US20050269738A1 - Layering process for forming a reinforced article - Google Patents
Layering process for forming a reinforced article Download PDFInfo
- Publication number
- US20050269738A1 US20050269738A1 US11/134,232 US13423205A US2005269738A1 US 20050269738 A1 US20050269738 A1 US 20050269738A1 US 13423205 A US13423205 A US 13423205A US 2005269738 A1 US2005269738 A1 US 2005269738A1
- Authority
- US
- United States
- Prior art keywords
- mixture layer
- reinforcing mixture
- fabric
- covering
- foam core
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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- 230000008569 process Effects 0.000 title claims abstract description 58
- 239000011162 core material Substances 0.000 claims abstract description 135
- 239000000203 mixture Substances 0.000 claims abstract description 105
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 88
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- 239000007787 solid Substances 0.000 claims abstract description 15
- 239000004744 fabric Substances 0.000 claims description 94
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- 150000001875 compounds Chemical class 0.000 claims description 14
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- 238000004519 manufacturing process Methods 0.000 claims description 6
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- 238000009966 trimming Methods 0.000 description 29
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
- B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0092—Producing upholstery articles, e.g. cushions, seats
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/22—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics reinforced
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- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
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- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/647—Including a foamed layer or component
- Y10T442/652—Nonwoven fabric is coated, impregnated, or autogenously bonded
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/653—Including particulate material other than fiber
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/654—Including a free metal or alloy constituent
Definitions
- the present invention relates generally to systems and methods for manufacturing covered articles.
- reinforced materials are well-known in the art, including U.S. Pat. No. 5,728,458 to Sweeney entitled “Light-Weight High-Strength Composite Pad” and U.S. Pat. No. 5,209,968 to Sweeney entitled “Composite Structure With Waste Plastic Core And Method of Making Same,” both of which are incorporated herein by reference. These examples disclose the use of core materials coated with reinforcing layers for multi-use pads, equipment pads, building panels, and other applications.
- these prior art reinforced layered structures are formed by manual covering processes such as wrapping a core, trimming excess wrapping material, and attaching the material to or into the article with adhesive, physical bindings, or direct insertion into the article core.
- manual covering processes such as wrapping a core, trimming excess wrapping material, and attaching the material to or into the article with adhesive, physical bindings, or direct insertion into the article core.
- the present invention answers this need by providing a covering apparatus and method that automates the covering process for manufacturing articles.
- the present invention provides an apparatus and method for covering articles.
- covering, trimming, and/or tucking of material into a core material is automated.
- a conveyor system for transporting an article to covering, trimming and/or tucking stations to cover the article.
- a fibrous fabric is tucked into a core material comprising expanded polystyrene (EPS) foam, moldable into any desired shape.
- EPS expanded polystyrene
- additional material layers may be applied or injected on and/or beneath the covering material to achieve desired reinforcing characteristics.
- the present invention further provides a system and method for manufacturing reinforced articles with a core material covered with a covering material by injecting a desired compound or mixture between the core material and covering material to create an inner reinforcing layer.
- an automated covering station wherein covering material is dispensed for surrounding an article core.
- the core material is covered by the dispensed material as the core drops through a slot in a covering table across which the covering material is dispensed.
- an automated tucking station is provided on a conveyor system for tucking one or more portions of the covering material into the core material.
- the tucking apparatus includes parallel pairs of horizontal and vertical tucking apparatuses for plunging covering material into the core.
- a corner trimming station with an automated pincher and welder is provided for trimming excess fabric at the corners of the covered core material by pulling and welding the excess corner fabric.
- FIG. 1 is a cross-sectional view of a reinforced article in an embodiment of the present invention.
- FIG. 2 is a perspective view of a bottom surface of a core material in a stack of core materials with receiving channels being burned at a receiving channel burning station in an embodiment of the present invention.
- FIG. 3 is a top perspective view of a core material and covering material being positioned thereon at a covering material template table in an embodiment of the present invention.
