JPS6215202Y2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION This invention describes an apparatus for forming thermosetting and thermoplastic materials, in particular brazier cups or similar members made from thermoplastic materials made from woven or non-woven forms of various natural or man-made fibers. This invention relates to a molding device.

In the manufacture of bras or similar garments, including loungewear, yukatas, etc., there has been a need for improved equipment to facilitate the formation of several components of such products. In particular, in brassieres, the molded components include a lid, a padding, a lining, etc., and these three components are molded separately and then stacked together, the padding is placed between the lid and the lining, and assembled into an integral relationship by basting and sewing. A wide variety of thermoset and thermoplastic materials are advantageously used in the manufacture of such articles, and may include combinations of woven and nonwoven natural or man-made fibers, such as polyurethane sheets and polyethylene foams.

For the mass production of such molded products, especially breast cups for bras and clothing products, it is preferable to have equipment available for producing molded parts, which can be continuously remanufactured and which can be accurately produced over a relatively wide range. It should be possible to adjust the main parameters for molding thermoplastic materials, namely molding pressure, temperature, time, etc.
By controlling these main parameters and being able to handle thermoplastic materials with varying thicknesses,
Such molding equipment has considerable flexibility and can be used to manufacture a wide variety of products from a variety of different materials, and can be efficiently and inexpensively manufactured in series.

Broadly speaking, the object of this invention is to obtain an improved forming apparatus to achieve the aforementioned objectives, and in particular it is an object of this invention to provide an improved forming apparatus which improves the shape of the molded product, particularly the depth of the forming recess. It is possible to perform various molding cycles in which molding pressure, temperature, and time can be freely controlled.

It is further an object of this invention to provide equipment for manufacturing products containing molded breasts or breast cups, typically bras, which are suitable for manufacturing in large quantities and at relatively low unit costs to precisely controlled specifications. It is to be.

Another object of the invention is to provide an improved molding apparatus for producing separate parts of a breast or breast cup in one controlled molding cycle.

The molding apparatus of the present invention includes an apparatus for molding brazier cups or similarly shaped products from molding material, the molding apparatus having a first mold member, typically a female mold member. A second mold member, typically a male member, is mounted to the support frame in interleaved relationship with the first mold member. A holding member is attached to the support frame and is removable from the first mold member and the material holding position. Apparatus is provided for moving the holding member into a material holding position and applying a predetermined material holding pressure to the molding material in temporal relation to the molding relationship of the second mold member with the first mold member. Apparatus is provided that is operative to move the second mold member in molding relation to the first mold member and to temporally move the holding member to apply a predetermined molding pressure during a molding cycle. The material retention pressure on the molding material can be adjusted to retain the material for subsequent molding operations and may allow controlled entry of the material into the molding cavity. Depending on the material, the retaining member may be deactivated to allow the material to enter the molding cavity without applying pressure, such as molding of foamed non-woven fabrics typically used as stuffing fillers in the manufacture of brazier cups. There are cases where

According to this invention, a material that can be formed by applying heat and pressure is directed into an open mold in which a first mold member and a second mold member cooperate with each other to form a molding cavity; The material is held at a predetermined clamping pressure to controllably mount the blank within the forming cavity. The mold then places the material between the two mold members, closes the mold, and applies heat and pressure to shape the material into the shape of the mold cavity. Particularly in the molding of foam fillings, the foam material is placed in a mold, the edges of the material are tightened to prevent the material from moving laterally, heat and pressure are applied to the closed mold for a certain period of time, and the foam material is shaped into the cavity. At the same time, a selvage is formed around the shape formed in the foam material.
Typically, the selvage joins the molded form along defined divisions that are utilized during subsequent cutting and sewing of the molded product.

The foregoing description and other objects, features and advantages of the invention will become apparent from the following description of the embodiments illustrated in the accompanying drawings.

