Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
  • B29C53/02—Bending or folding
  • B29C53/04—Bending or folding of plates or sheets
  • B29C53/06—Forming folding lines by pressing or scoring
  • B29C53/063—Forming folding lines by pressing or scoring combined with folding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
  • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
  • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
  • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
  • B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
  • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
  • B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
  • B26D3/06—Grooving involving removal of material from the surface of the work
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
  • B29C66/128—Stepped joint cross-sections
  • B29C66/1282—Stepped joint cross-sections comprising at least one overlap joint-segment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
  • B29C66/128—Stepped joint cross-sections
  • B29C66/1284—Stepped joint cross-sections comprising at least one butt joint-segment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
  • B29C66/128—Stepped joint cross-sections
  • B29C66/1286—Stepped joint cross-sections comprising at least one bevelled joint-segment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
  • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
  • B29C66/43—Joining a relatively small portion of the surface of said articles
  • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
  • B29C66/4326—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
  • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
  • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
  • B29C66/4722—Fixing strips to surfaces other than edge faces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
  • B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
  • B29C37/0057—Moulding single grooves or ribs, e.g. tear lines
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
  • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
  • B29C65/30—Electrical means
  • B29C65/305—Electrical means involving the use of cartridge heaters

Definitions

• the field of this invention relates to the art of cutting boards especially fiberglass boards having a foil backing on one surface thereof.
• the apparatus and method involve removing strips of fiberglass from a substantially- planar duct board whereupon the board can be fo ⁇ lded into a polygonal or rounded shape and a longitudinal joint sealed to make a duct section.
• BACKGROUND OF THE INVENTION The art of board cutting machines has been under development for many years. Early attempts were in the field of cardboard cutting and usually involved a plurality of feed rolls moving a piece to be cut across a stationary knife. Typical of such machines are those disclosed in U.S. Patents No. 810,971; 442,878; 667,055; and 527,963.
• Fiberglass duct board is manufactured in rectangular- sheets usually eight feet (2.44 meters) by ten feet (3.05 5 meters). These devices, such as discussed in the Barr 3,605,534 patent, employed a multiple number of blades which removed a plurality of parallel strips from the board. Thereafter, the board could, upon removal from the machine, be folded and sealed along a longitudinal joint
• Machines for feeding duct boards to be cut have also been developed. They had the shortcomings of being highly
• the apparatus and method of the present invention employ a plurality of frame mounted rollers to move a board.
• a plurality of cutting blade assemblies are movable in a direction transverse to board movement across the machine. 5
• a control system positions the board adjacent the cutting blade assemblies. The cutting blades are actuated to cut the board transversely to its direction of movement through the machine while the board is being held stationary. The machine is continuously fed, one board at
• IJO a time with the butt joint between boards being taped as an integral step in the cutting procedure. Boards to be cut are stacked and fed one at a time to be cut after proper alignment. The interaction between the rollers and the control system results in proper indexing of the board
• Each scored board has a shiplap cut at one end, a flap cut at the opposite end, and a plurality of modified shiplap cuts in between. After the strips are cut, the boards are folded into substantially a rectangular or square shape
• Fig. 1 is a perspective view of the board cutting machinery illustrating the loading, cutting and sealing
• Fig. 2 is a plan view of the power driven push bar of the board feeding means taken along lines 2-2 of Fig. 1;
• Fig. 3 is a sectional elevation of the board cutting apparatus, taken along line 3-3 of Fig 1, illustrating the
• Fig. 4 is the front elevational view of the board inlet as seen along lines 4-4 of Fig. 3;
• Fig. 5 is a detailed view of the cutter means illustrated in Fig. 3;
• Fig. 6 is a detailed elevational end view of a cut board after emerging from the board outlet as shown in Fig. 3; -6-
• Fig. 7 is .an assembled elevational end view of the duct in Fig. 6 showing the duct section ready to be taped along a longitudinal joint;
• Fig. 8 is a detailed perspective view of the blades used to make a modified shiplap cut
• Fig. 9 is an alternate view of the blades shown in Fig. 8.
