GB2490150A

GB2490150A - Placement of Moulding Materials

Info

Publication number: GB2490150A
Application number: GB1106671.9A
Authority: GB
Inventors: Thomas Corden; Alasdair Ryder
Original assignee: Umeco Structural Materials Derby Ltd
Current assignee: Cytec Industrial Materials Derby Ltd
Priority date: 2011-04-20
Filing date: 2011-04-20
Publication date: 2012-10-24
Also published as: GB201106671D0

Abstract

Apparatus 10 for the placement of moulding material M on a mould 12, the apparatus having a placement head 14 which comprises a first air permeable membrane 16, a second membrane 18, deformation means 20 arranged to selectively deform the first and second membranes, suction means 22 extending through the second membrane to selectively apply suction between the first and second membranes and through the first membrane 16; and spacing means 24 located between the first and second membranes to maintain an airflow passage between the suction means and the first membrane to prevent deformation of one or both of the first and second membranes blocking suction through the first membrane. Preferably, the membranes comprise an elastomeric material. The spacing means may be a porous member and the deformation means may be a pressurized fluid. The placement head is preferably located on a robotic arm and can be used to select mould material, such as prepreg sheets, from a presentation station and deliver it to a mould.

Description

Placement of Moulding Materials The present invention relates to the placement of moulding materials, particularly but not exclusively to the automated placement of moulding materials on or in moulds.

In the present specification the term "moulds" is used to relate to all forms of moulds, tools, models, patterns, master patterns and the like that provide surfaces against which a moulding material can be moulded.

Moulding materials often come in the form of sheets or plies that are laid on or in a mould, often in number, to produce a laminate or stack of material that is then further processed to form a moulded article or component. Moulding materials of particular interest to the present invention, although the present invention is not limited to use in relation to such moulding materials, are in the form of prepregs. Prepregs comprise fibre reinforcement impregnated, at least partially, with a matrix resin. The amounts and types of resins and fibrous materials in particular prepregs are generally predetermined according to the desired characteristics and properties of the prepreg and the products to be produced from the prepreg and the nature and benefits of prepregs are well known to those skilled in the art.

Conventionally, prepregs are placed by hand on or in moulds as part of the process for producing a moulded article therefrom. Typically, a plurality of prepregs is sequentially placed, usually to form a stack or laminate of prepregs. Once placement of the requisite prepregs is complete, they are typically subjected to further moulding procedures, often including curing of the matrix resin to consolidate the prepregs to form a moulded product.

Such materials can be used to produce products of considerable geometric complexity, but to do so the prepregs need to be carefully positioned on or in a mould, to ensure that they accurately conform to the shape of the mould to ensure accurately formed products are created.

Correct and accurate location of the moulding material over intricate mould geometries, whether internal or external, such as corners, projections and recesses, needs to be done carefully, which conventionally requires placement by a skilled hand, which is a time consuming task.

According to the present invention there is provided apparatus for the placement of moulding material on a mould, the apparatus having a placement head which comprises a first air permeable membrane, a second membrane, deformation means arranged to selectively deform the first and second membranes, suction means extending through the second membrane to selectively apply suction between the first and second membranes and through the first membrane and spacing means located between the first and second membranes to maintain an air flow passage between the suction means and the first membrane to prevent deformation of one or both of the first and the second membranes blocking suction through the first membrane.

The first air permeable membrane may comprise an elastomeric material and may be able to resiliently stretch to deform under the influence of the deformation means. The first air permeable membrane may provide a placement surface, which may be an outer, in use forward facing, surface against which moulding material can be held by applied suction.

The first air permeable membrane may be moveable between a first, relaxed condition and a second, deformed condition under the influence of the deformation means. The first air permeable membrane may comprise at least one, but preferably a plurality of apertures which provide one or more airways through which air can pass through the membrane, particularly air drawn thereth rough by the suction means. The aperture(s) may be provided at least in and desirably over an area of the membrane against which moulding material can be retained in use. The first air permeable membrane may be sealingly attached to a placement head housing, to preferably extend over at least one side of the placement head housing to present the aforesaid placement surface. The said side may be the in use, foremost side of the placement head. The or at least some of the apertures extend through the placement surface.

The second membrane may be non-permeable to gases, in particular air, and is preferably sealingly attached to the housing and positioned at least predominantly between the housing and the first air permeable membrane.

The second membrane may be located, in use, behind the first air permeable membrane, relative to the placement surface of the first air permeable membrane.

The second membrane may comprise a material that is impermeable to gases, in particular air, may be an elastomeric material and may be able to resiliently stretch to deform under the influence of the deformation means.

The second membrane may be moveable between a first, relaxed condition and a second, deformed condition under the influence of the deformation means.

A chamber may be defined between the first air permeable membrane and the second membrane.