- FIG. 4 is a top perspective view of a covering material tucking station in an embodiment of the present invention.
- FIG. 5 is a perspective view of a tucking apparatus including an automated tucking needle and plunger in an embodiment of the present invention.
- FIG. 6 is a perspective view of an excess fabric weld trimming station including pinchers, weld holders, and weld blade in an embodiment of the present invention.
- FIG. 7 is a top perspective view of a four corner automated weld trimming apparatus in an embodiment of the present invention.
- FIG. 8 is a top perspective view of a reinforcing layer injection station in an embodiment of the present invention.
- FIG. 9 is a perspective partial cut-away view of a covered core material being injected with an inner reinforcing layer mixture in an embodiment of the present invention.
- FIG. 10 is a texturizing station in an embodiment of the present invention.
- FIG. 11 is a top perspective view of a core material covering, trimming and tucking conveyor apparatus in an embodiment of the present invention.
- FIG. 12 is a top perspective view of an automated covering station in an embodiment of the present invention.
- FIG. 13 is a top perspective view of a magazine cylinders apparatus of an automated covering station in an embodiment of the present invention.
- FIG. 14 is a partial perspective view of a core material and fabric lowered beneath a fabric table of an automated covering station in an embodiment of the present of the invention.
- FIG. 15 of the is a partial perspective view of the trimming apparatus of an automated covering station prior to trimming the corner of a covered core material in an embodiment of the present invention.
- FIG. 16 is a partial perspective view of the trimming apparatus of an automated covering station during trimming of the corner of a covered core material in an embodiment of the present invention.
- FIG. 17 is a top perspective view of a horizontal tucking apparatus station in a conveyor apparatus with retracted tucking cylinders in an embodiment of the present invention.
- FIG. 18 a the top perspective view of a horizontal tucking apparatus station in a conveyor apparatus with tucking cylinders in lowered operation in an embodiment of the present invention.
- FIG. 19 is a top perspective view of a vertical tucking apparatus station in a conveyor apparatus with retracted tucking cylinders in an embodiment of the present invention.
- FIG. 20 is a top perspective view of a vertical tucking apparatus station in a conveyor apparatus with tucking cylinders in lowered operation in an embodiment of the present invention.
- EPS expanded polystyrene
- exemplary covering materials may include fabric, fibrous wrap, webs, mesh, glass mats, paper, and any other types of synthetic or natural fibrous material that is pregnable by a desired reinforcing layer.
- Core materials include foamable materials such as polyurethane, polyisocyanurate, EPS, other rigid foams, plastics, corks, wood, synthetic polymers, and similar rigid core materials.
- the reinforced mixture layer may include mixtures of concrete, plaster, epoxy, synthetic resins, polymers, paint, waterproofing compounds, glues, foams, and similar mixtures or materials capable of injection between a core material and covering material.
- injection may include the deposit of the reinforcing material by injection entirely through a core material at any desired angle, or, alternatively, with an appropriate injection head, through the covering material, so as to deposit the reinforcing layer between the covering material and core material.
- FIG. 1 a cross section of reinforced article 5 is shown.
- a core material 10 is surrounded by covering material 15 .
- covering material 15 includes fabric woven or non-woven.
- An inner reinforcing mixture layer 20 including a cement mixture in one embodiment, is provided between the core material 10 and the covering material 15 .
- Covering material edges 19 are tucked into tucking grooves 30 in the core material 10 .
- the tucked edges 19 keep the covering material 15 tightly surrounding the core material. Further, the tucked edges 19 and tucking groove 30 maximize retention of inner reinforcing mixture layer 20 between core material 10 and covering material 15 .
- tucking of edges 19 may be replaced or augmented by gluing or other adhesives, taping, stapling, sewing, heat binding, and like methods for adhering edges 19 to the core material 10 .
- the inner reinforcing mixture layer 20 is injected between the core material 10 and covering material 15 after the covering material 15 is secure with tucked edges 19 in tucking groove 30 .
