any desired angle in order
to achieve the particular final configuration. Furthermore,
portions of each panel can be removed prior to final cutting, for
further enhancing the overall shape of each resulting final
product. Regardless of the procedures employed, it is evident that
a unique and continuous thermoplastic foam shape forming and
manufacturing process is realized by the present invention, for
attaining virtually any desired thermoplastic, complex geometric
configuration.
[0023] As is evident from the foregoing discussion, the preset
invention achieves a unique extruded foam profile fusing and
cutting/contouring process in order to form any desired complex
geometric thermoplastic foam shape. In addition, the resulting
product may comprise a specific polymer material or a
multi-material composite of any desired three-dimensional
configuration. Furthermore, the desired configuration is formed in
a cost-effective, continuous operation with a minimum of waste or
scrap material.
[0024] The invention accordingly comprises the several steps and
the relation of one or more of such steps with respect to each of
the others, and the apparatus embodying the features of
construction, combination of elements and arrangement of parts
which are adapted to effect such steps, all as exemplified in the
following detailed disclosure, with the scope of the invention
being indicated in the claims.
THE DRAWINGS
[0025] For a fuller understanding of the nature and objects of the
invention, reference should be had to the following detailed
description taken in connection with the accompanying drawings, in
which:
[0026] FIG. 1 is a diagrammatic or schematic view of one embodiment
of the integrated, foam welding and profile manufacturing system of
the present invention;
[0027] FIG. 2 is a diagrammatic or schematic view depicting a
second embodiment of the overall integrated, foam welding and
profile manufacturing system of the present invention and its
ability to produce complex geometrically shaped foam products;
[0028] FIG. 3 is a further diagrammatic or schematic view depicting
the overall integrated, foam welding and profile manufacturing
system of the present invention and its ability to produce complex
geometrically shaped foam products;
[0029] FIGS. 4 and 5 are diagrammatic or schematic views depicting
alternate welding systems for simultaneously welding a plurality of
elongated foam profiles;
[0030] FIG. 6 is a diagrammatic or schematic view depicting the
integrated, foam welding and profile manufacturing system of the
present invention and its ability to produce multi-material
composite products having complex geometric shapes or
configurations;
[0031] FIG. 7 is a series of cross-sectional views of alternate
configuration for the extruded thermoplastic foam profile; and
[0032] FIG. 8 is a diagrammatic or schematic view depicting the
integrated, foam welding and profile manufacturing system of the
present invention and its ability to produce further multi-material
composite products having complex geometric shapes or
configurations.
DETAILED DISCLOSURE
[0033] By referring to FIGS. 1-8, along with the following detailed
discussion, the construction and operation of the integrated, foam
welding and complex geometric profile manufacturing system of the
present invention can best ne understood. In addition, the ability
of the present invention to achieve complex, geometric,
thermoplastic foam shapes of any desired three-dimensional
configuration and composition is also readily understood. It will
also be understood that variations and alternate construction
details can be employed without deviating from the scope of the
present invention. Consequently, the foregoing Figures, along with
the following detailed discussion, are provided for exemplary
purposes only, and are not intended as a limitation of the present
invention.
[0034] In FIG. 1, an overall, schematic representation of the
principal manufacturing system 20 of the present invention is fully
depicted. As shown for exemplary purposes only, elongated,
longitudinally extending thermoplastic foam profile 21 is depicted
as comprising a generally I-shaped cross-section and has been cut
into a desired overall length. However, as is evident from the
detailed disclosure contained herein, thermoplastic foam profile
section 21 may comprise any desired cross-sectional configuration,
size, shape, or length.
[0035] In addition, in carrying out the present invention, any
desired thermoplastic foam producing composition can be employed
for forming thermoplastic foam profile section 21. As examples of
the wide variety of alternate compositions that can be employed and
effectively used in the present invention, foam profiles may be
formed from one or more selected from the group consisting of
polystyrenes, polyefins, polyethylenes, polybutanes, polybutylenes,
polyurethanes, polyesters, ethylene acrylic copolymers,
ethylene-vinyl-acetate copolymers, ethylene-methyl acrylate
copolymers, ethylene-butyl-acrylate copolymers, ionomers,
polypropylenes, copolymers of polypropylene, and the like.
