IE54887B1 - Machine suitable for use in forming reinforcing/stiffening or decorative layers - 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.

Description

S 4 8 8.7 ? This invention relates to a machine suitable for use in forming reinforcing/stiffening or decorative layers for substrates, e.g. shoe upper or garment components.

The shoe and apparel industry have for many years 5 provided reinforcement/stiffening or decorative means to their products. Manufacturers of pajamas, blue jeans, sports 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 10 reinforcing material tp their products for a variety of reasons. It has been standard for the shoe industry to apply the reinforcement/stiffening means as a layer of molten thermoplastic material adherable to a shoe upper. Early attempts at reinforcing or stiffening a shoe upper 15 have included providing preformed stiffener elements or counters, which are inserted into a shoe upper, prior to lasting. Separate mouldable sheet 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 20 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^ 25 materials prior to lasting of the shoe upper, the shoe upper being stiffened by hardening of the impregnating material after the shoe is lasted.

One such way of stiffening shoe uppers is shown in OS patent 3316573 to Chaplick et al, wherein a shoe 30 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. 54887 Another arrangement for coating shoe parts is shown in OS 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 OS 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.

It is the object of the present invention to provide an improved machine for forming reinforcing/stiffening or decorative layers for substrates, which machine mitigates the inconveniences of the prior art.

There will be hereinafter described in detail, to illustrate the present invention by way of example, one machine for forming reinforcing/stiffening and/or decorating layers for substrates such as the underside of shoe uppers or portions of clothing or the like, by the application thereon of a fused powdered material, this illustrative machine comprising an elongated frame member 8488*? having an array of successive work stations arranged thereon to each of which successively a receiving surface, in the form of a belt, is moved for the performance of a succession of operations thereat. A first station 5 comprises a deposition station, a second station a fusing station, and a third station a join and cool or press station. The receiving belt, which is of rectangular configuration, is tensionably mounted on a frame which is movable or shuttleable into and out of the successive 10 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.

The deposition means comprises stencil means is hingedly 15 disposed above the receiving belt when disposed at the first station. 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 20 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 powder form from a conduit secured to a supply hopper 25 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 30 polyethylene, an ionomer or a ethylene vinyl acetate, if the illustrative 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 35 stencil by actuatable means such as a stepping motor engaged with a rack and pinion gear arrangement, or a cable 54887 ΰ cylinder and pulleys arranged adjacent the carriage and the screen frame.

The fusing station is disposed on the elongated frame member of the apparatus, transversely adjacent the 5 deposition station. The fusing station comprises a lower planar surface of preferably metal construction having a plurality of heating elements heatable to 37S°-500°F (1S0.6°C-260.0°C) arranged therein. The lower planar surface also has a plurality of openings arranged 10 thereacross, in fluid communication with a vacuum source. The fusing 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 15 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 comprises chilling means and pressing means. The chilling means comprising a lower 20 planar block in fluid communication with a refrigeration means. The pressing means comprises a substrate support in the form of a pallet in which a substrate to be reinforced/stiffened or decorated can be located, with the "inner" side of the substrate, e.g. a shoe upper component, 25 facing towards the lower'refrigerated block. The substrate support is supported by an upper support channel arrangement which is movably held above the lower block by a reciprocation means such as a double-acting piston-and-cyUnder unit secured to the frame member.

Actuation of the piston-and-cylinder unit effectuates movement of the support channel arrangement towards and away from the lower refrigerated block.

The frame of the shuttleable receiving belt is slidably mounted on a pair of horizontal guideways, which 35 frame is movable thereon by pressurisable means to move the belt from the first station, then to the second station and S48 8 7 Ο 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 5 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 10 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 illustrative 15 machine, 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 sire caused to sweep across the smooth upper 20 surface of the stencil, sweeping the fusible powder into the configured cut-out thereacross. Each wiper blade is alternately raisedffrom 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 25 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 30 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 35 gasket and therefore selectively space the receiving belt 54887 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 surface 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 of the shuttleable 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 powder 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 powder by conduction of heat from the lower 3 5488? 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 5 tacky mass, the receiving belt may be raised from the lower planar surface by reactuation of the frame height adjusting means, i.e. depressurisation of the cylinder therebeneath and shuttled transversely by actuation of further pressure in the pressure means which causes the frame of the 10 shuttleable receiving belt to move on its guideways to the third station for joining then cooling with an unfeinforced 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 15 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 20 be simultaneously pressed against the fused configuration, to place the reinforcement/stiffening or decorative material thereagainst, while it is still tacky, insuring adhesion. The chilling effect ‘of the lower planar block allows the release of the fused configuration from the 25 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_ 30 agents such as silicone oil, or lecithin, or dry preparations of powdered mica, silica and calcium carbonate or 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 35 arrangement, and a’subsequent unreinforced shoe upper in a frame may be inserted therein, with the "inner1' side of the 54887 ί) 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 pressurisation 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.

