GB2134418A - Powder deposition apparatus - Google Patents

Abstract

A machine for applying a configuration of reinforcement/stiffening or decorative material in powder form to a receiving surface (20), for subsequent fusing, cooling and pressing to a substrate such as shoe upper. The machine comprises a deposition station (12), a heating station (14) and a press station (16). A tensioned receiving belt (20) receives the configuration of powder through a cut-out (42) in the bottom of a swept screen frame (28). The receiving belt (20) is supported from beneath during the deposition activity to control the thickness of the powder deposit. The receiving belt (20) is shuttled in a displaceable frame (22) in a series of steps to the successive stations (12, 14, 16) for melting the powder and subsequent cooling and adhesion of the melted powder to the substrate such as an unreinforced shoe upper. The cutout (42) may have a peripheral gasket (S) arranged partially there around to displace at least part of said cut-out (42) from said receiving surface (20), leaving sufficient volume therebetween for filling by the powder as a three- dimensional (tapered) configuration. <IMAGE>

Description

SPECIFICATION Linear deposition apparatus and method of applying a fusible powder therefrom Background of the invention (1) Field of the invention This invention relates to depositon machinery useful for applying a fusible powder to a substrate to change certain reinforcement/stiffening or decorative characteristics of that substrate, and more particularly to a machine/method for producing reinforcing or decorative means for shoe uppers prior to their assembly on a shoe last.

62) Prior art The shoe and apparel industry have for many years provided reinforcement/stiffening or decorative means to their products. Manufacturers of pajamas, blue jeans, sport clothing, including sports equipment such as gloves, caps with visors, and the like, as well as shoe manufacturers have stitched, glued or applied layers of reinforcing material to their products for a variety of reasons. It has been standard for the shoe industry to apply the reinforce ment/stiffening means as a layer of molten thermoplastic material adherableto a shoe upper. Early attempts at reinforcing or stiffening a shoe upper have included providing preformed stiffener elements or counters, which are inserted into a shoe upper, priorto lasting.Separate mouldablesheet materials softenable by heating or by solvent have been inserted in the shoe uppers prior to lasting and are shaped in the course of lasting to a desired configuration which configuration they retain by being allowed to harden before removal of the shoe upper from the last. Shoe uppers have also been stiffened by impregnating a shoe component with a solution or dispersion in a volatile liquid vehicle of hardenable stiffener materials prior to lasting of the shoe upper, the shoe upper being stiffened by hardening of the inmpregnating material after the shoe is lasted.

One such way of stiffening shoe uppers is shown in U.S. Patent 3316573 to Chaplick et al, wherein a shoe upper has a selected area in which a resiliently flexible stiffener element is fluidly deposited, and heated to a mouldable point, and brought to a three-dimensional configuration which it will retain on cooling.

Another arrangement for coating shoe parts is shown in U.S.Patent 3342624 to Kamborian, wherein a stencil plate rests upon a shoe upper, a concave support surface holds the combination, whereupon a doctor blade wipes across the plate to deposit a fluid stiffener into the depression in the shoe upper.

A more recent arrangement for stiffening shoe components, is shown in U.S. Patent 3973285 to Babson et al, comprising an arrangement for depositing a molten charge of thermoplastic on a shoe upper held in a margin clamping means.

The prior art arrangements may occasionally work well, but they have difficulty producing a stiffener of uniform thickness over seams and overlaid patterns.

The adhesion of the stiffener at its edges is often poor. Rough edges, and strings or "spider webs" characteristic of the process all may be present. The machines may leak their molten material out of connecting joints, nozzles may drool and patterns require time and patience to change.

The materials usable in these prior art machines are limited to certain viscous flow and heat stability characteristics which necessitate careful tailoring often compromising performance of the final product These speciality materials are also more costly.

Thus it is an object of the present invention to provide a method which will overcome the shortcomings of the prior art.

It is a further object of the present invention to provide a machine and method for applying reinforcement/stiffening or decorative means in a desired configuration as an individual piece or as a part of a substrate such as a shoe upper or piece of cloth-type material, which configuration may be made from a wide choice of low cost polymeric materials having superior physical characteristics which may be readily changed to facilitate various shoe upper patterns or styles or reinforcement/ stiffening or decorative requirements of the garment with conveniently made low cost stencil tooling.

It is yet a further object of the present invention to provide an apparatus and a method which will permit the manufacture of smooth stiffened/reinforced shoe upper, without the inconveniences of the prior art.

Briefsummary ofthe invention The present invention includes an apparatus for reinforcing and/or stiffening and/or decorating substrates which may be flexible, such as the underside of shoe uppers or portions of clothing orthe like, by the application thereon of a fused powdered material. The apparatus comprises an elongated frame member having an array of successive work stations arranged thereon. The first station comprises a deposition station. The second station comprises a heat station, and the final station comprises a join and cool or press station. The deposition station has a horizontal receiving belt of rectangular configuration. The receiving belt is tensionably mounted on a frame which is movable or shuttleable into and out of the successive stations.The receiving belt acts as a support surface and is made from a thin web of woven glass fibres or metal screen coated with a low adhesion, plastic, heat resistant material which may incorporate a release agent therewith. A stencil means is hingedly disposed above the receiving belt.