[0036] In employing the process of the present invention, foam
profile section 21 is placed on support platform 30 in cooperating
relationship with cylinders 29, 29 and movable pusher plate 31. In
this embodiment, cylinders 29, 29 each incorporate axially movable
rods 32 associated therewith, with plate 31 mounted to the
terminating ends of rods 32. As a result, whenever cylinders 29, 29
are activated, rods 32, 32 causes plate 31 to move therewith,
contacting foam profile section 21 forcing section 21 to move in
its entirety in a direction perpendicular to its longitudinal
axis.
[0037] The next step in employing foam welding and profile
manufacturing system 20 of the present invention is the formation
of enlarged panels 22 which comprise a plurality of foam profile
sections 21. In order to form the desired enlarged panels, each
foam profile section 21 is integrally welded to an adjacent,
previously formed, foam profile section 21. In FIG. 1, two foam
profile sections 21, 21 are shown on endless conveyor belt 25,
after having been integrally welded to each other along welded line
26. In addition, a third foam profile section 21 is depicted,
positioned on support plate 30.
[0038] In order to achieve the desired integrally welded
interengagement between two adjacent foam profile sections 21,
welding means 27 is employed. In the embodiment depicted, welding
means 27 comprises a heated rod or wire which is constructed for
being rapidly advanced longitudinally along the facing side edges
of the adjacent foam profile sections 21, 21.
[0039] While rapidly passing by both exposed edges of foam profile
sections 21, 21, the heat emanating from welding means 27 heats the
exposed edges to their melting temperature, enabling the two
adjacent foam profile sections 21, 21 to be securely welded
together along weld line 11. By activating cylinders 29, 29 and
rods 32, pusher plate 31 is activated and forces foam profile
section 21 into secure, contacting, welded interengagement with the
adjacent foam profile profile 21. If desired, conveyor belt 25 may
be stopped and/or reversed in direction, in order to assure the
desired contact and welded interengagement between the two adjacent
foam profile sections is achieved.
[0040] Furthermore, if desired, a holding or stabilizing system can
also be employed for preventing unwanted slippage or movement of
the welded foam profile sections during the process of welding
additional foam profiles thereto. Such holding/stabilizing systems
include abutment of holding members, vacuum conveyors and the
like.
[0041] By continuously repeating this process, any desired number
of foam profile sections 21 are welded together in order to form
enlarged panel 22 having any desired overall size and shape. Once
the desired panel construction is completed, panel 22 is moved off
of conveyor belt 25 for further processing, as needed.
[0042] In FIG. 2, an overall, schematic representation of a second
embodiment of the manufacturing system of the present invention is
fully depicted. As shown, in this embodiment of the present
invention thermoplastic foam producing extruder 40 is employed for
continuously producing elongated, longitudinally extending
thermoplastic foam profile 23. In this embodiment, thermoplastic
foam profile 23 is depicted as comprising a generally I-shaped
cross-section and is formed as a single, elongated, continuous
component. However, as is evident from the detailed disclosure
contained herein, thermoplastic foam profile 23 may comprise any
desired cross-sectional configuration, size, or shape.
[0043] In addition, in carrying out the present invention, any
desired thermoplastic foam producing composition can be employed
for forming thermoplastic foam profile 23. As examples of the wide
variety of alternate compositions that can be employed and
effectively used in the present invention, the foam profiles may be
formed from one or more selected from the group consisting of
polystyrenes, polyefins, polyethylenes, polybutanes, polybutylenes,
polyurethanes, polyesters, ethylene acrylic copolymers,
ethylene-vinyl-acetate copolymers, ethylene-methyl acrylate
copolymers, ethylene-butyl-acrylate copolymers, ionomers,
polypropylenes, copolymers of polypropylene, and the like.