1, 2, 4 and 5, there is shown an apparatus 20 for forming brazier cups or similar shaped articles, the forming apparatus 20 being provided with identical forming stations 22 arranged side by side. Conveniently, four locations, substantially identical to the molding location 22, are provided so that they can be installed and removed by a single operator. Molding device 20
can be used to manufacture a wide range of products,
For example, as shown in FIG. 3, a typical brassiere cup is manufactured, consisting of an inner lining L, a cover C, and a foam filling F disposed therebetween. These 3
Two materials are molded separately and then stacked in three layers,
It is cut, basted, and finally incorporated into a bra or other garment. Typically the lining L and cover C are made of polyester, tricot or nylon or other man-made or natural fibers, and the filling F is made of synthetic foam products or fibres. The forming apparatus 20 has a support or frame 24 which is provided with a horizontally extending table 26 for arranging several forming stations 22 at a height suitable for the operator.
is supported by a pair of downwardly extending front legs 28 and rear legs 30.

A molding station 22, representing one of a plurality of side-by-side molding stations, has a female mold base 32 mounted on a table 26 and a female mold member 34 mounted thereon. Details in 5th and 6th
As shown in the figure. The female mold member 34 has spaced apart breast cup forming cavities 34a, 34b for forming right and left breast cups, respectively. Alternatively, only one breast cup cavity may be provided, and the right and left breast cups may be differentiated with the molded cups in opposite directions. However, the explanation will be given assuming that it has two cups. The molding cavities 34a, 34b are the fifth,
As seen in Figure 6, the edges or rims 34c, 34
It is surrounded by d. Edges 34c and 34d are inner peripheral edges and sharp edges 34e and 34f of spaces 34a and 34b.
meet and form the edges of each cup. Edges 34c, 34d meet the plane of the mold at connections 34h, 34i and form the outer periphery of each molded cup. The typical material shown in Fig. 3 (part of which is also shown on the right side of Fig. 5) is the female member 3.
4 molding cavities 34a, 34b, 34c, 34d,
It has a part corresponding to 34g, for example, for the lining L, the cups La, Lb, the edges Lc, Ld and the remaining flat part.
Lg.

A support post 36 extends upwardly from the table 26 behind the female member 34 and its base 32 and supports the head and cross plate 40 above and away from the female member 34. This upper structure includes a male base 42, a male base 44,
The retaining member 46 is attached to the female member 34 as described below.
Both the mounting and operating mechanism are attached to move the device in cooperation with the device. In particular, the male member 44 and its base 42 reciprocate vertically so that the female member 3
The cylinder 48 and piston 50 are pneumatically moved to cooperate with the cylinder 48 and the piston 50. Its operation will be described in detail later in connection with FIGS. 6-11.

Further, the upper structure has a head 38 and a horizontal plate 40, and a pneumatic actuator is used to hold the retaining member 46 to the piston cylinder assembly 5.
2, 54; 56, 58; 60, 62, and a fourth piston cylinder 60, 62 provided at the rear, of which only the rod 60 is shown in FIGS. 6 and 7. These four cylinders are mounted substantially squarely on the cross plate 40, and their piston rods 54, 58, 62, 64 extend through the cross plate 40.
extending downwardly at two points and being attached to the holding member 46;
A male member 44 and a female member 34, as will be explained later.
and make it work.

A device is provided for determining the final spacing or depth of molding between the female and male members at the molding position. For this purpose, the main piston rod 50 has two thin nuts 66, 68 (FIG. 4) which cooperate with a fixed limit stop 70 at the upper end of the main cylinder 48. The thin nuts 66, 68 are first adjusted so that the male member 44 bottoms out in the female member 34, after which the male member 44 is returned and the nuts 66, 68 are adjusted relative to each other and shaped by the stop member 70. Accurately predetermine the depth of formation in the operation.

Projecting upwardly from the front of the cross plate 40 at the forming station 22 is an operating control panel 72 containing the necessary controls and instrumentation. These instruments are shown in Figure 2 and their operation is shown in Figure 1.
1, as follows. start buttons 74, 76, stop button 78 (used for emergency stop); temperature control 80 for female member 34; temperature control 82 for movable male member 44; 1 pressure gauge 84, a second pressure gauge 86 that indicates the molding pressure during other parts of the molding cycle, a pressure control device 88 that can be adjusted for different molding cycles, and a molding that can also be adjusted for different molding cycles. cycle timer 90
etc.