The spacing means may be located within the chamber. The spacing means may comprise a porous structure, allowing gases, in particular air, to be drawn therethrough by the suction means. The spacing means may comprise a fibrous structure and may comprise a mat of woven and/or non-woven, typically dry, fibres.

The spacing means may extend over most and desirably all of the area of the first air permeable membrane over which the said aperture(s) extend(s).

The spacing means may extend over, preferably the entire of, the rear of the area of first air permeable membrane defining the placement surface. Means may be provided to retain the spacing means in place, such as adhesive or similar bonding agent.

The suction means may comprise a source of suction, such as a pump or similar arrangement, connected to suction delivery means which passes through the second membrane. The suction delivery means may comprise a suction member defining an air inlet to the suction means in the chamber.

The suction member may extend through the second membrane and is preferably sealed, desirably with a gastight seal, against the second membrane as it passes therethrough, whereby gases can substantially only pass through the second membrane through the suction member. The suction means may comprise a plurality of such suction members. The air inlet to a suction member may rest against or be locatable at least partly in the spacing means to be spaced from and may be held thereby in spaced relation with the first air permeable membrane. The or each suction member may be connected to the or a respective suction source via one or more suction conduits.

The inlet of the or at least one of the suction member(s) may be fixed in position relative to the second membrane to move with the second membrane as it deforms under the influence of the deformation means.

The or at least one of the suction members may be extendable, may be generally in its length, to enable the member(s) to extend and allow the inlet to move with the second membrane as the second membrane deforms. A member may comprise a resilient portion at a position along its length, which portion may be located in the placement head.

The portion may comprise an elastomeric material. Alternatively or in addition the portion may comprise a concertina or other resiliently extendible arrangement. A conduit may comprise an elastomeric material.

The deformation means may comprise a fluid source and a fluid delivery arrangement arranged to deliver fluid, particularly forced or pressurised fluid, to cause deformation of the second membrane. The fluid may act directly on the second membrane to urge and deform the second membrane. The fluid may comprise gas, and may be air. The fluid delivery arrangement may comprise a fluid outlet, which may be located behind the second membrane, may be within the placement head housing. The fluid delivery arrangement may connect the fluid outlet to the fluid source and may comprise a conduit, which may provide fluid-tight communication between the fluid source and the outlet.

The deformation means may comprise fluid driving means to drive forced movement of fluid out of the outlet, which fluid driving means may comprise a fluid pump or similar device to drive air out of the outlet.

Alternatively or in addition, the fluid source may comprise a pressurised or liquefied gas source.

The placement head may comprise a body of resiliently deformable material, such as a thermoplastic foamed or functionally similar material, which provides for resisted deformation of the first and second membranes into the placement head housing.

The placement head may be located on a robotic arm. The apparatus may comprise drive means to drive movement of the placement head to and from one or more moulding positions. The drive means may comprise one or more motors, such as electric motors, which may be provided on or in association with the robotic arm.

The apparatus may comprise a moulding material presentation station at which moulding material to be moulded is presented for the placement Irng head. The station may comprise indexing means to provide for accurate positioning of moulding material at the station.

The indexing means may comprise one or more formations against or in relation to which moulding material is located for accurate positioning. The formation(s) may comprise one or more projections or other formations which may upstand from a presentation surface on which presented moulding material rests.

The apparatus may further comprise a mould against which moulding material is placed by the placement head. The mould may comprise a mould release material, which may be in the form of a release agent and/or a slipper skin.

The apparatus may comprise softening means to soften moulding material prior to placement on the mould. The softening means may comprise an energy source such as a radiant or convection heater, an infra red radiation source or the like.

The softening means may be arranged to soften moulding material held on the placement head prior to placement on the mould.

The apparatus may comprise a moulding material delivery arrangement to deliver moulding material for presentation at the presentation station. The moulding material delivery arrangement may comprise apparatus arranged to provide automated placement of moulded material at the presentation station. The moulding material delivery arrangement may comprise one or more robotic arms.

The moulding material delivery arrangement may comprise moulding material retaining means to releasably retain moulding material thereagainst for the delivery arrangement to convey from a moulding material source to the presentation station. The retaining means may comprise a suction arrangement operable to selectively draw and retain moulding material against the moulding material delivery arrangement. The suction arrangement may comprise a suction cup locatable against moulding material and a suction source connected to the suction cup and operable to apply a suction force across the cup to suck and retain moulding material against the cup.

The suction cup may be resiliently deformable and may comprise elastomeric material.

The apparatus may comprise moulding material preparation means operable to prepare moulding material for presentation at the presentation station.

The preparation means may comprise means to process the moulding material and may comprise apparatus as defined in the Applicant's co-pending UK patent application filed on equal date and entitled "Automated Prepreg Processing".

The preparation means may comprise cutting means to cut the moulding material to the desired shape. The moulding material preparation means may be automated, and may comprise one or more robotic arms.