• Fig. 10 is a detailed perspective view of the blade carriage having a flap blade, a shiplap blade and a board ripping blade thereon;
• Fig. 11 is an alternate view of the blade assembly shown in Fig. 10;
• Fig-. 12 is a front elevational view of the board sealing apparatus taken along lines 12-12 of Fig. 1;
• Fig. 13 is a detailed view of the tape carriage on the board sealing apparatus as shown in Fig. 12 and the tape carriage for the joining means as shown in Fig. 4;
• Fig. 14 is a section through lines 14-14 of Fig. 13. DESCRIPTION OF THE PREFERRED EMBODIMENT
• the apparatus and method of the present invention relate to the board cutting and forming boards into a duct section.
• fiberglass duct boards are to be grooved on one face with the opposing face being a foil backing.
• the apparatus A is illustrated in Fig. 1.
• the components of the apparatus are as follows: board feeding means B; joining means J (Figs. 1 and 4); board support means S (Fig. 3); cutter means C (Fig. 3); sealing means T; and control means D.
• board feeding means B has an open frame 10a having a horizontal component 10b disposed parallel to a fixed support surface such as a working floor. It is generally desirable to secure open frame 10a by fixing horizontal component 10b to a working surface by means well known in the art.
• a substantially vertical component 10c extends from one end of horizontal component 10b of open frame 10a.
• Moving means M includes, a drive assembly lOd preferably housed adjacent the top of vertical component 10c, said drive assembly lod further includes drive motor lOe.
• a pair of arms lOf and lOg comprise a movable platform which can support a stack of duct boards lOh thereon.
• a solid platform may be employed in lieu of arms lOf and lOg without departing from the spirit of the invention. It has been found that fiberglass duct boards having a thickness of approximately one inch (2.54 cm) contain sufficient structural rigidity to be supported by a pair of arms. Alternatively, a pallet supporting a stack of boards lOh can be placed on arms lOf and lOg. The use of a pair of arms lOf and lOg instead of a solid platform reduces the overall weight of board feeding means B.
• Vertical component 10c preferably includes a worm-type drive for selectively raising and lowering arms lOf and lOg in tandem.
• the topmost board lOi of stack lOh is raised to the appropriate horizontal plane for feeding to the board support means S (Fig. 3). Having attained the appropriate elevation for topmost board lOi (Fig. 3) via moving means M, pushing means P can be employed to feed board lOi toward board inlet 20b for cutting.
• pushing means P is pivotally mounted to drive assembly lOd through a linkage lOj .
• Linkage lOj preferably contains a pair of links of equal length, 10k and 10m.
• Pushing means P further includes a push bar lOu having a pushing surface lOn (Fig. 2).
• Pushing surface lOn has a rearward extending section lOp with links 10k and 10m pivoted respectively at points lOq and lQr.
• pushing means P preferably actuates link 10k for rotation
• topmost board lOi (Fig. 3) is displaced in two directions as shown by arrows 10s and lot.
• the dashed lines in Fig. 2 illustrate that when push bar lOu is actuated, pushing surface lOn translates along an edge lOv of topmost board lOi in direction of arrow lot. Additionally, pushing surface lOn urges topmost board lOi in the direction of arrow 10s.
• the component of force exerted by pushing surface lOn on edge lOv in the direction of arrow lot forces board lOi against alignment means E (Fig. 1).
• Alignment means E can consist of a unitary or segmented guide bar(s) lOw having a guide surface(s) lOx thereon.
• Guide surface lOx is disposed parallel to edge lOy (Fig. 1) of topmost board lOi in stack lOh.
• edge lOy Fig. 1
• the topmost board lOi is urged not only in the direction of arrow 10s but also up against guide surfaces lOx so that the proper alignment of board lOi is maintained as it is being driven in direction 10s.
• Pushing means P operates in a fixed horizontal plane (Fig. 1). When arms lOf and lOg raise topmost board lOi to the proper elevation, pushing means P can push topmost board lOi towards board inlet 20b.
• the operation of pushing means P in a fixed, horizontal plane elevated from a working floor, allows board feeding means B to be loaded with a stack of boards lOh from the direction of arrows- lOz and lOaa (Fig. 1).
• board feeding means B can continue to feed from the stack of boards lOh until the last board is fed into board inlet 20b.
• control means D stops the board support means B and cutter means C to allow board feeding means B to be adjusted to receive another stack of boards lOh.
• the topmost board lOi is abutted to a preceding board 20, which is retained by board support means S for cutting with cutter means C.
• Control means D not only regulates the movement of board support means S but senses the position of trailing edge 20a of board 20.
• control means D stops of board support means S so that joining means J can effectively connect board 20 to board lOi before cutting operations with cutter means C are resumed.