The stencil means comprises a wire mesh screen preferably sandwiched between an overlaid covering of smooth impervious material and a lowermost surface of foil, each adhering to their side of the screen and to one another through the screen, each having a matching, aligned cut-out, exposing the screen; the mesh and the covering are held in a frame which -is traversed by a carriage functioning to disperse reinforcing/stiffening material in power form from a conduit secured to a supply hopper thereabove. A gasket of varying thickness may be arranged around at least a portion of the cut-out on the bottom side of the wire mesh screen to permit a pre-determined "volume" of powdered material to be pushed therewithin. The powdered material dispersed from the hopper is preferably a polyethylene, an ionomer or a ethylene vinyl acetate, if the machine is used for shoe box toes.For other types of reinforcements, various formulations of vinyl and nylon may be used. The dispenser-carriage supports a pair of wiper blades and is movable across the stencil by actuatable means such as a stepping motor engaged with a rack and pinion gear arrangement, or a cable cylinder and pulleys arranged adjacent the carriage and the screen frame.

The heat station is disposed on the elongated frame member of the apparatus, transversely adjacent the deposition station. The heat station comprises a lower planar surface of preferably metal construction having a plurality of heating elements heatableto 375 -500 F (190.60C-260.0"C) arranged therein. The lower planar surface also has a plurality of openings arranged thereacross, in fluid communication with a vacuum source. The heat station includes an upper planar surface hingedly attached at one end thereof, to the elongated frame member.

The upper planar member comprises a plurality of radiant heating elements having a temperature range of about 400 -700 F (204.4"C-371.1"C) in a parallel array therein.

The press and/or cool station disposed at the end of the elongated frame is comprised of cool and join means. A lower planar block is in fluid communication with a refrigeration means. An upper support channel arrangement may receive a frame which holds an unreinforced flexible substrate such as a shoe upper or piece of cloth, held by its margin therein. The "inner" side of the flexible substrate, i.e.

the shoe upper, is disposed towards the lower refrigerated block. The upper support channel arrangement may be movably held above the lower block by a reciprocation means such as a double action piston-and-cylinder unit secured to the frame member. Actuation of the piston-and-cylinder unit at the final press station effectuates movement of the support channel arrangement towards and away from the lower regrigerated block.

The frame of the shuttleable receiving belt is slidably mounted on a pair of horizontal guideways, which frame is movable thereon by pressurisable means to move the belt from the first station, then to the second station and then finally to the third station, and back again to the first station. The frame of the receiving belt is movable upwardly and downwardly with respect to the guideways, by frame height adjusting means such as a pressurisable cylinder to ensure contact of the belt with the stations during their operating time, and to ensure separation between the belt and the station during non-operating times.The receiving belt, when disposed at the deposition station, has a lower support means thereunder and secured to the elongated frame, synchronisably movable upwardly and downwardly with respect to the stencil means, to provide backing thereagainst during application of powder thereon, in the deposition process.

In a cycle of operation of the flexible substrate (i.e.

shoe upper) reinforcing/stiffening or decorating apparatus, a quantity of fusible polymer powder such as an ionomer, a polyethylene or an ethylene vinyl acetate of preferably a 35 mesh size is caused to flow from the hopper through the conduit and into the dispenser-carriage. The wiper blades are caused to sweep across the smooth upper surface of the stencil, sweeping the fusible powder into the configured cut-outthereacross. Each wiper blade is alternately raised from the upper surface of the stencil, by camming means, depending on the direction of sweep of the blades. The receiving belt is pushed by the lower support means thereunder into contact with an arrangement of spacer means such as the peripheral gasket type of spacer means on the bottom side of the stencil means.The receiving belt thus has deposited on it a configuration of powder thereon, the powder being applied in a particular desired uniform thickness, a varying thickness or taper, depending upon the way the spacer means is arranged around the cut-out on its bottom side and upon the way shims (if any) have been placed on the lower support. The spacer means may include a full peripheral gasket or a partial gasket and therefore selectively space the receiving belt from a portion of the bottom side of the stencil means cut-out.

Upon receipt of a proper control signal from a proper source, the lower support and any shim or shims thereon under the receiving belt is caused to move downwardly, and a pneumatically actuated cam is caused to move a cam follower and gradually raise the lower surface of the stencil and dispenser assembly from contact with the receiving belt such face in such a manner as to minimise the inrush of "wind" caused by the displacement of air when the dispenser assembly is lifted, as well as to minimise any electrostatic effects. Thus the three-dimensional configuration of the powder produced by the stencil pattern and the spacer and shim means are transferred to the receiving belt.A further proper control signal initiates pressure in the shuttle means to cause the frame oftheshuttleable receiving belt to move transversely on its horizontal guideways, from the first "deposition" station, to the second "heat" station. Acceleration of the receiving belt and its frame is carefully limited so that the configuration of powder is not disturbed. While various power particle sizes and formulations and receiving belt conditions will cause the tolerance of the configurations to vary, acceleration forces are generally kept below 0.8.g.