Embodiments of the present invention will now be described by way of example only, with reference to the accompanying drawings in which: Fig 1 is a diagrammatic cross-sectional view of a placement head of apparatus according to the present invention; Fig 2 is a diagrammatic cross-sectional view of the placement head of Fig 1, in a deformed condition; Fig 3 is a diagrammatic cross-sectional view of the placement head of Fig 2 in use in placing moulding material on a mould; Fig 4 is a diagrammatic representation of apparatus of the present invention in a stage of use; Fig 5 is a representation of the apparatus of Fig 4 in a subsequent stage of use; Fig 6 is a diagrammatic representation of the apparatus of Fig 5 in a subsequent stage of use; Fig 7 is an enlarged, diagrammatic illustration of the apparatus of the present invention placing moulding material against a mould; and Fig 8 is a diagrammatic representation of alternative indexing means according to the present invention.

The present invention provides apparatus 10 for the placement of moulding material M on a mould 12, the apparatus 10 having a placement head 14 which comprises a first air permeable membrane 16, a second membrane 18, deformation means 20 arranged to selectively deform the first 16 and second 18 membranes, suction means 22 extending through the second membrane 18 to selectively apply suction between the first and second membranes 16, 18 and through the first membrane 16 and spacing means 24 located between the first 16 and second 18 membranes to maintain an airflow passage between the suction means 22 and the first membrane 16 to prevent deformation of one or both of the first 16 and second membranes 18 blocking suction through the first membrane 16.

The apparatus and the method of use of the apparatus of the present invention finds particular application in the placement of generally flat or planar moulding materials such as sheets, plies, strips and the like, although it will be appreciated by those skilled in the art that the apparatus and method will be suitable for the placement of other forms of moulding materials.

Moulding materials can come in the form of prepregs and the apparatus and methodology of the present invention find particular application in relation to the placement of prepregs on or in moulds. Again however the invention is not limited to the placement of prepregs and other forms of moulding material can likewise be placed by the apparatus and methods of the present invention.

In more detail, and with particular reference to Figs 1 to 3, the placement head 14 comprises a placement head housing 26 shown for ease of illustration with a generally rectangular cross-section but which can be of any suitable shape. The housing 26 would typically be of rigid construction to withstand and contain the forces generated therewithin by the deformation means 20, as will be described. The housing 26 houses a body of deformable, resilient sponge 28 which substantially fills the housing 26 and provides a degree of support for the deformation means 20 and the suction means 22, as will be described. The body 28 does not necessarily need to be of a sponge material, but does preferably provide at its outer surface 30 a degree of resilient deformability, to accommodate any inward movement of the membranes 16, 18 into the head housing 26. In a particular embodiment the body 28 comprises a thermoplastic material, although other suitable resiliently deformable materials can be used.

The first air permeable membrane 16 is sealed by a seal 32 to the outside of the placement head housing 26. The seal 32 extends around the head housing 26 to provide an airtight seal of the first air permeable membrane 16 against the head housing 26.

The first air permeable membrane comprises an elastomeric material and is able to resiliently stretch to deform under the influence of the deformation means 20. The first air permeable membrane 16 provides an outer placement surface 34 against which moulding material M can be held by the applied suction of the suction means 22, as will be described.

A series or pattern of apertures 36 extends through the first air permeable membrane 16 to provide a plurality of airways through which air can be drawn through the membrane 16 by the suction means 22. The apertures are generally provided in a dispersed arrangement over the placement surface 34.

The second membrane 18 is also sealed against the placement head housing 26 and in this embodiment is sealed by the same seal 32 as that which seals the first air permeable membrane to the housing 26.

The second membrane comprises a non-permeable material and is generally non-permeable to gases, in particular air, and is positioned behind the first air permeable membrane 16 to be between the first air permeable membrane 16 and the housing 26, and importantly to be between the first permeable membrane 16 and the deformation means 20.

The second membrane 18 comprises an elastomeric material and is able to resiliently stretch to deform under the influence of the deformation means 20.

A chamber 38 is defined between the first air permeable membrane 16 and the second membrane 18 and the spacing means 24 is located in that chamber 38.

The spacing means 24 comprises a gas permeable, porous structure through which air can be drawn by the suction means 22. The spacing means 24 can be of any suitable material, with dry fibrous mats of woven and/or non-woven fibre being suitable.

Means (not shown) such as adhesive or other bonding agent may be provided to retain the spacing means 24 in position between the first and second membranes 16, 18. The spacing means 24 helps to ensure that an air path is maintained between the first membrane 16 and the suction means 22 and so preferably the spacing means 24 extends behind the area over which the apertures 36 extend across the first air permeable membrane 16.

The suction means 22 comprises a source of suction (not shown) such as a pump or similar arrangement, connected to suction delivery means 40 shown in this embodiment in the form of a pair of conduits 40 which extend generally mutually parallel and through the placement head housing 26, the body 28 and the second membrane 18 to each define a suction inlet 42. The body 28 helps hold the conduits 40 in position. Each suction conduit 40 is sealed against the second membrane 18 as it passes therethrough by any suitable gastight seal means (not shown), such as adhesive, welding, etc, whereby air can substantially only pass through the second membrane 18, which is otherwise gas impermeable, through the suction conduits 40.