• Joining means J includes a mounting rail 20c secured to frame 20d.
• Mounting rail 20c extends transversely to the direction of board movement through board support means S, as indicated by arrow 20e (Fig. 3).
• Carriage 20f (Fig. 4) is drivably mounted for translation in two directions along mounting rail 20c.
• Carriage 20f further includes a rotatably mounted tape spool 20g which holds a supply of heat sealable tape 20h thereon. Tape 2Oh is threaded from tape spool 20g under leading heat roller 20i and trailing heat roller 20j .
• An intermediate idler roller 20bb may be employed between spool 20g and leading heat roller 20i.
• a cutting apparatus 20k is disposed between leading heat roller 20i and trailing heat roller 20j .
• the cutting apparatus 20k is illustrated in Figs. 4 or 13 and generally includes a vertically oriented blade which, in combination with appropriate springs and solenoids can be actuated to travel downwardly to sever tape 20h when carriage 20f has traversed the entire butt joint 20m (Fig. 3) between board 20 and board lOi.
• control means D senses that trailing edge 20a of board 20 is in alignment with tape 20h on joining means J, further movement of board support means S is curtailed. It wilL be appreciated that as board 20 is driven from board inlet 20b to board outlet 20n of frame 20d, pushing means P maintains board lOi in constant contact with 5 trailing edge 20a.
• control means I actuates a drive (not shown) causing carriage 20f to translate along mounting rail 20c.
• Leading and trailing heat rollers 20i and 20j have their lowermost Q point slightly below the upper face 20p of board 20.
• Upper face 20p contains the foil backing.
• leading and trailing rollers 20i and 20j slightly compress butt joint 20m against an underlying support 20q (Fig. 3) " which is preferably integral with frame 20d.
• Leading heat roller 20i has a thermostatically controlled heat source 20r therein and is preferably set at a approximately two hundred fifty degrees Fahrenheit.
• Trailing heat roller 20j has a similar thermostatically controlled heat source 0 20s and is preferably set at five hundred fifty degrees Fahrenheit.
• the neutral position of carriage 20f is illustrated in Fig. 4.
• Cutting 5 apparatus 20k includes a vertically disposed cutting blade 20t secured to carriage 20u which is guided by guide 20v.
• Solenoid 20w has a piston 20x which is connected to carriage 20v.
• Spring 20y resists the movement of piston 20x of solenoid 20w.
• actuation of solenoid 20w results in inward retraction of piston 20x into the solenoid 20w which overcomes the spring force of spring 20y and results in downward movement blade 20t to sever tape 20h.
• spring force exerted by spring 20y lifts carriage 20u as piston 20x is extended from solenoid 20w.
• the apparatus of the present invention employs staged heating wherein the leading heat roller 20i (Fig. 4) is set at a lower temperature than the trailing heat roller 20j.
• leading heat roller 20i Fig. 4
• trailing heat roller 20j the leading heat roller 20i
• board support means S includes a pair of inlet rollers 30a and 30b. Rollers 30a and 30b are disposed transverse to the direction of board movement
• rollers 30a and 30b have longitudinal center lines disposed in a common vertical plane with roller 30a disposed above upper face 20p of board 20. Roller 30b is. disposed directly below roller 30a such that board 20 is
• Board support means S further includes a pair of outlet rollers 30c and 30d disposed adjacent board outlet 20n and secured to frame 20d. Outlet rollers 30c and d extend in a direction transverse to board movement as illustrated by arrow 20e.
• rollers 30a through d provide two functions of supporting the board through frame 20d, as well as moving the board in the direction of arrow 20e.
• the amount that rollers 30a and b or rollers 30c and d pinch board 20 can be varied.
• the spacing between rollers 30a and b and rollers 30c and d can be set at three quarters of an inch (1.875 cm) for a nominally one inch (2.54 cm) thick board.
• Control means D regulates the rotation of rollers 30a through d. Proper indexing of the board with respect to
• 15 cutter means C is accomplished using control means D to drive rollers 30a through d in tandem.
• control means D to drive rollers 30a through d in tandem.
• occasions may arise wherein all the boards for a particular job have been cut, yet one board 20 still remains within frame 20d secured by rollers 30a through d. In that event, should a
• control means D senses when a job is
• Cutter means C (Fig. 3) is disposed between inlet rollers 30a and b and outlet rollers 30c and d adjacent to board 20.