At the "heat" station, the receiving belt is brought into touching contact with the lower planar surface thereof. Upon contact with switches at the second station the receiving belt frame is lowered into contact with the lower planar surface by actuation of the frame height adjusting means, i.e. pressurisation of its cylinder therebeneath, and the vacuum source in the lower planar surface is actuated, causing the receiving belt to be drawn tightly against the lower planar surface to improve heat transfer to the power by conduction of heat from the lower heating elements in planar surface and radiation from the upper planar surface.

After the configured powder on the receiving belt has been heated and fused into a molten three dimensional viscous mass, the receiving belt may be raised from the lower planar surface by reactuation of the frame height adjusting means, i.e. depressur isation of the cylindertherebeneath and shuttled transversely by actuation of further pressure in the pressure means which causes the frame of the shuttleable receiving belt to move on its guideways to the third station for joining then cooling with an unreinforced substrate such as a shoe upper or piece of cloth or, in the case where an individual loose product is desired, for just cooling thereof.The receiving belt is lowered into close proximity with the upper surface of the lower planar block in a manner similar to that of the heating station, as well as by the actual pressing of a substrate thereagainst, which helps cool the fused configuration on the low thermal mass receiving belt. A shoe upper in its support frame may be simultaneously pressed against the fused configuration, to place the rein forcement/stiffening or decorative material there against, while it is still tacky, insuring adhesion. The chilling effect of the lower planar block allows the release of the fused configuration from the receiving belt when the substrate, i.e. shoe upper in its support frame is retracted by actuation of the piston means, upwardly, from its contact with the receiving belt.

The release action from the receiving belt may be optimised by the use therewith of a variety of commercial release agents such as silicone oil, or lecithin, or dry preparations of powdered mica, silica and calcium carbonate our a combination of these elements. The frame holding the now reinforced/ stiffening or decorated substrate, i.e. shoe upper is slidably removable from the upper support channel arrangement, and a subsequent unreinforced shoe upper in a frame may be inserted therein, with the "inner" side of the substrate in the case of shoe uppers, being directed downwardly, the frame being pushable into the channels in the upper support arrangement, and the receiving belt and its frame being raised by the frame height adjusting means and being returnable to the first station by pressur isation of its pressurisable means to effect its motion on the guideway, to begin the cycle anew.

In the case where individual reinforcement or stiffening or decorative pieces are desired, the lower foil surface of the stencil and/or the receiving belt may be provided with a release surface preferably made of a porous material from which the piece may easily be peeled. The purpose of the porosity is to ensure that air bubbles on and in the surface of the molten mass may escape, thereby facilitating a high quality bubble free product.

Brief description ofthe drawings The objects and advantages of the present inven tion will become more apparent when viewed in conjunction with the following drawings, in which: Figure 1 is a perspective view taken generally from the front of a machine constructed according to the principles of the present invention; Figure 2 is a elevational view of the front of the machine shown in Figure 1; Figure 3 and Figure 3A are a perspective view and a partial side elevational view respectively of the first work station of the present invention; Figure 4 is a perspective view taken generally from the rear of the first work station of the present invention, in an.opened configuration; Figure 5 is a perspective view taken generally from the front of the second work station of the present invention, in an opened configuration; and Figure 6 is a perspective view of a pallet with a shoe upper arranged therein.

Description of the preferred embodiment Referring now to the drawings in detail, and particularly to Figure 1, there is shown a linear powder deposition machine 10 useful for therein forcement and stiffening and/or decorating of substrates such as cloth or of shoe uppers. The machine 10 comprises a linear arrangement of three work stations, the first being a powder deposition station 12, the second station being a heat station 14, and the third station being a press and cool station 16.

The three work stations 12, 14, and 16 are supported on a common elongated frame 18. The deposition station 12, shown more clearly in Figures 2,3 and 4, has shown thereat, a horizontally arranged surface or receiving belt 20 stretched across a belt holder 22.

The receiving belt 20 and belt holder 22 comprise a portion of a movable unit 24 which is movable into and outofthe remaining work stations 14 and 16.

Referring to Figure 4, the belt 20 is held taut by a first holder member 22A secured to a lower platen 24A of the movable unit 24. A second holder member 22B biases the belt 20 by securement to a pair of uprights 22C, each being pivotably held near its mid-point thereof by a bracket 22D secured to the lower platen 24A. The lower end of each upright 22C has a spring 22E which is attached to the uprights holding the first frame member 22A securely to the lower platen 24A. A pair of biased opposing frame members 23A and 23B are each secured to an upright bracket 23C which is pivotally biased to the lower platen 24A by captive means therearound to bias the brackets 23A and 23B accordingly, as shown in Figure 4.