The suction inlets 42 are located in the chamber 38 and may rest against or be located at least partly in the spacing fabric 24, but importantly the inlets 42 are spaced and held so by the spacing means 24 from the first air permeable membrane 16.

Suitable suction conveying conduits (not shown) connect the suction conduits 40 to the suction source. The seal of the conduits 40 against the second membrane 18 also acts to hold the inlet 42 of each conduit 40 in substantially fixed position relative to the second membrane 18. This provides for the movement of the inlets 42 in concert with the deformation of the second membrane 18, as will be described.

To accommodate such movement, each conduit 40 has an extendible portion 44 at a position along its length within the housing 26 which provides for the elongation of the conduits 40 to accommodate the aforesaid movement. The portion 44 is shown with a generally concertinaed configuration, but it will be appreciated by those skilled in the art that any suitable arrangement that allows for resilient elongation of a conduit 40 can be provided, including a section of elastomeric or other resiliently stretchable material at one or more positions, or indeed along the length of a conduit 40 behind the membrane 18.

The deformation means 20 comprises a fluid source (not shown) and a fluid delivery arrangement comprising a conduit 46 to deliver fluid, particularly pressurised fluid, to cause deformation of the second membrane 18, as will be described. The conduit 46 extends through the rear of the housing 26 in a general sealed manner and defines an outJet 48 through which pressurised fluid is expelled in use. The outlet 48 is shown partway through the porous body 28, which can help to act to disperse the fluid (as shown diagrammatically by the arrows F in Figs 2 and 3) in a direction towards the membrane 18 to help provide a broader application of pressure to the rear of the membrane 18. The body 28 also helps to hold the conduit 46 and outlet 48 in position within the housing 26.

It will be appreciated however that outlet 48 can be placed closer to the membrane 18, and indeed can be located outside of the body 28 to provide more direct and focused application of pressurised fluid to the rear of the membrane 18.

The fluid source typically used is compressed air and appropriate delivery conduits connect the outlet conduit 46 to the source.

As an alternative or in addition to the fluid source comprising compressed air, the deformation means may comprise fluid driving or pressurising means, such as a pump or similar such arrangement, to drive fluid through and out from the outlet 48.

The placement head 14 is located on the end of a robotic arm 50, which may locate on the operatively rear of the placement head 14. The deformation means 20 and suction means 22, in particular the conduits that connect the fluid source and the suction source, extend through the arm 50, although it will be appreciated that some or all of them can extend outside of the arm 50.

The robotic arm 50 can be of generally conventional design and construction and preferably comprises drive means (not shown) to drive movement of the placement head between one or typically a plurality of mouiding positions. The drive means typically comprises one or more motors, such as electric motors.

With particular reference to Figs 4 to 7, the apparatus may further comprise a moulding material presentation station 52 at which moulding material M to be moulded is presented for the placement head 14. The station 52 comprises two upstanding indexing pegs 54 which provide a means of indexing and thus accurately positioning moulding material M at the station 52. It will be appreciated that the nature of the means used for indexing can be other than pegs 54, such as any other form of upstanding formation or formations and/or markings on the surface of the station 52.

The apparatus may further comprise the mould 12 against which the moulding material M is placed by the placement head 14, as will be described.

This can be of generally conventional design, although it has been found that for subsequent release of moulded material M therefrom, particularly in an automated environment, release agents and/or a slipper skin are provided.

The apparatus further comprises softening means, shown in the form of an infra red lamp 58, located at a position to enable moulding material located on the placement head 14 to be softened, if desired or required, prior to placement on the mould 12. The nature of the softening means can be other than an infra red lamp, such as for example a radiant heater, convection heater or the like.

The apparatus can also comprise a moulding material delivery arrangement (not shown) to deliver moulding material M for presentation at the presentation station 52. The delivery arrangement may comprise apparatus arranged to provide automated placement of moulded material M at the station 52. The moulding material delivery arrangement may comprise one or more robotic arms.

The moulding material delivery arrangement may comprise moulding material retaining means to releasably retain moulding material M thereagainst for the delivery arrangement to convey from a moulding material source (not shown) to the presentation station 52. The retaining means may comprise a suction arrangement operable to selectively draw and retain moulding material M against the moulding material delivery arrangement. The suction arrangement may comprise a suction cup locatable against moulding material and a suction source connected to the suction cup and operable to selectively apply a suction force across the cup to suck and retain moulding material against the cup. The cup can be resiliently deformable and typically comprises an elastomeric material.