• upper face 2Op contains the foil backing with cutter means disposed below board 20 for removal of strips 40a.
• board 20 can be fed through frame 20d with the foil side down and cutter means C disposed above the board 20.
• cutter means C below the plane of board movement so that strips 40a can drop or be easily tapped out of board 20 while board 20 is suspended above a suitable receptacle 40b.
• Cutter means C further includes first, second and third blade rails 40c-e, respectively (Fig. 3).
• Each of blade rails 40c-e has a carriage thereon labeled 40f-h, respectively (Fig. 5).
• carriage 40f is preferably disposed between carriages 40g and 40h with carriage 40g closest to board inlet 20b and carriage 40h disposed closest to board outlet 2On. All three carriages 40f-h are aligned in an identical horizontal plane.
• Blade rails 40c through e are each disposed in a direction transverse to the direction of board movement through frame 20d.
• Control means D coordinates the movements of board support means S to position board 20 adjacent carriages 40f through h for cutting strips 40a therefrom.
• Each carriage, 40f through h has a blade assembly 40i-k, respectively, thereon (Fig. 5).
• Carriage 40f is shown in more detail in Figs. 10 and 11 and for the purposes of description will be referred to as the first carriage.
• First carriage 40f includes a flap cutting blade 40m, a shiplap blade 40n and a board ripping blade 40p.
• Board ripping blade 40p is designed to cleanly slit through the board including the foil backing upon movement of carriage 40f.
• Board ripping blade 40p extends from carriage 40f in a plane perpendicular to board movement through frame 20d.
• Blade 40p has a pair of opposed cutting edges 40q and 40r which are adjacent to each other and meet at point 40s.
• Board. ripping blade 40p is adapted for bidirectional cutting.
• Cutting edge 40q is rearwardly inclined with respect to movement of carriage 40f as the board ripping blade cuts in one direction while cutting edge 40r is 5 rearwardly inclined with respect to movement of carriage 40f in the opposite direction, for cutting completely through- board 20 including the foil backing on upper surface 20p.
• Both cutting edges 40q and 40r are double beveled as shown in Figs. 10 and 11 by beveled surfaces
• Retaining bar 40v is disposed immediately above upper face 20p to prevent board 20 from riding up board ripping blade 40p during cutting. The tendency of board 20 to ride up is increased as blade 40p gets progressively duller.
• Carriage 40f also includes a shiplap blade 40n.
• Shiplap blade 40n has a first segment 50a extending from carriage 40f in a direction perpendicular to the plane of board movement.
• a second segment 50b extends from the free end of first segment 50a in a direction substantially
• second segment 50b runs substantially parallel to upper surface 2Op of board 20 as carriage 40f is moved in either of two directions transverse to the direction of board movement through frame 20d. As seen in Fig. 5, second segment 50b 5 intersects the plane of board ripping blade 40p. Both first segment 50a and second segment 50b each have a pair of opposed cutting edges with edges 50c and d disposed on first segment 50a and edges 50e and f disposed on second segment 50b. When carriage 40f is driven in one direction 0 and cutting edges 50c and 50e are cutting, such edges are rearwardly inclined in the direction of movement of carriage 40f.
• first segment 50a and second segment 50b are single beveled as indicated by beveled surfaces 50h-k (Fig. 10). The significance of single beveling shiplap blade 40n will be discussed in more detail hereinbelow.
• First carriage 40f further includes flap blade 40m.
• Flap blade 40m has a first segment 60a extending from carriage 40f in a plane perpendicular to a direction of board movement through frame 20d.
• Second segment 60b extends from the free end of first segment 60a and in a plane substantially parallel thereto.
• second segment 60b is disposed substantially parallel to upper face 20p of board 20 which includes the foil backing.
• First segment 60a has opposed cutting edges 60c and d thereon and second segment 60b has opposed cutting edges 60e and f thereon.
• first segment 60a has opposed cutting edges 60c and d thereon and second segment 60b has opposed cutting edges 60e and f thereon.
• Fig. 11 when carriage 40f is moving in one direction and cutting edges 60d and 60f are cutting board 20, such edges are rearwardly inclined with respect to the direction of carriage movement.
• Cutting edges 60d and 60c are disposed at a spaced relation to each other while cutting edges 60f and 60e are adjacent to one another meeting at intersection point 60g.
• second segment 60b of flap blade 40m intersects the plane of board ripping blade 40p.