[0044] In order to assure the continuous, free flow of
thermoplastic foam profile 23 from extruder 40, puller 41 is
employed. As depicted, puller 41 is positioned in cooperating
relationship with extruder 40 to continuously advance thermoplastic
foam profile 23 in a longitudinal direction, for enabling further
operations to be performed on the elongated length of thermoplastic
foam profile 23. In order to achieve this desired continuous
longitudinal movement of thermoplastic foam profile 23, puller 41
incorporates a pair of co-operating endless belt assemblies 42 and
43 which are positioned for contacting opposite surfaces of
thermoplastic foam profile 23 and continuously draw
thermoplastic_foam profile 23 from extruder 40 and advance foam
profile 23 in the desired direction. In this way, the desirable
advantages of a continuous, mass-produced operation are
realized.
[0045] Once thermoplastic foam profile 23 has been advanced away
from puller 41, cutting blade assembly 45 is activated in order to
produce elongated thermoplastic foam profile sections 21 in a
specific overall length. Once cut, foam profile section 23 is
placed on support platform 30 in cooperating relationship with
cylinders 29, 29 and movable pusher plate 31. In this embodiment,
cylinders 29, 29 each incorporate axially movable rods 32
associated therewith, with plate 31 mounted to the terminating ends
of rods 32. As a result, whenever cylinders 29, 29 are activated,
rods 32, 32 causes plate 31 to move therewith, contacting foam
profile section 21 and forcing section 21 to move in its entirety
in a direction perpendicular to its longitudinal axis.
[0046] The next step in the foam welding and profile manufacturing
system of the present invention is the formation of enlarged panels
22 comprising a plurality of foam profile sections 21. In order to
form the desired enlarged panels, each foam profile section 21 is
integrally welded to an adjacent, previously formed, foam profile
section 21. In FIG. 2, two foam profile sections 21, 21 are shown
on endless conveyor belt 25, after having been integrally welded to
each other along welded line 26. In addition, a third foam profile
section 21 element 9 is depicted, after having been cut, positioned
on support plate 30.
[0047] In order to achieve the desired integrally welded
interengagement between two adjacent foam profile sections 21,
welding means 27 is employed. In the embodiment depicted, welding
means 27 comprises a hot air delivery tube 35 which is constructed
for receiving hot-air from flexible conduit 36, as generated by
heat producing fan member 37. In this embodiment, hot air delivery
tube 35 is constructed for being rapidly advanced longitudinally
along the facing side edges of the adjacent foam profile sections
21, 21.
[0048] While rapidly passing by both exposed edges of foam profile
sections 21, 21, the hot air emanating from the tube 35 heats the
exposed edges to their melting temperature, enabling the two
adjacent foam profile sections 21, 21 to be securely welded
together along weld line 26. By activating cylinders 29,29 and
causing pusher plate 31 to force foam profile section 21 into
secure, contacting, welded interengagement with the adjacent foam
profile section 21, the desired welded engagement is achieved. If
desired, conveyor belt 25 may be stopped and/or reversed in
direction, in order to assure the desired contact and welded
interengagement between the two adjacent foam profile sections is
achieved. Furthermore, a holding or stabilizing system can also be
employed for preventing unwanted slippage or movement of the welded
foam profile sections during the process of welding additional foam
profiles thereto. Such holding/stabilizing systems include abutment
of holding members, vacuum conveyors and the like.
[0049] By continuously repeating this process, any desired number
of foam profile sections 21 are welded together in order to form
enlarged panel 22 having a particular, desired overall size and
shape. Once the desired panel construction is completed, panel 22
is moved off of conveyor belt 25 for further processing, as
detailed below.
[0050] In addition to employing the hot air delivery system
detailed above for welding the plurality of foam profile sections
21 together, other welding and/or bonding systems may be employed.