The apparatus may also comprise moulding material preparation means (not shown) operable to prepare moulding material for presentation at the presentation station 52. The preparation means can comprise means to process the moulding material M and may comprise apparatus as defined in the Applicant's co-pending UK patent application filed on equal date and entitled "Automated Prepreg Processing".

The preparation means may comprise cutting means to cut the moulding material to the desired shape and is preferably automated, comprising one or more robotic arms.

In use, the apparatus of the present invention provides a means of automated placement of moulding material M on a mould 12. Moulding material M to be placed is accurately located on the presentation station 52 using the indexing means 54. Preparation means such as described above may have been employed to prepare the material M and moulding material delivery arrangement as described above used to deliver the moulding material M and correctly locate the material at the station 52. Fig 4 shows material M correctly positioned at the presentation station 52.

The placement head 14 is manoeuvred by the robotic arm 50 to locate over the moulding material M as shown in Fig 4. The robotic arm 50 then lowers the head 14 down onto the material M, as shown in Fig 5. Referring to Fig 1, the suction means 22 is activated. Air is drawn from the outside of the placement surface 34, through the apertures 36, through the spacing means 24, in through the suction inlets 42 and away through the suction conduits 40.

The series of arrows S shows diagrammatically the general air flow of the suction. The suction provided is sufficient to draw the moulding material M against the head 14, such that when the robotic arm 50 lifts the placement head 14, the moulding material M is lifted with it, as can be seen in Fig 6.

If desired, the robotic arm 50 can manoeuvre the placement head 14 and the material M thereon in appropriate position against a softening lamp 58 to expose the material M to heat or other energy, or indeed other softening means, to soften the material M to the desired degree. For materials that do not require softening, this stage can be omitted.

The robotic arm 50 then manoeuvres the placement head 14 to the mould M, and in particular the appropriate position on or over the mould 12 at which the particular piece of moulding material M held on the placement head 14 is to be located. Once the material M has been so positioned on the placement head 14, if the particular location requires the material M to be urged to conform to the geometries of the mould 12, the deformation means is activated. Upon activation of the deformation means 20, pressurised air is expelled out of the outlet 48 of the conduit 46 to impinge upon the rear of the second membrane 18 (see Fig 2). The arrows F diagrammatically illustrate the movement of pressurised air through the body 28, which acts to disperse the air, to urge against the membrane 18. As the pressure increases, the membrane 18 deforms, the resilient and elastic nature of the membrane 18 allowing the membrane 18 to balloon outwards from a first, relaxed condition (Fig 1) to a second, deformed condition (Fig 2). The amount of pressure applied by the deformation means 20 is controlled to control the degree of deformation. The seal 32 holds the membrane 18 in sealed location on the head housing 26.

As the membrane 18 stretches and balloons away from the housing 26, the suction conduits 40 correspondingly elongate, enabled or facilitated by the extendible portion or portions 44, so that the suction inlets 42 remain in position ahead of the membrane 18. As can be seen in Fig 2, the portions 44 which were generally of concertinaed configuration when the membrane 18 was in the relaxed condition (Fig 1) have been straightened, at least to some degree.

The deformation of the second membrane 18 causes corresponding deformation of the first membrane 16, as the second membrane 18 urges the spacing means 24 against the first membrane 16.

The porous nature of the spacing means 24, which as described above can be in the form of a dry fibrous mat, ensures that there is always a pathway for air between the first and second membranes 16, 18, which ensures that air can always be drawn from outside the first air permeable membrane 16 by the suction means 22, regardless of the state of deformation of the membranes 16, 18. This arrangement ensures that the suction is also maintained during the application of external deforming pressures on the membranes 16, 18 during moulding.

Fig 7 shows the placement head 14 placing a moulding material M against a geometry of a mould 12, with the membranes 16, 18 in the deformed, ballooned condition. Fig 3 is a cross-sectional view of the placement head 14 in use placing material M against the mould 12.

As the head 14 is urged against the mould 12 by the robotic arm 50, with the membranes 16, 18 in the secured, deformed condition, the membranes 16, 18 are pushed inwardly by the geometry of the mould 12.

The internal pressure of the head 14 provided by the deforming means 20 helps to resist this and to urge the material M onto and around the mould 12 to conform to the shape of the mould. It has been found that the placement head 14 of the present invention allows material to be accurately placed against quite intricate and complex mould geometries, both internal, such as recessed geometries, and external, such as external corners and projection geometries. Again, the arrangement of the placement head 14 allows for the maintenance of suction and thus retention of the material M on the placement head 14 as the membranes 16, 18 are deformed, both by the deformation means and also by the mould 12.

The deformable nature of the body 28, whilst providing support for deformation means 20 and suction means 22, allows for deformation of the membranes 16, 18 into the body of the housing 26 during the placement process (see Fig 3) without damage.

As the membranes 16, 18 are deformed inwardly by the reaction forces of the mould 12, the portion(s) of the conduits 40 can return, at least in part, to their relaxed state, allowing the length of the conduits 40 to reduce accordingly.