- a needle head with a dispersion hole may be used for depositing the inner reinforcing mixture layer 20 .
- the inner reinforcing mixture layer 20 is injected as a slurry mixture, such as a cement mixture, concrete mixture, plaster mixture, epoxy mixture, synthetic resin mixture, polymer mixture, paint mixture, or waterproofing mixture and the like, depending on the desired end use of the reinforced article.
- a slurry mixture such as a cement mixture, concrete mixture, plaster mixture, epoxy mixture, synthetic resin mixture, polymer mixture, paint mixture, or waterproofing mixture and the like, depending on the desired end use of the reinforced article.
- Such mixtures are preferably metered to deposit such amounts as are necessary to create a desired thickness and characteristics of the reinforcing layer 20 and reinforced article 5 . Accordingly, depending on the properties of the mixture deposited for the inner reinforcing mixture layer 20 , such mixture is cured to provide the desired reinforcing characteristics of the mixture used.
- one or more outer reinforcing mixture layers 25 may be provided in reinforced article 5 .
- Outer layer 25 may be the same or a different substance from inner layer 20 .
- both the inner layer 20 and outer layer 25 are cured cement mixtures.
- optional outer layer 25 may comprise one or multiple layers that include any materials with desired characteristics for reinforced article 5 .
- the outer reinforcing mixture layer 25 includes concrete, plaster, epoxy, synthetic resins, polymers, paint, waterproofing compounds, cement, glues, and the like. It will be understood that this is only an exemplary list, and further appreciated that the curing of any applied mixtures, such as slurry mixtures, may be desirable to achieve desired characteristics of the outer reinforcing mixture layer 25 .
- an outer reinforcing layer 25 includes a texture layer 50 ( FIG. 10 ).
- the texture layer 50 includes a solid substance, such as sand 710 ( FIG. 10 ), but may include virtually any solid with desired texture and binding characteristics with outer layer 25 .
- covering material 15 is a fabric or other fibrous material
- inner layer 20 and optional outer layers 25 and texture layer 50 at least in part, impregnate the covering material 15 to bind and create the desirable reinforced surface layers surrounding core material 10 of reinforced article 5 .
- core material 10 includes inner reinforcing layer receiving channels 40 .
- core material 10 is EPS foam
- the receiving channels 40 are burned at a receiving channel burning station 100 .
- the receiving channel burning station includes hot wire burners 105 on which the core material 10 is placed to burn the receiving channel 40 .
- the receiving channels 40 are burned on any surface of the core material which will contact the inner reinforcing mixture layer 20 and be surrounded by covering material 15 .
- the receiving channels may be burned along all surfaces of the core material 10 , or along side surfaces 15 , or top surfaces and side surfaces, or any combinations thereof.
- the receiving channels 40 permit greater deposition of the inner reinforcing mixture layer 20 than a mere flat surface. Accordingly, the depths of the receiving channels 40 may be increased or decreased for the desired purpose of the reinforced article 5 and reinforcing characteristics of the inner layer 20 .
- the core material may be stacked as a plurality of core materials to burn receiving channels on multiple core materials' 10 surfaces at once.
- the stack is rotated to each desired receiving channel burning surface for burning on hot wires 105 .
- front and back surfaces may be burned with receiving channels 40 by separating each individual core material 10 from the stack to burn the desired surface.
- receiving channels 40 may be formed by alternative methods such as cutting, drilling and boring.
- the receiving channels 40 are preferably burned into a top surface (not shown) and side surfaces of a core material 10 made of EPS foam.
- the inner reinforcing mixture layer 20 of cement mixture forms a layer on the top and side surfaces of the core material and between the covering material 15 .
- the covering material is preferably pregnable fibrous fabric and the tucked ends 19 sustain the inner reinforcing layer 20 around the top and side surface of the core material 10 to also promote deposition of the inner reinforcing mixture layer 20 into the receiving channels 40 of the top and side surfaces.
- the receiving channels 40 are preferably 1 ⁇ 8′′ wide by 1 ⁇ 4′′ deep.