A stencil means 26, shown in Figure 3 and 4, is hingedly attached to a support 25 extending upwardly from the elongated frame 18. The stencil means 26 comprises the lower surface of a screen frame 28 which receives a reinforcing/stiffening or decorative material "P" in powder form from a supply hopper 33, through a flexible conduit 30 to a dispensercarriage 32 which dispenser-carriage 32 is disposed within the screen frame 28 and transverses across it by actuation of a double acting cable cylinder 27 secured to a structure 29 which supports axial bearing rods upon which the dispenser-carriage 32 moves, A cable 31 is arranged about a pair of sheaves 31A, the cable 31 being attached from each side of a piston in the cylinder 27 to a contact point in the side of the dispenser-carriage 32, to pull it accordingly, when the cable cylinder 27 is actuated by a proper signal from a pressure source, not shown. The dispenser-carriage 32 includes a pair of wiper blades 34 which are shuttleable across the length of the screen frame 28 against the stencil means 26 when the carriage 32 is actuated there across. The wiper blades 34 (also partially shown in a side elevation view in Figure 3A), one on each side of the carriage 32, are biased downwardly with respect to the carriage 32, but are movable upwardly and downwarly with respect thereto. Each wiper blade 34 has a pin 35 on each end thereof. A pair of cam levers 37 and 39 are arranged on the edge of the screen frame 28 adjacent the blade pins 35.Each lever 37 and 39 is pivotable about an axis 41 at its outer end and is biased to facilitate the respective upward and downward movement of the particular wiper blades 34, depending upon the direction of traverse of the dispenser-carriage 32. The trailing wiper blade 34 may be dragged along the surface of the stencil means 26 past the cut-out 42, and the leading wiper blade 34 is gradually raised, as shown in the sectional view in Figure 3A where the dispenser-carriage 32 is shown moving to the right.

When the carriage 32 reverses its direction of travel a newly "bottomed-out" (previously raised) wiper blade 34 sweeps the stencil top surfce 40 and the other wiper blade 34 is lifted upwardly in its sweep as its proceeds towards its respective end of the screen frame 28. It is to be noted that other means such as a pressurisable piston-and-cylinder could be hingedly arranged between each wiper blade 34 and the dispenser-carriage 32 to pull up and push down each wiper blade 34.

The stencil means 26 is slidably received in a pair of channels 36 attached to the bottom of the sides of the structure 29 and is comprised of a wire mesh screen 38 and an overlay of smooth stiff impervious material 40, as shown in Figures 1,3, 3A and 4. A gasket-like perimeter spacing element G may be arranged at least part way around the periphery of the cut-out 42 on the lower or foil side of the screen 38. The element G may have a uniform thickness along its entire length, but preferably tapers from a mid-point thereof towards its end.

The powder "P" used in stiffening shoe uppers is preferably 35 mesh, and possibly a finer mesh powder, such as 50 mesh to 100 mesh which is preferable for more finely defined patterns of intricte designs of shoe reinforcements. The powder types used with this apparatus are preferably polymers such as an ionomer, polyethylene, or ethylene vinyl acetate or a combination of these. The wire mesh screen 38, is of larger mesh, typically 8 to 30 to allow the powder "P" from the dispenser 32 to pass therethrough. The smooth material 40 will have at least one cut-out 42 as shown in Figure 3, which cut-out 42 will have the overall configuration of the shape of the desired reinforcement/stiffener or decorative powder to be applied to the unreinforced substrate, i.e. shoe upper at the third work station 16.

Afoil-like lower surface 40A may be adhered to the lower side of the screen 38 having a similar cut-out 42 in matched alignment with the cut-out 42 in the upper surface 40. The upper and lower surfaces 40 and 40A may be pressed so as to adhere, through an adhesive therebetween, to one another through the mesh openings in the screen 38.

The second work station, comprising the heat applying station 14, is secured to the frame member 18, transversely adjacent the deposition station 12, as shown in Figures 1,2 and 5. The heat applying station 14 comprises a lower planar surface 44 having a plurality of electric heating elements, not shown, arranged therewith in. The lower surface 44 also has a plurality of openings 46 disposed thereacross, in fluid communication via a vacuum line 47 to a vacuum source, also not shown. The heat applying station 14 also comprises an upper planar surface 48 arranged in a housing 50 hingedly connected by a bracket 52 at one end of the housing 50 to the frame member 18. A stop bracket 51 at the other end of the housing 50 strikes a limit bracket 53 which acts to control the closeness of the upper planar surface 48 to the lower planar surface 44.The upper planar surface 48 comprises a plurality of radiant heating elements 54 energised from a proper electrical source, which elements 54 are arranged in a parallel array within the housing 50.

The third station 16 is a press station comprising a join and/or cool means, as shown in Figures 1 and 2.