Once the material M has been placed as desired onto the mould 12, the suction can be released, allowing the placement head to be manoeuvred away from the mould, leaving the material M in place on the mould 12. The use of suction to retain the material M in place helps to prevent undesirable damage to the material M during placement.

It will be appreciated that the apparatus 10 of the present invention provides for the accurate placement of moulding material M on moulds 12.

The sequential application of pieces of moulding material M on, in and around the mould 12 can be automated by repeating the steps described above, until the desired number of pieces of moulding material M have been placed. The placed material is then subjected to appropriate moulding conditions, such as cure conditions, typically according to processes known to those skilled in the art.

The apparatus and methodologies of the present invention provide for a completely automated procedure for the placement or laying up of moulding materials, including prepregs, of quite intricate and complex mould geometry.

Various modifications may be made without departing from the spirit or scope of the present invention. The actual size and shape of the placement head 14, and in particular the placement surface 34, can be varied according to the size, shape and to some extent the complexities and intricacies of the material and moulds with which the head is to be used. For example, more intricate and perhaps internal geometries (such as deep recesses, internal corners) may be best moulded using relatively small placement heads and/or heads that have relatively large degrees of deformation, that enable material M to be accurately placed within such geometries.

Fig 8 illustrates an alternative indexing means 154 in use to accurately locate the moulding material M at the processing station 52. The indexing means 154 comprises two upstanding projections or pegs which in this embodiment are positioned to extend from the station 52, through the moulding material M. Apertures (not shown) are preferably preformed in the moulding material M so that when the moulding material M is located at the station 52, over the pegs 154, the moulding material M is in the correct location and alignment. It will be appreciated that the number and positioning of the projections or pegs 154 can be of any suitable combination and the example of two pegs located generally centrally is just one example. In a very simple form, the indexing means 154 could comprise a single peg that is located preferably in the centre of the moulding material M. However, for accuracy of location, both from a positional and orientational perspective, it is envisaged that a plurality of projections or pegs will be provided. Indeed, asymmetric arrangements of such pegs can help improve correct location of a moulding material M at the station 52. Such indexing means has particular advantage where the external shapes and dimensions of the moulding material M that can be located at the station can vary. The indexing means 54 described above find general application where the external size and shape of the moulding material being located at the station 52 are the same.

However, in practice moulding materials of varying size and shape can be used in the apparatus of the present invention and therefore indexing means such as that illustrated at 154 which do not index against the external dimensions of the moulding material for location find utility use for such applications.

The precise arrangements of the suction means 22 and deformation means 20 can be varied, such as for example two or more deformation outlets 48 may be provided within a placement head housing 26, and one or more suction inlets 42 may be provided in the chamber 34.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

Claims 1. Apparatus for the placement of moulding material on a mould, the apparatus having a placement head which comprises a first air permeable membrane, a second membrane, deformation means arranged to selectively deform the first and second membranes, suction means extending through the second membrane to selectively apply suction between the first and second membranes and through the first membrane and spacing means located between the first and second membranes to maintain an air flow passage between the suction means and the first membrane to prevent deformation of one or both of the first and second membranes blocking suction through the first membrane.
2. Apparatus as claimed in claim 1, in which the first air permeable membrane comprises an elastomeric material.
3. Apparatus as claimed in claim 1 or claim 2, in which the first air permeable membrane is resiliently stretched to deform under the influence of the deformation means.
4. Apparatus as claimed in any preceding claim, in which the first air permeable membrane provides a placement surface against which moulding material can be held by suction.

*.*.25
5. Apparatus as claimed in claim 4, in which the placement surface is an outer, in use forward facing surface
6. Apparatus as claimed in any preceding claim, in which the first air permeable membrane is moveable between a first, relaxed condition and a °.30 second, deformed condition under the influence of the deformation means. *.fl

S * 55 * S
7. Apparatus as claimed in any preceding claim, in which the first air permeable membrane comprises at least one aperture which provides one or more airways through which air can pass through the membrane, particularly air drawn therethrough by the suction means.
8. Apparatus as claimed in claim 7, in which the first air permeable membrane comprises a plurality of apertures.
9. Apparatus as claimed in claim 7 or claim 8, in which the aperture(s) are provided at least in an area of the membrane against which moulding material can be retained in use.
10. Apparatus as claimed in claim 9, in which the aperture(s) is/are provided over the said area.
11. Apparatus as aimed in any preceding claim, in which the first air permeable membrane is sealingly attached to a placement head housing.
12. Apparatus as claimed in claim 11, in which the first air permeable membrane extends over at least one side of the placement head housing to present the aforesaid placement surface.
13. Apparatus as claimed in claim 12, in which the said side is the in use, foremost side of the placement head. * * * * **
14. Apparatus as claimed in any of claims 7 to 13, in which the or at least some of the apertures extend through the placement surface. Os.
15. Apparatus as claimed in any preceding claim, in which the second : *°.30 membrane is non-permeable to gases. ***.S