Temperature control device 80 controls electric heater 92, which is embedded in female member 34, and temperature control device 82 similarly controls electric heater 94, which is embedded in male member 44. . In this way, the mold member 34,
The heat applied to 44 is precisely controlled. Since retaining member 46 does not require precise temperature control for the manufacture of, for example, breast cups, heater 96 for retaining member 46 is simply thermostatically controlled (FIG. 11).

Having described the brass molding apparatus 20 generally, the operation of the apparatus comprised of three mold members 34, 44, 46 will now be described with reference to FIGS. 6-8. This controls the amount of material or backing L fed into the mold, and the spread of the material L is controlled to give it a uniform, reproducible working shape.
The male mold member 44 feeds the material into the mold cavity, and the retaining member 46 provides the necessary drag or lateral tension to precisely condition the material being processed within the machine.
Adjusting the material in this way ensures that the apex of the breast cup will be elongated or molded into a precise shape after the breast cup or similar product has been manufactured, but it is different from conventional It was difficult to carry out continuous production under the necessary conditions using the equipment. In FIG. 6, the three mold members 34, 44, 46 are shown in the open position, with the male mold member 44 and the surrounding retaining member 46 being retracted from the female mold member 34, and the material lining L being placed in the female mold. It can be placed on member 34. The molding cycle is started by a compressed air control device as will be explained later, and the holding member 46 is
It first moves into the material clamping position shown in the figure, and in this embodiment precisely controls the supply of material L to the breast cups La, Lb into the mold cavities 34a, 34b. After the edges of blank L have been tightened, male member 44 is moved to the operating position relative to female member 34, as shown in FIG. 8, and a molding cycle, such as that described with respect to FIG. 3, is performed. At the end of the molding cycle, the operation is reversed and the male mold member 44 is moved upwardly with the base 42 into the mold open position, and the retaining member 46 is then retracted to separate each of the three mold members shown in FIG. return to the original position.

As shown in FIGS. 9 and 10, before tightening the edges of the material, i.e., the foam material F, the material F is placed into the molding cavity to form an edge around the shape formed from the material. An elastic separating device is provided as shown in FIG. The elastic separating device has four pin mounting sockets 91 formed at the four corners of the female mold member 34 and opening into the plane 34g forming the separating plane of the mold members 34 and 44. Each socket 91 is fitted with a separating device having two elastic members or compression springs 93 and a pin shaft 95A and a pin head 95B placed within the socket. The vertical separation device for the holding member 46 operates while the male member 44 is moved towards the female member so as not to impose any restriction on the blank F as shown in FIG. As shown in FIG. 9, after the foamed material F is attached between the mold members 34 and 44, a downward force is applied to the holding member 46 to hold the material F against the force of the spring 93. position and the head 95 of the pin 95 as shown in FIG.
The minimum distance in the vertical direction determined by b. When the pins 95 are thus attached to their respective sockets 91, the mold members 34, 44, 46 compress and hold the blank F into the molding cavity formed by the engagement of the male mold member 44 with the female mold member 34. The member 46 is separated from the blank F and the female mold member 34, but after a certain period of time, a predetermined force is applied to the retaining member 46 and the spring 93 is pressed, causing the retaining member 46 to continue through the molding cycle as shown in FIG. Keep the intermediate material F in the holding position.

A typical control circuit for the brass molding apparatus of this invention is shown in FIG. Although the arrangement of the control member shown in FIG. 2 and each mechanism of the molding device 20 shown in FIGS. 1 and 4 to 8 is shown, the control member and each mechanism are not attached to the molding device 20, Frame 2
4 may be incorporated into a control box 102 (FIG. 1) attached to. In this embodiment, AC power supply 104
is connected to the heating device 9 of the female member 34 by suitable wiring.
2 and the control device 82 of the heating device 94 for the male member 44 and the holding member 46
The thermostatic heating device 96 is connected to the thermostatic heating device 96. Although such temperature control devices are generally known and will not be described in detail, for example, the Fenwal 500 manufactured by the Fenwal Company of Ashland, Massachusetts may be used.