The press station 16 lincludes a lower planar block 56 which is in fluid communication, through proper conduits 58, to a refrigeraton source, not shown. The lower planar block 56 is secured to the elongated frame member 18. An upper support channel 60 is in vertically movable registration with a bracket 62 which is also attached to a vertical portion of the frame member 18. A pressurisable double acting piston-and-cylinder unit 64 is secured between the top of the upper support channel 60 and the bracket 62. The piston-and-cylinder unit 64 is connected to a pressurisable fluid source actuated by means of a proper signal from a switch attached adjacentto one of a pair of guideways 66 running through the lower portions of the three work stations 12, 14 and 16.The upper support channel 60 slidably receives a substrate holding the pallet or frame 70, which pallet 70 is shown in an open position in Figure 6, the substrate in this embodiment comprising a shoe upper "U".

The pallet 60 comprises two rectangular planar members 72 and 74 having a hinge 75 arranged therebetween on one side thereof. A pad, not shown, is secured to the inner side of one of the planar members 72, the substrate, (if any being desired), in this embodiment being the unreinforced shoe upper "U", is placed over the pad. A cut-out 76 is arranged in the other planar member 74 which cut-out 76 conforms with sufficient clearance to the pattern of reinforcement/stiffener or decoration desired on the substrate/shoe upper"U". The pad causes the "to be reinforced/stiffened" or "decorated" portion of the substrate/shoe upper "U" to be pressed slightly outwardly through the cut-out 76 in the planar member 74, when they are closed together.Figure 6 shows a layer of fused material "M" already applied as a box toe to the shoe upper "U".

The frame 24 supporting the receiving belt 20 is slidably mounted on the guideways 66, the frame 24 being movable on the guideways 66 by interaction of a pressurisable double-acting piston-and-cylinder unit 80 one end of which is secured between the vertical portion of the frame member 18 and a piston rod, not shown, is attached to the frame 24 supporting the receiving belt 20. Other motive means, such as a stepping motor with a rack and pinion gear arrangement could be utilised here. Each work station 12, 14 and 16 has a signal device such as a switch, not shown, on its adjacent portion of the guidway 66, to actuate the subsequent steps in the operating cycle of the machine 10.

The receiving belt 20 has a lower planar support 82 movable toward and away from the bottom of said belt and actuatable by double-acting pressurisable means 84, upon receipt of a proper signal, to provide backing to the receiving belt 20 during application of the configured reinforcement/stiffening or decorative powder thereon, in the deposition process. The double-acting pressurisable means 84 is secured to a bracket 81 which itself is attached to a side of the frame 18, as shown in Figure 4. A shim "S" may be arranged on the top side of the lower planar support 82 as shown in Figures 3A and 4. The shim "S" may comprise a strip of gasket material and is disposed so as to distort and press the receiving belt 20 against the bottom side of the foil 40A on the mesh screen 38 where there is no peripheral gasket around the cut-out 42.The shim "S", is preferred when the product made is for reinforcing a shoe upper, because a sharp taper or scarf may be produced on the powder configuration from the edges of the peripheral gasket to the opposing (no peripheral gasket) edge of the cut-out 42. If no shim "S" is arranged on the lower planar support 82 beneath the receiving belt 20, the product may be of gradual tapered configuration, depending on the thickness and taper of the peripheral gasket.

The structure 29, on which the screen frame 28 is mounted, has a hinge 83, shown in Figure 1, on one end thereof, which is secured to the elongated frame 18, and a bracket 85 is attached to the mid-point of the other end thereof, as shown in Figure 4. A cam following wheel 87 is mounted on the lower end of the bracket 85. A cam 89 is arranged on a track 91, movably connected by a rod 93 to a double-acting pressurisable cylinder 95 towards and away from the belt frame 24. The cam 89 has a gradually increasing inclined surface 97 on which the following wheel 87 turns.

In operation of the shoe upper reinforcement or stiffener or decorative powder applying machine 10, a quantity of fusible powder is discharged from the hopper 33, through the flexible conduit 30 and into the dispenser-carriage 32. The dispenser-carriage moving means, here the cable cylinder 27 attached to the dispenser-carriage 32, upon receipt of a proper signal, acts with the cable 31 secured to the piston in the cylinder 27 to move the carriage 32 on the guide rods of the structure 29 across the screen frame 28. The wiper blades 34 are thus caused to sweep across the stencil top surface 40, the stencil 26 being brought free from contact with the stencil means 26, including the spacers or gaskets thereon.

The "rise" of the cam 89 is preferably a modified sinusoidal shape, moving the stencil 26 upwardly at a slow rate initially to avoid the deleterious effects of inrushing air and related static electrical phenomena on the delicate three-dimensional powder configuration on the receiving belt 20 prior to its being shuttled to the second work or heating station 14.

The selection of the position and use of the "dot" spacers D, shown in Figure 4 is to further control the inrush of air when the stencil 26 is lifted from the receiving belt 20, keeping them apart sufficiently to prevent a partial vacuum therebetween and its related problems.