In this regard, as described above, fuse welding can be realized by
rapidly passing high temperature elements, such as rods or wires,
along the exposed edges of the adjacent foam profile elements for
raising the temperature of the edges to the melt point. In
addition, other systems such as adhesive bonding, mechanical
bonding or laminate attachments can also be employed with equal
efficacy.
[0051] Furthermore, in order to position foam profile section 21 in
a precisely desired location for achieving the welding and/or
bonding for the foam profile section to an adjacent foam profile
section, positioning systems can be employed other than the
positioning systems detailed above. In this regard, movement
control arms for picking and placing each foam profile section can
be employed wherein the section is moved from a first location
where the section is stored or cut to a second location where the
element is welded to adjacent sections. Furthermore, sweep arms,
mechanical diversion systems, multi-axis conveyors and pneumatic
operations can all be employed for achieving the desired movement
control, and welding functions.
[0052] In addition, it is to be understood that foam profile
sections 21 as well as enlarged panels 22 can be moved and
positioned using a wide variety of alternate constructions an/or
systems beyond the specific systems detailed herein. In this
regard, a gantry pick and place system can be employed for moving
these components, as well as various pneumatic and/or vacuum based
conveyance systems. Regardless of which movement, conveyance, or
transfer system is desired or employed, the teaching of this
invention is still employed with the scope of this invention being
encompassed by all such variations.
[0053] Once panel 22 has been completely formed, the final
processing, trimming, and cutting operations are performed thereon.
By referring to FIG. 2, representative, exemplary steps that can be
performed on panel 22 are shown, and discussed below.
[0054] In addition, however, it is also possible to construct a
continuous elongated, enlarged panel or continuous role of material
by employing the present invention. In this regard, a single panel
22 would not be formed and, instead, foam profile section 21 would
be continuously added for forming an elongated, continuous,
longitudinally extending roll like member. Depending on the end use
desired for such product, subsequent processing steps can be
implemented during formation or subsequent thereto, if needed.
[0055] Furthermore, the present invention can also be employed for
forming three-dimensional blocks of integrally welded foam profile
sections 21. In achieving an end product of this nature, welding of
each foam profile section would be achieved in both horizontal
planes and vertical planes. Of course, the foam profile would be
constructed in a manner which would enable interengagement to be
realized. In addition, once the desired integrally welded block
configuration is completed, further processing can be employed for
constructing a wide variety of alternate products therefrom having
complex geometric shapes which were previously unattainable without
substantial expense and/or wasted material.
[0056] The versatility and unique production capabilities achieved
employing the present invention, as well as the ability of the
present invention to achieve complex geometric thermoplastic foam
shapes of any desired three-dimensional configuration is most
evident by referring to the following detailed discussion along
with FIGS. 2 and 3.
[0057] As depicted, panel 22 is modified into a desired
configuration by passing panel 22 through processing equipment 50.
In FIGS. 2 and 3, processing equipment 50 is diagrammatically
represented as a bandsaw mounted on two rotationally driven
rollers. However, in actual operation, any desired processing
equipment can be employed, such as millers, grinders, die cutting
and stamping equipment, slitters, razors, saws, notching equipment,
multi-axis machining equipment, multi-axis cutting equipment, hot
blade formers and the like.
[0058] In the finishing operation depicted in FIG. 2, bandsaw
cutting system 50 is employed for cutting away portions of the
elongated foam profile section 21, and then cutting panel 22 into a
plurality of separate, smaller segments or strips 51. In this way,
each segment or strip 51 incorporates a configuration which is not
able to be produced by extrusion directly.
[0059] As is evident from the foregoing detailed discussion, it has
been clearly demonstrated that the integrated, foam welding and
profile manufacturing system of the present invention is able to
produce a plurality of elongated, continuous segments or strip 51,
having a unique configuration. Clearly, depending upon the
cross-sectional shape of profile 23, virtually any desired
configuration an be achieved in strip 51.