*. 5*S * *
16. Apparatus as claimed in any preceding claim, in which the second membrane is sealingly attached to the housing and positioned at least predominantly between the housing and the first air permeable membrane.
17. Apparatus as claimed in any of claims 4 to 16, in which the second membrane is located, in use, behind the first air permeable membrane, relative to the placement surface of the first air permeable membrane.
18. Apparatus as claimed in any preceding claim, in which the second membrane comprises a material that is impermeable to gases.
19. Apparatus as claimed in any preceding claim, in which the second membrane is an elastomeric material.
20. Apparatus as claimed in any preceding claim, in which the second membrane is able to resiliently stretch to deform under the influence of the deformation means.
21. Apparatus as claimed in any preceding claim, in which the second membrane is moveable between a first, relaxed condition and a second, deformed condition under the influence of the deformation means.
22. Apparatus as claimed in any preceding claim, in which a chamber is defined between the first air permeable membrane and the second .25 membrane.* ns..S S
23. Apparatus as claimed in claim 22, in which the spacing means is located within the chamber.

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24. Apparatus as claimed in any preceding claim, in which the spacing means comprises a porous structure, allowing gases, in particular air, to be drawn therethrough by the suction means.
25. Apparatus as claimed in any preceding claim, in which the spacing means comprises a fibrous structure.
26. Apparatus as claimed in any preceding claim, in which the spacing means comprises a mat of woven and/or non-woven, typically dry, fibres.
27. Apparatus as claimed in any of claims 9 to 26, in which the spacing means extends over most of the area of the first air permeable membrane over which the said aperture(s) extend(s).
28. Apparatus as claimed in any of claims 9 to 26, in which the spacing means extends over all of the area of the first permeable membrane of which the said aperture(s) extend(s).
29. Apparatus as claimed in any of claims 9 to 28, in which the spacing means extends over the rear of the area of first air permeable membrane defining the placement surface.
30. Apparatus as claimed in any preceding claim, in which means is provided to retain the spacing means in place.
31. Apparatus as claimed in claim 30, in which the means is adhesive or similar bonding agent. S. S * *e * Sb
32. Apparatus as claimed in any preceding claim, in which the suction means comprises a source of suction connected to suction delivery means which passes through the second membrane.

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33. Apparatus as claimed in claim 32, in which the suction delivery means comprises a suction member defining an air inlet to the suction means in the chamber.
34. Apparatus as claimed in claim 33, in which the suction member extends through the second membrane and is sealed against the second membrane as it passes therethrough, whereby gases can substantially only pass through the second membrane through the suction member.
35. Apparatus as claimed in claim 34, in which the seal is a gas-tight seal.
36. Apparatus as claimed in any of claims 33 to 35, in which the suction means comprises a plurality of such suction members.
37. Apparatus as claimed in any of claims 33 to 36, in which the air inlet to a suction member rests against or be locatable at least partly in the spacing means to be spaced from the first air permeable membrane.
36. Apparatus as claimed in any of claims 33 to 37, in which the or each suction member is connected to the or a respective suction source via one or more suction conduits.
39. Apparatus as claimed in any of claims 33 to 38, in which the inlet of the or at least one of the suction member(s) is fixed in position relative to the second membrane to move with the second membrane as it deforms under the influence of the deformation means.

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40. Apparatus as claimed in any of claims 33 to 39, in which the or at least one of the suction members is extendible to enable the member(s) to extend * * and allow the inlet to* move with the second membrane as the second membrane deforms.