Upon transverse movement of the receiving belt 20 with its cargo of configured powder "C" thereon, along the guideways 66, a switch is actuated at the heating station 14to stop movement in the frame 24 holding the receiving belt 20, and a signal is made by proper means to cause the receiving belt 20 to be lowered by frame height adjusting means 77 arranged between the frame 24 and the bushings which ride upon the guideways 66, into touching contact with the lower planar surface 44. Thereupon, the vacuum source is actuated, causing the vacuum in the openings 46 to act to retain the receiving belt 20 against the heated lower planar surface 44 by the suction it causes against the receiving belt 20 to insure maximum heat transfer therebetween.The heating elements within the lower planar surface 44 and the radiant heating the powder thereon to fuse into its three-dimensional configuration.

After an appropriate time, preferably up to about 25 seconds, and upon receipt of a proper signal the vacuum source is shut off, the receiving belt 20 and frame 24 are raised from the lower planar surface 44 by the frame height adjusting means, which may comprise a pressurisable piston-and-cylinder arrangement, and thereupon shuttled by unit 80 to the third work station 16 which is arrangeable to present a substrate such as an unreinforced shoe upper "U" to the viscous configuration on the receiving belt 20.

The receiving belt 20 in the third station 16 may (1) be lowered onto supporting contact by the lower planar block 56, by the frame height adjusting means 77, or (2) be held slightly thereabove and pushed into contact with the block 56 by the pallet 70, the receiving belt being chilled by the refrigeration means therefor, to solidify the incoming viscous configuration on the receiving belt 20. A shoe upper "U" in the shoe upper holding pallet 70, assembled in the upper support channel 60 may be then caused by the pressurisable piston-and-cylinder unit 64 to be pressed downwardly, the substrate, here an unreinforced shoe upper"U", having its "inner" side pressed and held momentarily against the now cooling but still adherable and tacky viscous configuration on the receiving belt 20. Upon reversal of the pressurisable piston-and-cylinder unit 64 to its uppermost position, the cooled viscous configuration, adhering to the "inner" portion of the shoe upper "U" is lifted from the smooth receiving belt 20. The substrate (shoe upper) holding pallet 70 may be withdrawn from the upper support channel 60 in the third work station, and a subsequent unreinforced/unstiffened or undecorated substrate such as a shoe upper installed therewithin. The receiving belt 20, now free of any fused powder configuration, may be returned to its position at the first work station. It is lifted slightly from the lower planar block 56 by the frame height adjusting means 77 to allow the frame 24 to clear the block 56, and by actuation, through proper means of the pressurisable piston-and-cylinder unit 80 to effectuate movement of the frame 24 on the guideways 66.

If it is desired to manufacture the fused configuration of powder by itself, then no substrate would be attached to the pallet 70, the configuration of fused powder being pressed, if desired, by the pad on the pallet, which pad would be made from a low friction material which would not be damaged by heat, which pressing would be used to "smooth out" any rough parts of the fused powder. The pad may be made of or covered by a porous material to insure a bubble free product. The fused powder might comprise a box toe for subsequent application to a shoe upper in a further manufacturing operation.

The types of powder "P" usable by conditions of operating the present invention are shown by the following examples: A) A preferred utilisation of the present invention comprises the reinforcement of stiffening of a shoe upper. A 35 - 50 mesh ionomer powder of the sodium cation type having: a melt index of 2.5, a flexural modulus of 51,000 psi (351.72mN/m2), a heat softening temperature (Vicat) 63"C, with no additives. A cut-out in the planar surfaces is prepared to the particular shape desired and placed on an 8 mesh screen woven from .015 inch (0.38mm) stainless steel wire.The choice of an 8 mesh screen represents a balance of opposing factors: a - fine mesh produces a smooth action to the wiper blades; b - too thick a screen wire size makes the scarf or taper edge too thick; c - coarse, small diameter wire mesh presents less surface for residual powder particles to cling to or bridge across.

Spacer means on the bottom of the stencil are utilised for an approximately .040 inch (1.02mm) thick fused product. Considering the bulk density and flow behaviour of the powder, a .100 inch (2.54mm) thick peripheral gasket is used on the bottom side of the stencil means. The scarf shim "S", on the lower support surface is adjusted thereon so as to distort the "no-spacer means" portion of the receiving belt into contact with the bottom surface of the stencil means as to provide a proper (desired) taper on the powder applied on the receiving belt and within the confines of the peripheral gasket.

In the heating station, the lower heating units are set for about 490"F (254.4"C). Each radiant heater above the receiving belt is set for about 600"F (315.6 C) surface temperature.

The deposition mechanism is actuated to allow an overall time of about 25 seconds for fusing the powder on the receiving belt, at which time, the product is transferred to the final station for application to the substrate, here the bottom of a shoe upper, then chilled by the chill plate as it is pressed thereagainst.

The final product for a box toe shoe upper is tapered from .012 inches (0.30mm) thick at its scarf edge, to .035 inches (0.89mm) thick along its full edge.