• Second segment 50b of shiplap blade 40n is parallel but below second segment 60b of flap blade 40m.
• shiplap blade 40n is offset from flap blade 40m as shown by the misalignment of intersection points 50g and 60g in a direction parallel to movement of carriage 40f.
• Flap blade 40m and shiplap blade 40n are both offset from board ripping blade 40p in a direction parallel to movement of carriage 40fT.
• Cutting edges 60c -f are single beveled as indicated by beveled surfaces 60h-k (Fig. 11).
• Fig_ 6 The cuts made by the blades on carriage 40f are illustrated in Fig_ 6.
• Shiplap blade 40n makes the 5 leading cut as illustrated by surfaces 70a and b of Fig. .6.
• a quadrilate ally shaped strip 40a is removed from the board adjacent its leading edge 20aa.
• Board ripping blade 40p and flap blade 40m make the last two cuts along the trailing end 20a of board 20.
• flap blade 40m removes a strip 40a, indicated by dashed lines, thereby leaving exposed, surface 70c and an overhanging flap 70d of foil backing.
• edges 60d or 60c are responsible for creating surface 70c while cutting edges 60f or 60e cut 5 parallel but immediately below the foil of upper surface 20p to remove, in a quadrilaterally shaped strip 40a, substantially all the fiberglass below the backing at upper surface 20p.
• cutting edges 50c or 50d create surface 70b 0 while cutting edges 50e or 50f create surface 70a.
• board ripping blade 40p severs the backing and cuts through the entire board at trailing edge 20a.
• the removal of a strip 40a from the trailing edge 20a requires the strip 40a to 5 pass between carriage 40f and the underside of .second segment 60b.
• the other two parallel sides of strip 40a to be removed from tailing edge 20a must pass adjacent to surfaces 40v and 60m, of the board ripping blade 40p and flap blade 40m, respectively.
• the quadrilaterally shaped . strip 40a must be passed between carriage 40f and underside of second segment 50b of shiplap blade 40n.
• the other two surfaces must pass between surface 40bb of board ripping blade 40p and 50m of shiplap blade 40n.
• the surfaces of such blades are single beveled to minimize compression -L7-
• the blade assemblies 40j and 40k are disposed, respectively, on second and third carriages 40g and 40h. These assemblies present a significant improvement in the art of blade design with respect to cutting fiberglass boards. In the aggregate, blade assemblies 40j and 40k make what is aptly described as a "modified shiplap cut" . As seen in Fig. 5, blade assemblies 40j and 40k are identical with the mounting of the individual blades reversed. Specifically, both carriages 40g and 40h include a shiplap blade 40n as previously described. On carriage 40g, shiplap blade 40n is mounted to the carriage on an end closest to board inlet 20b, whereas on carriage 40h shiplap blade 40n is mounted on the end of the carriage closest to board outlet 2On.
• Figs. 8 and 9 illustrate the shiplap blade 40n with the modified shiplap blade 80a as shown on carriage 40h of Fig. 5.
• Modified shiplap blade 80a has a first segment 80b which extends from carriage 40h perpendicular to the plane of board movement through frame 20d.
• the second segment 80c extends from the free end of first segment 80b and in a plane inclined with respect to first segment 80b.
• Third segment 80d extends from the end of second segment 80c, opposite from first segment 80b, and downwardly toward carriage 40h, thereby defining an included and acute angle 80t- between- second segment 80c and third segment 80d.
• the preferred angles are an included angle of 130° 5 between first segment 80b and second segment 80c and an included angle of 54° between second segment 80c and third segment 80d.
• third segment 80d intersects the plane of second segment 50b of shiplap blade 40n.
• modified shiplap As seen, in Figs. 8 and 9, modified shiplap
• blade 80a has opposed cutting edges 80e and 80f on first segment 80b. Opposed cutting edges 80g and 80h are disposed on second segment 80c. Opposed cutting edges 80i and 80j are disposed on third segment 80d. When carriage 40h travels in one direction, cutting edges 80e, 80h, and
• 25 cutting edges 80i and 80j are adjacent to each other meeting at a point 80u.
• Carriage 40h removes a strip 40a defined by remaining surfaces 70e-i.
• the cuts made by carriage 40g in removing a strip 40a are indicated on Fig. 6 by remaining surfaces 70j, k, m, n, and p.