- a covering material application station 200 is shown.
- the core material 10 is covered with covering material 15 after forming the receiving channels 40 .
- the covering material is applied prior to injection of inner reinforcing mixture layer 20 .
- the covering material application station provides proper alignment of fabric covering material 15 .
- a fabric template 205 is sized to the shape of the core material 10 so that the core material is centered on the fabric covering material 15 .
- the fabric application station 200 is preferably a light table wherein the fabric template includes a template periphery for aligning the fabric covering material 15 .
- the flaps 17 of the fabric are folded over the core material 10 .
- the core material 10 including the folded flaps 17 of covering material 15 is placed in covering material tucking station 300 .
- the tucking station 300 includes a conveyor belt 305 for directing a plurality of covered core materials to a tucking apparatus 320 . As shown in FIG. 4 , two pairs of tucking apparatuses 320 are used in one embodiment of the invention to tuck flaps 17 into tucking grooves 30 ( FIG. 1 ) as folded edges 19 ( FIG. 1 ).
- flap rail guides 310 are provided for maintaining the folded flaps 17 in a desired position against core material 10 .
- the rail guides 310 terminate at flap folder 315 as the covered core material 10 is directed at each opposite flap 17 to tucking apparatus 320 .
- tucking apparatus 320 includes a groove perforation needle 325 and tucking plunger 330 .
- Each of the needle 325 and plunger 330 are automated so as to actuate a rapid up and down plunging movement.
- the needle 325 perforates the flap 17 and core material 10 to create a tucking groove 30 ( FIG. 1 ) perforation line.
- a blunt plunger head 330 follows the perforation needle 325 to tuck covering material edge 19 ( FIG. 1 ) into tucking groove 30 ( FIG. 1 ).
- a plurality of tucking apparatuses 320 may be used to reinforce tucking of the covering material edge 19 into tucking groove 30 .
- multiple tucking apparatuses are implemented to form multiple tucked grooves for additional tucking of portions of the covering material 15 into the core material 10 .
- the covered core material 10 is rotated 90 degrees following initial tucking on opposite flaps 17 . Unfolded opposite flaps 14 are folded and the covered core material similarly placed on conveyer 305 of the tucking station 300 to tuck flaps 14 with tucking apparatus 320 .
- the top and four side surfaces of the core material 10 are completely covered by covering material 15 and all four edges of the fabric covering material 15 are tucked into the bottom surface 11 of the core material 10 .
- the corner trimming station 500 includes actuated pinchers 505 that pinch excess fabric corner 16 and subsequently pull the excess fabric corner 16 outward from the core material corner 12 .
- Corner weld holders 510 actuate to pinch and hold the excess fabric corner 16 at a point near the core material corner 12 .
- An automatic trim weld blade 515 is actuated toward the pinched excess fabric corner 16 and the weld blade 515 welds the excess fabric corner 16 , such as a fibrous woven or non-woven fabric, to create a welded tight, trimmed edge while the excess fabric corner 16 is burned off and discarded.
- additional trimming such as by hand, of the fabric welded corner may be necessary to achieve a smooth welded corner edge.
- the corner trimming station 500 includes four sets of pinchers 505 , weld holders 510 , and weld blades 515 .
- the covered core material 10 is placed so that each corner is positioned between each set of pinchers 505 , weld holders 510 , and weld blades 515 , to allow automatic welding and trimming of all four corners at once.
- a plurality of covered core materials may be stacked to permit trimming of a plurality of stacked corners 12 simultaneously.
- a reinforcing layer injection station 600 is depicted with an injector 620 connected to a mixture supply line 630 .
- the injection station 600 includes a conveyor 602 to provide automated injection of a plurality of covered core materials 10 .
- square or rectangular covered core materials 10 are stacked at a stacking partition 605 that aligns the stacked covered core material 10 for positioning on the conveyor 602 to the injector 620 .