B) A further example includes the preferred utilisation above-described, having as additions in the powder 0.3% polyalkoxy tertiary amine as an antistatic agent, and 0.3% fine silica as a dryer and flow promoter, resulting in less residual powder on the screen and less electrostatic motion of the powder particles during the deposition process, as well as having the printed pattern of a higher quality. The product here may be .040 inches (1.02mm) thick at its full edge.

C) A still further example includes the earlier described preferred embodiment (A) having as its additives: .05% conductive furnace black. The deposition behaviour, flow behaviour and product pattern are similar to example (B). The time for fusion at the heating station may be reduced here, to about 20 seconds, having a product thickness of about .040 inches (1.02mm).

D) For a flexible box toe for mens' or womens' shoes, a 35 mesh low density polyethylene powder may be used, having a melt index of 22, a flexural modulus of 19,000 psi (131.04mN/m2), a heat softening temperature (Vicat) of 83"C with no additives. The lower heating block is raised to a temperature ofabout400'F (204.4"C) and the upper radiant heater to about 500"F (260.0 C) for a tapered product from about .012 (0.30mm) to .035 (0.89mm) inches for a heating (fusion) time of about 18 seconds.

E) For a soft box toe for slippers, womens' and some childrens' shoes, a 35 mesh ethylene vinyl acetate copolymer, having a melt index of 9, a flexural modulus of about 13,500 psi (93.1 m N/m2) and a heat softening temperature of about 59"C. The machine conditions are the same as those for example (D), with a heating (fusing) time of 12 seconds producing a tapered product of from about .012 (0.30mm)to .035 (0.89mm) inches thick.

F) If the apparatus is to be used for throat reinforcement, eyelet stay or topline reinforcement for a shoe upper, then the preferred powder is 100 mesh nylon 12 and 0.3% polyalkoxytertiary amine.

The stencil screen would be of about 30 mesh size.

This particular product is not tapered, therefore the gasket is arranged about the entire periphery of the cut-out, and is of uniform thickness, of the type of "dot" spacers .040 inches (1.02mm) thick, utilising machine conditions as in example (A), with a heating time of 12 seconds and a print pattern thickness of .017 inches (0.43mm).

G) A thin film reinforcement similar to example (F) wherein a 100 mesh vinyl powder and 0.3% polyal koxytertiary amine powder is used, with a heat stabiliser if desired, having the same deposition means, conditions and results as in the previous example.

It is to be noted that the receiving surface may be in the form of an endless belt, which would be intermittently advanceable between a pair of rolls, one at each end, the belt having one "run" which is disposed along the work stations as the abovedescribed belt is transported therethrough on a frame arrangement. The powder deposited on the receiving surface may be useful for reinforcing or stiffening the toe areas of the shoe uppers or straps for shoes, orto provide reinforcing and/or colour decorations on those shoes or boots.

Advantageously, the fused powder may be deposited on articles of cloth such as cap visors, sports gloves, collars, pajamas, knee or elbow patches or the like, where reinforcement/colour or decoration is desired. The capability for a taper or variation in thickness of the applied powder permits variation in the flexibility of the substrate to which it is applied, very desirable for footwear applications.

Thus there has been shown a unique apparatus for applying reinforcing and stiffening or decorative material to portions of substrates, preferably flexible substrates such as the inner portion of a shoe upper, the material being a fusible powder which permits a more even, cleaner and more efficient manner of manufacturing shoes.

Claims (34)

1. A machine for depositing a fused configuration of powder on a substrate comprising: a frame member; a receiving surface movable with respect to said frame member; a material deposition means arranged over said receiving surface so as to supply said powdered material and said receiving surface; and a cut-out arranged in said deposition means to permit a quantified configuration of said powdered material to be deposited on said receiving surface.

2. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 1, including: a heating member disposed adjacent to said deposition means in said frame member, to heat said movable receiving surface with said powdered configuration thereon.

3. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 2, including: a press station having said substrate arranged in a holder with respect thereto, said press station receiving said held substrate on a slide arrangement.

4. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 3, wherein said press station includes press means for pressing said holder and said substrate onto said receiving surface.

5. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 4, wherein said press station includes cooling and supporting means under said receiving surface as said substrate and said holder are pressed thereagainst.

6. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 5, wherein said receiving surface is shuttled in a plurality of steps, from beneath said deposition means to said heating means to said press station, by motive means attached between said frame member and said receiving surface.

7. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 6, wherein said deposition means deposits said powder into said container.

8. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 7, wherein said powder is melted by said heating means, into a fused mass of desired configuration.

9. A machine for depositing a fused configuration of powder on a substrate, as recited in claim 8, wherein said melted powder is pressed while molten and tacky, by said cooling and supporting means, sufficient to render said fused powder adherable to said substrate such as a shoe upper held in said holder.

10. A machine for depositing a fusible configuration of powder on a substrate, as recited in claim 9, wherein said substrate holder is removable from said press station, said tacky fused powder material adhering to said substrate such as a shoe upper as said fused powder releases from said receiving surface.