• the preferred sequence of cuts on any piece of board is as 5 follows: blade 40n of carriage 40f; blade assembly 40k of carriage 40h; blade assembly 40j of carriage 40g; blade assembly 40k of carriage 40h; and flap blade 40m and board ripping blade 40p of carriage 40f.
• V-groove joints make it extremely difficult to effectively join a lateral duct to a main duct and obtain a good seal.
• Shiplap joints presented an improvement over V-groove joints in
• the modified shiplap cut made by blade assemblies 40j and 40k represents an improvement over blade designs in the past by incorporating the beneficial features of both the V-groove and the shiplap cut in one unitary cut.
• the modified shiplap cut made by blade assemblies 40j and 40k represents an improvement over blade designs in the past by incorporating the beneficial features of both the V-groove and the shiplap cut in one unitary cut.
• the cut board as illustrated in Fig. 6 can be folded into a rectangular shape (or square shape) as shown in Fig. 7 and taped while held in that position.
• the closure of the longitudinal shiplap joint 70s with flap 70d can thus be accomplished using far simpler machinery than that previously known.
• the folded duct board retains its longitudinal strength and resistance to twist buckling along its longitudinal axis without any need to fold the duct into a parallelogram shape, tape it, and allow it to spring back to a rectangular shape.
• the modified shiplap cut made by blade assemblies 40j and 40k has other advantages over blade assemblies previously used.
• the included angle 80t between second segment 80c and third segment 80d acts to minimize clogging of a strip being cut in that the angular disposition of second and third segments 80c and 80d imparts and downward force toward carriage 40h or 40g on the strip 40a being cut.
• the downward force tends to minimize clogging of modified shiplap blade 80a as carriage 40g or 40h is moved across the board 20 in either direction.
• the shiplap blade 40n is offset in the plane of carriage movement, from the modified shiplap blade 80a on both carriages 40g and 40h as seen by the positions of points 80u and 50g (see Figs. 8 and 9). Additionally, the single beveling of cutting edges 80e-j as well as all the cutting edges 50c-f of shiplap blade 40n further reduces compressive forces on a strip to be removed by carriages 40g or 40h. These compressive forces exist between surface 50m and first segment 80b; between second segment 50b and the carriage 40g or 40h; and between second segment 80c or third segment 80d and the carriage 40g or 40h.
• sealing means T is employed to effectively close such scored boards into duct sections.
• a typical heating, ventilating and air conditioning job it is desirable to precut a stack of boards lOh into individual segments 20 (Fig. 3) and ship the scored boards to a job site.
• each flat scored board 20 can be folded into a rectangular shape as shown in Fig. 7 and sealed by sealing means T. Since sealing means T may be required on various job sites, it is advantageous to employ a lightweight construction to allow simple and efficient closure of longitudinal joints 70s for each board 20. It is understood that, alternatively, the scored boards 20 can be folded and taped into duct sections at a location remote from point of installation and shipped thereto by truck or other suitable means.
• sealing means T includes a frame 90a having a movable platform 90b thereon.
• Frame 90a further includes a backstop 90c which has a horizontal component 90d extending in a plane parallel to movable platform 90b.
• a duct segment 20 is folded into the shape shown in Fig. 7 by hand or by machine after strips 40a are removed therefrom (see Fig. 3).
• the folded duct board 20 is placed on movable platform 90b with longitudinal joint 70s positioned as shown in Fig. 14.
• Actuating controls 90e selectively raises movable platform 90b until such time as horizontal component 90d contracts flap 70d and presses it firmly against panel 70t-
• the folded duct is raised with platform 90b to the position shown in Fig. 14, further movement of platform 90b is curtailed via controls 90e. At this time, the duct section is ready to be sealed.
• sealing carriage 90f is mounted on mounting rail 90g.
• Mounting rail 90g is disposed parallel to longitudinal joint 70s which is to be taped closed.
• the internal details of the tape dispensing and cutting elements found on carriage 90f are preferably identical in construction and operation to carriage 20f illustrated in Fig. 13 and described hereinabove.
• a stapling gun 90h of a type known in the art can be incorporated into carriage 90f (as well as carriage 20f), if desired, on certain applications.
• sealing the longitudinal joint 70s with tape only is satisfactory for almost all heating, ventilating and air conditioning applications today.
• carriage 90f is actuated by control 90e to traverse across flap 70d to seal flap 70d to panel 70t along the outer foil.