The AC power supply 104 has a pair of manual buttons 74 and 7.
6. Connected to the timer 90 and the normally open auxiliary switch 106 associated with the timer 90, which operates in time to complete the molding cycle under normal operation, but in the event of an emergency, the operation An emergency stop device 78 is provided which is connected to a timer 90 for operator control of the molding cycle.
Timer 90 is, for example, a Model 7000 time relay manufactured by the Agusta Division of Esna, Amerase, Elizabeth, N.J., and has a normally open auxiliary switch 106 which, when the relay coil of timer 90 is operated, adjusts the timer. prior to the end of a certain molding cycle as determined by the method. Timer 90 operates solenoid controlled valves 108, 110, and 112 at the beginning of a molding cycle. The valve 108 has its input connected to the main air line 114 and in the normal or rest position connects the main air line 114 to the piston cylinder assembly (i.e. 56, 58 and 6) against the retaining member 46 through the branch line 116 and the emergency exhaust valve 118.
0, 62) to the supply pipes 120, 122, etc. Thus, before the molding cycle is started under the control of the timer, the solenoid control valve 10
8 is the main air pipe 114 to the pipes 116, 120, 12
2, and the holding member 46 is
It is maintained in the retracted position shown in FIG.

When timer 90 is activated, solenoid control valve 108 connects main air line 114 to pressure control device 88,
The opposite ends of the four cylinder piston assemblies are connected to the retaining member 46 through a check valve 126 and supply pipes 130,132. When the solenoid-controlled valve 108 is operated under the control of the timer 90, the air pressure applied from the main air pipe 114 is applied from the branch pipe 124 to the upper end of the cylinder piston assembly, causing the retaining member 46 to The material is moved from the retracted or open position shown in the figures to the material clamping or operating position shown in FIGS. 7 and 8, for example. The clamping pressure applied by the holding member 46 is controlled by the pressure control device 8.
8, the pressure of which is indicated by gauge 84.

Before the pressure control device 88, the solenoid control valve 10
After 8, branch pipe 124 is connected to bypass pipe 134, which is connected to the input of solenoid control valve 110, which is normally open. valve 110
The output of is connected through meter 86 to check valve 126 and supply lines 130, 132 to form a high pressure path to retaining member 46. This high pressure pipeline is operated by a solenoid control valve 108 and a solenoid control valve 11.
Provided only when 0 does not operate. Initially, during the timing cycle and at predetermined intervals, solenoid control valve 110 operates to close the high pressure bypass formed by pipes 134 and 136 under control of auxiliary switch 106. However, when the auxiliary switch 106 is returned to its normal open position during a molding cycle, the solenoid controlled valve is changed to provide a relatively high pressure passage for pneumatic control of the retaining member 46.

Main cylinder and piston 4 to male member 44
The solenoid control valve 112 for 8, 50 has its input side connected to the main air pipe 114 through a branch pipe 138.
The output side is connected to the lower end and the upper end of the main cylinder through supply pipes 140 and 142, respectively. Solenoid control valve 112 is connected to the lower end of main cylinder 48 through tubes 138, 140, with male member 44 in its normal, retracted or open position. Valve 1
12 to the start position of the timing cycle, pressure is applied to the upper end of cylinder 48 through branch tube 138 and supply tube 142 to move male member 44 from its retracted position to its closed or molding position.

The solenoid-controlled valves 108, 112 have adjusting holes 108a, 112a, respectively, to move the male member 44 and the retaining member 46 in temporal relation to each other, i.e., to cause downward shaping of the male member 44. When the retaining member 46 is moved to its material clamping position and conversely the three mold members are moved to the open position, the male mold member 44 is moved before the retaining member 46 is retracted. can be retracted.