[0060] As is evident to one of ordinary skill in this art, a foam
product of this configuration is incapable of being produced by
foam extrusion, using conventional technology. However, by
employing the foam welding and profile manufacturing system of the
present invention, products of this general nature are quickly and
easily produced, in a continuous, manufacturing process which is
capable of attaining the final product in a cost-effective manner.
As a result, the present invention clearly and unequivocally
overcomes all of the prior art difficulties and drawbacks and
provides a unique foam welding and profile manufacturing system
achieving results which have heretofore been incapable of being
produced in such an efficient and effective manner.
[0061] In FIG. 3, a further depiction is provided of a complex
geometric thermoplastic foam shaped product which is capable being
produced by employing the present invention. As shown, panel 22 is
formed from a plurality of longitudinally extending foam profile
sections 21, each of which have been welded to each other along
weld lines 26. In this embodiment, processing equipment 50 is
employed for cutting and contouring the upstanding, vertical wall
forming a part of each foam section 21.
[0062] As shown, processing equipment 50 forms a plurality of
separate upstanding segments from each elongated wall, while also
forming one wall portion into adjacent segments with facing slanted
edged. In addition, a small notched zone is formed in the base of
panel 22 directly between the slanted wall portions. As shown, this
construction enables the segment, when finally produced, to be
arcuately pivoted 90.degree. to form a unique final product which
would otherwise be incapable of being produced using extrusion
equipment.
[0063] In FIGS. 4 and 5, an alternate construction for welding a
plurality of elongated, longitudinally extending foam profile
sections 21 is depicted. In this embodiment, a plurality of foam
profile sections 21 are welded together simultaneously, thereby
enhancing the operation and production speed of the present
invention. As shown, this embodiment employs welding means 27 which
comprises a plurality of hot air delivery tubes 35 mounted in
cooperating engagement with each other. Each hot air delivery tube
35 is connected to flexible conduit 36 which receives the required
heated air and airflow from heat producing fan member 37.
[0064] As shown in FIG. 4, by simultaneously moving each of the
plurality of hot air delivery tubes 35 along the adjacent side
edges of a plurality of aligned and longitudinally adjacent foam
profile sections 21, the plurality of foam profile sections 21 are
simultaneously welded to each other. In this way, the production
speed for forming panel 22 is substantially enhanced.
[0065] Alternatively, as shown in FIG. 5, a plurality of elongated,
longitudinally extending foam profile sections 21 can be positioned
adjacent each other and simultaneously moved along their central
axis through welding means 27. In this way, an enlarged panel is
quickly and easily attained. Furthermore, as discussed above,
adhesive means can be applied to the side edges of foam profile
sections 21 for achieving the desired affixation.
[0066] Another feature of the present invention is the ability to
produce complex geometric thermoplastic foam shaped products which
are formed from multi-material composites. By enabling the
resulting product to be formed, cut, processed, and/or contoured as
desired, a multi-material composite product is realized having a
unique cross-sectional shape or configuration which is otherwise
unattainable, without employing expensive molding equipment and/or
producing extensive waste.
[0067] By referring to FIG. 6, along with the following detailed
discussion, one method of the present invention, for producing
multi-material composites having a complex geometric shape can best
be understood. As depicted, in this embodiment, longitudinally
extending, foam profile 23, depicted with a generally U-shaped
cross-sectional configuration, is formed in an extruder (not shown)
and controllably advanced by puller 41. After passing through
puller 41, a desired laminating material 55 is applied to the
longitudinally exposed surfaces of U-shaped cross-sectional
configuration of profile 23. In the embodiment depicted, laminating
material 55 is mounted on rollers 56 and fed from rollers 56
directly onto the exposed of the U-shaped cross-sectional
configuration of profile 23, and securely affixed thereto.