The objects and advantages of the present invention 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 the illustrative machine; Figure 2 is a elevational view of the front of the illustrative 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 illustrative machine; Figure 4 is a perspective view taken generally from the rear of the first work station, in an opened configuration; Figure 5 is a perspective view taken generally from the front of the second work station of the illustrative machine, in an opened configuration; and Figure S is a perspective view of a pallet with a shoe upper component arranged therein.

Referring now to the drawings in detail, and particularly to Figure 1, the illustrative machine 5 4 8 8 7 . Ο comprises a linear powder deposition machine 10 useful for the reinforcement 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 5 first being a powder deposition station 12, the second station being a fusing station 14, and the third station being a press and cool station 16. The three work stations 12, 14, and 16 axe supported on a common elongated frame 18. As shown, more clearly in Figures 2, 3 and 4, the 10 illustrative machine comprises 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 out of the remaining work stations 14 and 16. Referring to 15 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 20 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 25 to the lower platen 24A by captive means therearound to bias the brackets 23A and 23B accordingly, as shown in Figure 4.

The deposition station is provided with stencil means 26, shown in Figures 3 and 4, hingedly attached to a 30 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 dispenser-carriage 35 32 which dispenser-carriage 32 is disposed within the screen frame 28 and traverses across it by actuation of a 54887 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 5 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 10 which are shuttleable across the length of the screen frame 28 against the stencil means 26 when the carriage 32 is actuated thereacross. 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 IS to the carriage 32, but are movable upwardly and downwardly 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 20 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 25 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 30 blade 34 sweeps the stencil top surface 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 35 wiper blade 34 and the dispenser-carriage 32 to pull up and push down each wiper blade 34. 54 8 8? 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 5 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 10 from a mid-point thereof towards its end.

The powder "P" used in stiffening shoe upper components 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 intricate designs of shoe 15 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 20 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 25 work station 16. A foil-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 30 therebetween, to one another through the mesh openings in the screen 38.

The second work station, comprising the fusing (heat applying) station'14, is secured to the frame member 18, .transversely adjacent the deposition station 12, as 35 shown in Figures 1, 2 and 5. The heat applying station 14 comprises a lower planar surface 44 having a plurality of 54887 electric heating elements, not shown, arranged therewithin. 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 chilling means and pressing means, as shown in Figures 1 and 2. The chilling means includes a lower planar block 56 which is in fluid communication, through proper conduits 58, to a refrigeration 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. The pressing means comprises a pressurisable double-acting piston-and-cylinder unit 64 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 adjacent to 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 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 component "U". The pallet 60 comprises two rectangular planar members 72 and 74 having a hinge 75. arranged 54837 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 unreinforeed shoe upper component "U", is placed 5 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" 10 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 "tJ".

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 20 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, 25 not shown, on its adjacent portion of the guideway 66, to actuate the subsequent steps in the operating cycle of the machine 10.

At the first station a lower planar support 82 is mounted for heightwise movement toward and away from the 30 under-side of the belt 20 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 35 double-acting pressurisable means 84 is secured to a bracket 81 which itself is attached to a side of the frame 54887 18, as shown in Figure 4. Distorting means in the form of 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 5 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 10 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, IS 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 20 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 25 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 illustrative machine 10, a quantity of fusible powder is discharged from the hopper 30 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 35 cylinder 27 to move the carriage 32 on the guide rods of the structure 29 across the screen frame 28. The wiper 5 £ 8 8 7 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 5 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 10 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 15 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 fusing station 14 to stop movement in the frame 24 holding the receiving belt 20 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 25 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 30 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 35 raised from the lower planar surface 44 by the frame height adjusting means, which may comprise a pressurisable 54887 rt 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 component "0* to the viscous configuration on the receiving 5 belt 20.

The receiving belt 20 when disposed at 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 10 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 component "U" in the pallet 70, assembled in the upper support channel 60 may be 15 then caused by the pressurisable piston-and-cylinder unit 64 to be pressed downwardly, the substrate, here an unreinforced shoe upper component "0", having its "inner" side pressed and held momentarily against the now cooling but still adherable and tacky viscous configuration on the 20 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 component "U" is lifted from the smooth receiving belt 20. The pallet 70 is then withdrawn 25 from the upper support channel 60 in the third work station, and a subsequent unreinforced/unstiffened or undecorated substrate such as a shoe upper component installed therewithin. The receiving belt 20, now free of any fused powder configuration, is then returned to its 30 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 35 movement of the frame 24 on the guideways 66. 541887 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, 5 which pad provides a transfer surface of 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 10 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: 15 20 25 30 A) _ A preferred use of the illustrative machine is for the reinforcement of stiffening of a shoe upper component. 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/m3), 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 35 5 4 8 8 7 (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.