Cycle timer 9 during a typical molding cycle
After adjusting the pressure control device 88 to
The two start buttons 74 and 76 are pressed simultaneously to move the solenoid control valves 108, 110, 112 from the position indicated by the solid arrow to the position indicated by the dotted arrow. A quick exhaust valve 118 is provided on the underside of the air pressure control device for controlling the adjustment holes 108a, 112a and for the retaining member 46 before the male member 44 engages the female member 34, as shown in FIG. is moved to the material holding position shown in . The material is held at a predetermined clamping pressure, which is less than the pressure in the main air line 114 and regulated by a pressure controller 88 . This relatively small tightening force is determined by timer 90.
is maintained until the auxiliary switch 106 returns to its open position, at which time the solenoid control valve 110
is in its normal position and in the direction of the arrow shown by the solid line, and the main air pipe 114, valve 108, side pipe 1
34, valve 110, branch pipe 136, cylinder 56,
60 etc. through the check valve 126. Check valve 126 limits pressure within the tube from being applied downstream of pressure control device 88 in tube 136 . At the end of the molding cycle, timer 90 operates to return solenoid controlled valves 108, 112 to the position indicated by the solid arrows and the mold opening sequence is initiated. While male member 44 and retaining member 46 move upwardly, it is important that the male member move first, as this restricts the flow of air exiting the discharge ends of the four retaining cylinders and prevents the solenoid control valve 112 from moving. This is done by adjusting the hole 112a with respect to the main cylinder 48.

The molding device 20 operates in a similar sequence as described during the molding of foam fillings or similar products, but with the following differences. The separation pin 95 is inserted into the socket 91 of the female member 34a as shown in FIG.
The pressure applied to the pneumatic actuator is sufficient to move only the retaining member 46 to the detached position shown in FIG. 9, but is not large enough to overcome the resistance of the spring 93 associated with the pin 95. do it like this. The holding member 46 is attached to the female member 34 as shown in FIG.
The filler material F is held in the female member 34 at a distance from the auxiliary switch 106 which is returned to its normal open position by the timer 90 and a high pressure bypass is established through the solenoid control valve 108. It is allowed to slide up to. High pressure is then applied to the cylinder-piston assembly controlling the retaining member 46, causing the retaining member 46 to overcome the resistance of the spring 93 and move into the operative position around the formed foam cup in contact with the female member 34. to form a sharp discontinuity and a rim to the cup.

Typical adjustments for molding 100% polyester are main air pressure 5.62 Kg/cm ² (80 lbs/in2), molding cycle 40 seconds ± 5 seconds, molding temperature 182°C ±
It is 3° (360〓, ±5〓). When the male member is completely connected to the female member, the gap between the two members is approximately 3.2
mm (1/8)'', and the pneumatic system has a delay of approximately 5 seconds between when the retaining member engages the polyester woven material and when the male member contacts that material. The required holding pressure is determined by the control device 88, and in this embodiment the pressure applied to the holding member is the same whether applied through the control device 88 or through the bypasses 134, 136. Care should be taken to ensure that the member does not engage the material before the retaining member engages the polyester material, so that too much material is fed into the mold and the cup depth is increased between one molding and the next. Avoid being different.
It is important that the molding cycle be chosen so that the material is subjected to heat and pressure for only the required period of time; an incorrect molding cycle will result in an incomplete molded cup. There is no problem if the molding period is slightly excessive, but productivity will decrease. Temperature control is important;
When high temperatures are used, the polyester material becomes plastic and creates a relatively hard breast cup; when low molding temperatures are used, the breast cup does not form properly.