• suitable position sensing devices actuate the cutting blade on carriage 90f when it is aligned with the end of the joint as represented by the carriage having traversed from the right end to the left end of Fig. 12.
• translation of carriage 90f slightly compresses the flap 70d against panel 70t which helps in holding the duct in place during sealing and further provides adequate contact between the heating rolls on carriage 90f and the tape being applied underneath them to flap 70d and panel 70t.
• an iron 90i Fig.
• the board cutting is initiated by loading a stack, of boards lOh on arms lOf and lOg.
• the stack lOi is then raised via moving means M such that a topmost board lOi (Fig. 3) is disposed in a horizontal- plane extending between in the rollers 30a and 3Ob as well as between outlet rollers 30c and 30d.
• Pushing means P on board feeding means B is actuated whereupon pushing surface lOn moves topmost board 10i in the direction of arrow 10s (Fig. 2). Translation of pushing surface lOn along edge lOv of topmost board lOi also forces topmost board lOi against guide surface lOx.
• Control means D actuates inlet rollers 30a and 30b and outlet rollers 30c and 30d whereupon when pushing surface lOn moves topmost board lOi into board inlet 20b and topmost board 10i engages inlet rollers 30a and 30b, the board will proceed toward board outlet 20n until it engages outlet rollers 30c and 30d.
• the first board is fed into frame 20d, until it can be held by both inlet rollers 30a and b and outlet rollers 30c and d.
• Carriage 40f is then actuated on rail 40c to make the initial cut, thereby indexing all subsequent boards to be fed into frame 20d.
• the segment of the first board fed into frame 20d which extends between board ripping blade 40p and board outlet 20n is the only discard piece generated in using the system.
• board feeding means B continues to feed that first board into board inlet 20b for further cutting. It should be noted that upon feeding the first board into board inlet 20b and making the initial cut with board ripping blade 40p as well as shiplap blade 40n, the next cut on the same board, to be made- by actuating carriage 40h, takes place only after the first board fed into board inlet 20b is further driven such that its leading edge contacts outlet rollers 30c and 30d.
• joining means J in conjunction with control means D tapes a butt joint 20m (Fig. 3) when control means D indexes the butt joint adjacent joining means J by selective operation of board support means S.
• control means D indexes the butt joint adjacent joining means J by selective operation of board support means S.
• control means D actuates outlet rollers 30c and 30d independently of inlet rollers 30a and 30b to drive the last piece from frame 20d via outlet 2On.
• the trailing segment of the last board remains indexed between inlet rollers 30a and 30b for an immediate start of the next production run.
• the boards 20 having been scored and driven through board outlet 20n (Fig. 3) are each individually folded into the shape shown in Fig. 7 and placed upon sealing means T.
• Movable platform 90b is raised until flap 70d is held tightly against the foil backing of panel 70t whereupon carriage 90f is actuated to seal longitudinal joint 70s by applying tape over flap 70d and the foil backing of panel 70t. The platform 90b is then lowered and the duct section is ready for use.
• the apparatus A and associated method of the present invention present an improvement in the duct forming arts in that independent of the size of boards being used, no waste is generated after the initial board has been - indexed in the machine. It should be noted, however, that a variation of thickness of board being cut will require a blade change and adjustment of clearances for joining means J as well as board support means S.
• board feeding means B and joining means J a tall stack of boards (usually 48) can be continuously fed one at a time for scoring by cutter means C.
• the modified shiplap cut performed by blade assemblies 40j and 40k provides the structural rigidity of V-groove cuts with the flexibility of the shiplap cut to allow easy connection of branch ducts.
• the modified shiplap cut further allows the scored boards to be folded into substantially rectangular or square shapes for taping thus obviating the need for overbending into a parallelogram shape during taping as was done in the past.
• the ability to tape a duct section while in essentially a square to rectangular shape allows the use of a simply constructed sealing means- T. Due to its lightweight construction sealing means T can be employed adjacent frame 20d for taping duct sections remote from the job site or can be used on a job site to seal a stack of boards scored by cutter means C at a remote location. When a job is completed, sealing means T can be easily transported another job site and the process repeated.

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• 1986
  • 1986-11-21 EP EP87900413A patent/EP0245501A1/de not_active Withdrawn
  • 1986-11-21 WO PCT/US1986/002531 patent/WO1987003240A1/en not_active Ceased
  • 1986-11-21 AU AU67399/87A patent/AU6739987A/en not_active Abandoned

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