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41. Apparatus as claimed in claim 40, in which the member(s) is/are **s* extendible generally in its length.
42. Apparatus as claimed in any of claims 33 to 41, in which a member comprises a resilient portion at a position along its length.
43. Apparatus as claimed in claim 42, in which the portion is located in the placement head.
44. Apparatus as claimed in claim 42 or claim 43, in which the portion comprises an elastomeric material.
45. Apparatus as claimed in any of claims 42 to 44, in which the portion comprises a concertina or other resiliently extendible arrangement.
46. Apparatus as claimed in any of claims 38 to 45, in which a conduit comprises an elastomeric material.
47. Apparatus as claimed in any preceding claim, in which the deformation means comprises a fluid source and a fluid delivery arrangement to deliver fluid, to cause deformation of the second membrane.
48. Apparatus as claimed in claim 47, in which the deformation means is arranged to deliver forced or pressurised fluid.
49. Apparatus as claimed in any of claims 47 to 48, in which the fluid acts directly on the second membrane to urge and deform the second membrane. S. S * S S * SS
50. Apparatus as claimed in any of claims 47 to 49, in which the fluid comprises gas. 50*5
51. Apparatus as claimed in any of claims 47 to 50, in which the fluid is air. * 05 * S * *500* *.***S S
52. Apparatus as claimed in any of claims 47 to 51, in which the fluid delivery arrangement comprises a fluid outlet located behind the second membrane.
53. Apparatus as claimed in any of claims 47 to 52, in which the fluid delivery arrangement comprises a fluid outlet within the placement head housing.
54. Apparatus as claimed in any of claims 47 to 53, in which the fluid delivery arrangement connects the fluid outlet to the fluid source and comprises a conduit.
55. Apparatus as claimed in any of claims 47 to 54, in which the fluid delivery arrangement provides fluid-tight communication between the fluid source and the outlet.
56. Apparatus as claimed in any of claims 52 to 55, in which the deformation means comprises fluid driving means to drive forced movement of fluid out of the outlet.
57. Apparatus as claimed in claim 56, in which the fluid driving means comprises a fluid pump or similar device to drive air out of the outlet.
58. Apparatus as claimed in any of claims 47 to 57, in which the fluid :,,: 25 source comprises a pressurised or liquefied gas source.S.. 55. * S
59. Apparatus as claimed in any preceding claim, in which the placement head comprises a body of resiliently deformable material which provides for resisted deformation of the first and second membranes into the placement : *.30 head housing. �SItS*05 50. * S
60. Apparatus as claimed in claim 59, in which the body comprises thermoplastic foamed or functionally similar material.
61. Apparatus as claimed in any preceding claim, in which the placement head is located on a robotic arm.
62. Apparatus as claimed in any preceding claim, in which the apparatus comprises drive means to drive movement of the placement head to and from one or more moulding positions.
63. Apparatus as claimed in claim 62, in which the drive means comprises one or more motors provided on or in association with the robotic arm.
64. Apparatus as claimed in any preceding claim, in which the apparatus comprises a moulding material presentation station at which moulding material to be moulded is presented for the placement head.
65. Apparatus as claimed in claim 64, in which the station comprises indexing means to provide for accurate positioning of moulding material at the station.
66. Apparatus as claimed in claim 65, in which the indexing means comprises one or more formations against or in relation to which moulding : 25 material is located for accurate positioning.
67. Apparatus as claimed in claim 66, in which the formation(s) comprise one or more projections or other formations which upstand from a SOS. . . presentation surface on which presented moulding material rests.

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68. Apparatus as claimed in any preceding claim, in which the apparatus further comprises a mould against which moulding material is placed by the placement head.
69. Apparatus as claimed in claim 68, in which the mould comprises a mould release material.
70. Apparatus as claimed in claim 69, in which the mould release material is in the form of a release agent and/or a slipper skin.
71. Apparatus as claimed in any preceding claim, in which the apparatus comprises softening means to soften moulding material prior to placement on the mould.
72. Apparatus as claimed in claim 71, in which the softening means comprises an energy source such as a radiant or convection heater, an infra red radiation source or the like.
73. Apparatus as claimed in claim 71 or claim 72, in which the softening means is arranged to soften moulding material held on the placement head prior to placement on the mould.
74. Apparatus as claimed in any of claims 64 to 73, in which the apparatus comprises a moulding material delivery arrangement to deliver moulding material for presentation at the presentation station.
75. Apparatus as claimed in claim 74, in which the moulding material : 25 delivery arrangement comprises apparatus arranged to provide automated placement of moulded material at the presentation station. OS*
76. Apparatus as claimed in claim 74 or claim 75, in which the moulding material delivery arrangement comprises one or more robotic arms. * .* *� S S.,.
77. Apparatus as claimed in claim 74, 75 or 76, in which the moulding material delivery arrangement comprises moulding material retaining means to releasably retain moulding material thereagainst for the delivery arrangement to convey from a moulding material source to the presentation station.
78. Apparatus as claimed in claim 77, in which the retaining means comprises a suction arrangement operable to selectively draw and retain moulding material against the moulding material delivery arrangement.
79. Apparatus as claimed in claim 78, in which the suction arrangement comprises a suction cup locatable against moulding material and a suction source connected to the suction cup and operable to apply a suction force across the cup to suck and retain moulding material against the cup.
80. Apparatus as claimed in claim 79, in which the suction cup is resiliently deformable.
81. Apparatus as claimed in claim 79 or claim 80, in which the suction cup comprises elastomeric material.
82. Apparatus as claimed in any preceding claim, in which the apparatus comprises moulding material preparation means operable to prepare moulding material for presentation at the presentation station.
83. Apparatus as claimed in claim 82, in which the preparation means comprises cutting means to cut the moulding material to the desired shape.

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84. Apparatus as claimed in claim 82 or claim 83, in which the moulding material preparation means is automated.

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85. Apparatus as claimed in any of claims 82 to 84, in which the moulding r material preparation means comprises one or more robotic arms. 4 0
86. Apparatus for the placement of moulding material on a mould substantially as hereinbefore described with reference to the accompanying drawings.
87. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims. * * S ts * * S Sb StSS* S S S 55 * tS*55 *55S