Foam filling or material, for example about 6.35mm thick
(1/4)” To form one layer of material, the main air pipe 1
The pressure at No. 14 is again 5.62 kg/cm ² (80 lb/in 2 ), and the pressure controller 88 moves the retaining member to No. 9.
The separated position shown in the figure is achieved, but air pressure is applied so as not to overcome the force of the spacing spring 93. The cycle time is approximately the same and the temperature is determined by the foam material. For example, 230℃±3゜(415〓±5
゜) is suitable for molding foam materials. The male member is adjusted to lower approximately 3.2 mm (1/8)" from the female member and is lowered 5 seconds later than the movement of the retaining member. The pressure applied by controller 88 is such that the retaining member 1.4 Kg/cm ² (20 pounds per square inch) is suitable for moving the retaining member to the detached position, and operation of the solenoid-controlled bypass valve 110 under the control of the auxiliary switch 106 forces the retaining member to full clamping pressure. and move it from the position shown in FIG. 9 to the molding position shown in FIG.

As discussed, the present invention provides an improved molding apparatus that allows molding from many different materials under widely varying molding conditions such as temperature pressure and molding time. The forming device of this invention has two states: a first state in which the peripheral edge of the blank is clamped under controlled pressure before the central part of the blank is secured in the shaping cavity; It is suitable for molding that is operated in a second state that is adapted to the location. When the molding cycle is complete, the molded product is clearly surrounded by a border line, which line is surrounded by a formed rim.

Although the above description describes brazier cup forming, the forming of this invention involves precisely controlling the feeding of preformed sheet or blanket material, and then using precisely controlled temperatures, pressures, and forming times. It is clear that the method can be applied to the molding of many different molded articles in which the molding is carried out.

[Brief explanation of the drawing]

FIG. 1 is a side view of a molding device according to an embodiment of the invention for molding brazier cups; FIG. 2 is an enlarged front view of the control panel for one molding location of the molding device; and FIG. Fig. 4 is a left side view of the molding device shown in Fig. 1, with the control panel removed to show the internal structure, and brass molding is performed using this invention. FIG. 5 is a top view of the female mold member used in the illustrated molding device, and FIG. 6 is a sectional view taken along line 6-6 in FIG. 4, showing the female mold as seen from the direction of the arrow. The male member holding member is shown in an open state;
The holding member is shown in the starting state of the molding cycle when it is retracted from the female mold member, and FIG. 7 is a cross-sectional view similar to that of FIG. FIG. 8 is a cross-sectional view similar to FIG. FIG. 9 is a cross-sectional view similar to FIGS. 6-8, but showing the three members used in molding a foam filler or similar material in a separated position and the material being applied to the mold cavity; ,
FIG. 10 shows the position of the three mold members during a molding cycle for a foam filling, and FIG. 11 shows a typical control arrangement for a brass molding apparatus according to the invention. In the figure, 20: Molding device, 22: Molding place, 24: Frame,
26: Table, 28, 30: Legs, 32: Molding base, 34: Female member, 36: Support column, 40: Horizontal plate, 44: Male member, 46: Holding member, 48: Main cylinder, 50: Piston ,52,54,56,
58, 60, 62: cylinder piston assembly, 6
6, 68: thin nut, 70: stop member, 72: control panel, 74, 76: start button, 78: stop button, 80, 82: temperature control device, 84, 8
6: Pressure gauge, 88: Pressure control device, 90: Timer device, 91: Socket, 92: Heating device, 9
3: Compression spring, 94: Heating device, 95: Pin, 9
6: heating device, 102: control box, 104: power supply,
108: Emergency exhaust valve, 114: Main air pipe, 11
8: Emergency exhaust valve, 126: Check valve.

Claims (1)

[Scope of utility model registration request] a support frame, a first mold member on the support frame, a second mold member, a device for attaching the second mold member to the support frame for movement into and out of molding relationship with the first mold member, a retaining member, and a second mold member; an apparatus for attaching a retaining member to a support frame for movement into and out of a material holding position with respect to the mold member; and a first, relatively small, means for moving the retaining member into and out of a material holding position relative to the mold member and for moving the holding member into the material holding position and for applying a first relatively small amount of material to the molding material during a first position of the molding cycle. applying a predetermined material holding pressure and a second relatively large predetermined material holding pressure to the molding material during a second position of the molding cycle in molding relation to the first mold member in time relation to advancement of the second mold member; Apparatus for forming brazier cups or similarly shaped articles from formable materials, with a working apparatus.