[0068] Thereafter, longitudinally extending foam profile 23 is cut
by knife assembly 45 into a desired length, forming elongated foam
profile section 21. Foam profile section 21 is welded to the
previously formed foam profile section 21 using weld means 27 and
the processing steps detailed above. In this way, panels 22 are
formed, following the procedures fully discussed above, in order to
achieve a panel having a desired size and shape, with laminating
material 55 permanently mounted thereto, resulting in a
multi-material composite product.
[0069] Once panel 22 has been formed, panel 22 is advanced into
processing equipment 50, in order to form a desired resulting
complex geometric thermoplastic foam component 60. In the
processing depicted in FIG. 6, a portion of each panel 22 is
removed prior to cutting panel 22 into elongated longitudinally
extending components 60. In this way, uniquely constructed
components 60 are created having a precisely desired complex
geometric shape while also comprising a multi-material composite.
As a result, it is evident that the present invention can be used
in this further alternate manufacturing process to further enhance
the viability and production capabilities of the present
invention.
[0070] In FIG. 8, an alternate, multi-material, composite product
production system is depicted. In this embodiment, as with the
embodiment shown in FIG. 6 and discussed above, longitudinally
extending, foam profile 23, depicted with a generally L-shaped
cross-sectional configuration, is formed in extruder 40 and,
preferably, advanced by a puller (not shown). Thereafter, a desired
composite forming material 55 is applied to a longitudinally
exposed surface of L-shaped cross-sectional configuration of
profile 23.
[0071] In the embodiment depicted, composite forming material 55
comprises a continuous strip of material incorporating either the
hook or loop portion of well-known hook/loop fastening materials.
As shown, the elongated strip of composite forming material 55 is
mounted on roller 56 and fed from roller 56 directly onto the
exposed surface of L-shaped cross-sectional configuration of
profile 23 for being securely affixed thereto. In this way, the
hook/loop bearing material forms an integral component of profile
23, for enabling subsequent use to be made of this material when
the final product is formed.
[0072] In the next step, longitudinally extending foam profile 23
is cut by a knife assembly (not shown) into a desired length,
forming elongated foam profile section 21. Foam profile section 21
is welded to the previously formed foam profile sections 21 using
weld means 27, employing the processing steps detailed above. In
this way, panels 22 are formed, following the procedures fully
discussed above, in order to achieve a panel having a desired size
and shape, with hook/loop fastening material 55 permanently mounted
thereto and forming an integral component thereof, resulting in a
multi-material composite product.
[0073] Once panel 22 has been formed, panel 22 is advanced into
processing equipment 50 in order to form a desired complex
geometric thermoplastic foam component 60. In the processing
depicted in FIG. 8, a portion of each panel 22 is removed prior to
cutting panel 22 into elongated longitudinally extending component
60. In the final step, one segment of component 60 is arcuately
pivoted and secured to the other segment in order to form a
uniquely constructed final product having a complex geometric
shape. In addition, foam component 60 incorporates hook/loop
fastening material integrally affixed to surfaces thereof, for
enabling other independent products which incorporate the opposed
fastening material to be capable of nested, secure interengagement
with the cooperating surfaces of foam component 60.
[0074] In FIG. 7, various alternate exemplary shapes are provided
representing further cross-sectional shapes which may be employed
in the foam welding and profile manufacturing system of this
invention. Although these alternate shapes are not exhaustive of
the wide variety of cross-sectional configurations that can be
employed, the shapes are provided as an example of the various
configurations that may be used in addition to the configuration
shown and detailed above.
[0075] It will thus be seen that the objects set forth above, among
those made apparent from the preceding description, are efficiently
attained and, since certain changes may be made in carrying out the
above process and in the construction set forth departing from the
scope of the invention, is intended that all matter contained in
the above description or shown in the accompanying drawings shall
be interpreted as illustrative and not in a limiting sense.
[0076] It is also to be understood that the following claims are
intended to cover all of the generic and specific features of the
invention herein described, and all statements of the scope of the
invention which, as a matter of language, might be said to fall
therebetween.
* * * * *