At the fusing 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 means 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 hare 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/iaa), a heat softening temperature (Vicat) of 83°C with no additives. The lower heating block is raised to a temperature of about 400°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 (93.1mSl/ma) 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 illustrative machine 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% polyalkoxy tertiary 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 pr: .it pattern thickness of .017 inches (0.43mm).

G) A thin film reinforcement similar to example (P) wherein a 100 mesh vinyl powder and 0.3% polyalkoxy tertiary 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 in a machine in accordance with the invention otherwise similar to the illustrative machine the receiving surface may be in the form of an endless belt which is intermittently advanceable between a pair of rolls, one at each end, the belt having one run which is disposed -along the work stations in the same manner as the above-described 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, or to 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 S48 8? applied powder permits variation in the flexibility of the substrate to which it is applied, very desirable for footwear applications.

Claims (14)

1. A machine suitable for use in forming reinforcing/stiffening or decorative layers for substrates comprising a receiving surface movable along a linear path to a plurality of treatment stations, deposition means, arranged at a first one of said stations, for depositing on said receiving surface, when disposed thereat, a quantity of a fusible powder in a desired three-dimensional configuration, fusing means, arranged at a second of said stations "downstream" of said first station, for heating the quantity of powder deposited on the receiving surface, when disposed thereat, and thus for causing said quantity to be fused into a cohesive tacky mass while retaining.its three-dimensional configuration, chilling means, arranged at a third of said stations, for cooling the fused mass supported by the receiving surface, when disposed thereat, and thus for consolidating said mass in its three-dimensional configuration, and pressing means for pressing a transfer surface against said fused mass supported by the receiving surface, sequence control means being provided for causing the pressing means to operate while the exposed surface of said fused mass is still tacky so that it adheres to said transfer surface.

2. A machine according to Claim 1 wherein the pressing means comprises a support for a substrate to be reinforced/stiffened or decorated, said substrate providing the transfer surface.

3. A machine according to Claim 2 wherein the substrate support is in the form of a pallet in which the S 4 8 8 ? substrate can be located with the region thereof to be reinforced/stiffened or decorated left exposed.

4. A machine according to any one of the preceding Claims wherein the pressing means is also 5 arranged at the third station, the arrangement being such that the chilling means lies below the level of the path of the receiving surface and the pressing means above such level.

5. A machine according to any one of the 10 preceding Claims wherein the receiving surface has a coating of a low adhesion plastic, heat-resistant material incorporating a release agent.

6. A machine according to any one of the preceding Claims wherein the receiving surface is provided 15 by a continuous conveyor belt along one run of which the treatment stations are arranged, said belt thus providing a plurality of receiving surface portions which are moved successively to the treatment stations.

7. A machine according to any one of the 20 preceding Claims wherein the fusing means comprises a heater disposed below the level of the path of the receiving surface, against which heater the receiving surface is held when disposed at the second station.

8. A machine according to Claim 7 wherein the 25 heater has vacuum means associated therewith for drawing the receiving surface thereagainst.

9. A machine according to either one of Claims 7 and 8 wherein the receiving surface is mounted for heightwise movement towards and away from said heater.

10. A machine according to any one of Claims 7 to 9 wherein the fusing means also comprises radiant heater means disposed at the second station above the level of the path of the receiving means.

11. A machine according to any one of the preceding Claims wherein the deposition means comprises stencil means including a cut-out corresponding to the desired configuration, means connecting the stencil means to a supply of powder, and means for doctoring powder through the stencil means on to the receiving surface when disposed at the first station.

12. A machine according to Claim 11 wherein distorting means is provided at the first station, disposed below the level of the path of the receiving surface and serving to distort said surface thus to control the thickness of the powder doctored through the stencil means on to said surface.

13. A machine according to Claim 12 wherein said distorting means is provided on a support plate member by which the receiving surface is supported during deposition of the powder, said support plate member being movable heightwise towards and away from the receiving surface.

14. A machine according to Claim 1 for applying a reinforcing/stiffening or decorating layer to a substrate constructed arranged and adapted to operate substantially as hereinbefore described with reference to the accompanying drawings. P. R. KELLY & CO., AGENTS FOR THE APPLICANTS..