11. A machine for depositing a fusible configuration of powder on a substrate, as recited in claim 6, wherein said substrate comprises a piece of cloth.

12. A machine for manufacturing a fused configuration of powder, which fused configuration will be applicable to a substrate, said machine comprising: a frame member; a receiving surface movable with respect to said frame member; a material deposition means arranged over said receiving surface so as to supply said powdered material to said receiving surface; and a cut-out arranged in said deposition means to permit a quantified configuration of said powder to be deposited on said receiving surface.

13. A machine for manufacturing a fused configuration of powder as recited in claim 12, including: a heating member disposed adjacent to said deposition means in said frame member, to heat said movable receiving surface and said powdered configuration thereon.

14. A machine for manufacturing a fused configuration of powder as recited in claim 13, including: a press station having a cooling means thereat for cooling said configuration of fused powder on said receiving surface.

15. A machine for manufacturing a fused configuration of powder as recited in claim 14, including: pressing means at said press station to press said configuration of fused powder on said receiving surface against said cooling means.

16. A machine for manufacturing a fused configuration of powder being constructed and arranged to operate substantially as herein before described with reference to the accompanying drawings.

17. A method for reinforcing a shoe upper, comprising: applying a reinforcing material onto a receiving surface through a shaped cut-out; heating said reinforcing material on said receiving surface; and transferring said heated reinforcing material from said receiving surface to a shoe upper by applying a shoe upperthereagainst.

18. A method for reinforcing a shoe upper, as recited in claim 17, including: cooling said upper during the application of pressure between said upper and said reinforcing material on said receiving surface.

19. A method for reinforcing a shoe upper as recited in claim 18, wherein said step of applying of reinforcing material onto an upper includes: arranging said shaped cut-out in the bottom of a container; supporting said receiving surface beneath said cut-out in said container; depositing reinforcing material into said container; wiping said reinforcing material across said cutout and onto said receiving surface.

20. A method for reinforcing a shoe upper as recited in claim 19, including: moving said reinforcing material and said receiving surface into a heating unit for said heating operation.

21. A method for reinforcing a shoe upper as recited in claim 20, including: holding said reinforcing material against said receiving surface during said heating operation, by means of a vacuum placed under said receiving surface.

22. A method for reinforcing a shoe upper as recited in claim 21, including: moving said heated reinforcing material to said press station to transfer thereat said heated reinforcing material to said shoe upper.

23. A method for reinforcing a shoe upper as recited in claim 21, including: providing a cooling plate beneath said receiving surface to cool said reinforcing material thereon during the pressing of said reinforcing material and said shoe upper.

24. A method for reinforcing a shoe upper as recited in claim 23, including: withdrawing said upper from said press station, said reinforcing material adhering thereagainst.

25. A method for reinforcing a shoe upper, comprising: applying a powdered reinforcing material onto a permeable receiving surface through a shaped cutout so as to define a three-dimensional configuration of powder on said receiving surface; heating said powdered reinforcing material so as to fuse said powder into a molten three-dimensional configuration form.

26. A method for reinforcing a shoe upper as recited in claim 25, including: cooling said heated molten configuration during pressure thereon, to effectuate release of said receiving surface therefrom.

27. A method of utilising a fusible powder for changing the stiffness or decorative characteristics of a substrate, comprising: depositing a fusible powder in a holding means; sweeping said fusible powder through a cut-out in a stencil means; receiving said fusible powder on a receiving surface beneath said stencil means; accumulating said fusible powder in a threedimensional configuration on said receiving surface within the confines of at least a partial peripheral partition disposed on the bottom side of said cut-out.

28. A method of utilising a fusible powder for changing the characteristics of a substrate, as recited in claim 27, including: transferring said receiving surface to a heating means to fuse said powder configuration thereon.

29. A method of utilising a fusible powder for changing the characteristics of a substrate, as recited in claim 28, including: transferring said receiving surface with said fused configuration of powder thereon to a cooling means to solidify said fused configuration thereon.

30. A method of utilising a fusible powder for changing the characteristics of a substrate, as recited in claim 29, including: pressing a substrate onto said cooling fused configuration of powder on said receiving surface, so as to join them together, thereby changing the characteristics of said substrate therewith.

31. A method of utilsing a fusible powder for changing the characteristics of a substrate, as recited in claim 29, including: applying a partial peripheral gasket of diminishing thickness towards its ends thereof onto the bottomside periphery of said cut-out to produce a tapered configuration of powder thereby.

32. A method of utilising a fusible powder for changing the characteristics of a substrate, as recited in claim 31, including: pressing a support surface upwardly beneath said receiving surface prior to said fusible powder accumulating thereon.

33. A method of utilising a fusible power for changing the characteristics of a substrate, as recited in claim 32, including: disposing a shim on said support surface to provide a distorted receiving surface, to facilitate surface configurations in said powder configuration.

34. A method of utilising a fusible powder substantially as described hereinabove and shown in the attached drawings.