- An indexer 610 is actuated in the line of conveyor movement toward the bottom covered core material 10 in the stack.
- the indexer 610 strikes the bottom covered core material 10 from the stack to propel it out of the stack and along the conveyor toward the injector 620 .
- Gravity causes the remaining covered material 10 in the stack to move downward along the partition 605 when the indexer 610 retracts in a reverse direction from the movement of the conveyor 602 .
- the covered core material propelled from the stack is covered facedown and the reverse face, facing upward, includes the bottom surface 11 tucked portions. Accordingly, the tucked face is exposed toward the injector 620 .
- the indexer 610 and injector 620 are in timed synchronization so that the indexer pushes the next covered core material 610 forward as the injector 620 lifts up and down to receive and pin the covered core material in the injector.
- Metal injector guide 622 preferably holds the covered core material in position for injection. Following injection of the inner reinforcing layer 20 , the injection guides 622 retract upward to permit the next indexed covered material into the injector 620 .
- the injector includes an injection needle 625 and retracting needle arm 621 .
- needle arm 621 and needle 625 are lowered through the core material 10 until injection needle 625 is positioned so that injection hole 628 is positioned between the surface of the core material 10 and the covering material 15 .
- the reinforcing mixture 21 such as cement slurry, is provided by a mixture feed line 630 connected to injection needle 625 .
- the mixture 21 is injected in a desired metered amount, depending on the desired characteristics and thickness of the inner reinforcing layer 20 .
- the injector 620 includes a vacuum base that removes excess water from the mixture 21 ( FIG. 9 ) to form inner reinforcing layer 20 between the covering material 15 and the core material 10 .
- the injected mixture 21 includes a 1:1 cement/water ratio to promote dispersion. The increased water ratio, compared to typical cement mixtures, provides a better dispersion consistency for venting the reinforcing layer 20 .
- the vacuum action acts to dewater the mixture 21 to solidify the injected cement mixture 21 .
- the injector including the injector guide 622 , retractable needle arm 621 and needle 625 , are lifted upward to permit the injected article 5 to be removed.
- the next covered core material 10 is indexed forward and the injector, including injector guide 622 , needle arm 621 and injector needle 625 , lowered to pin the covered core material 10 and repeat the process.
- the reinforced article with inner injection layer 20 may be cured as desired.
- the covered core material 10 including the injected inner reinforcing layer 20 is further coated with an outer reinforcing mixture layer 25 ( FIG. 1 ).
- the application of an outer reinforcing mixture layer 25 is well known in the art, and may include automated or by-hand application of a desirable outer reinforcing layer 25 to the outside of the covering material 15 .
- a solid textured layer 50 ( FIG. 1 ) is further applied to the outer reinforcing mixture layer 25 .
- the covered core material 10 including inner and outer mixture layers, is moved along conveyor 701 beneath pad texturizer 705 .
- Sand, or other desired solid texture substance, is disbursed by the rotating pad texturizer 705 to create a desired textured surface on reinforced article 5 ( FIG. 1 ).
- core material covering, fabric trimming and fabric tucking operations are automated with computer settings and a conveyor system.
- a fabric dispenser provides fabric 15 from a fabric roll 815 to an automated covering station 900 and automated trimming station 1000 .
- Fabric 15 is provided to the core material 10 at the covering table 905 and the fabric corners are trimmed beneath the table 905 .
- the tucking station 1100 includes a pair of horizontal plunging apparatus 1105 and a pair of vertical plunging apparatus 1110 for automatically tucking the fabric 15 into and along each side of the core material 10 .
- the fabric dispenser 810 includes a fabric roll 815 that dispenses fabric 15 across the automated covering table 905 .
- the fabric dispenser 810 rolls out the desired length of fabric 15 based on computer programmable settings. Such programs settings are well known in the art.
- the fabric 15 is dispensed between a raised stack 910 of core material 10 and a trimming station elevator 915 .
- a “hot wire” powered by a moveable cylinder is lowered to burn the fabric 15 so it is cut to the desired length. It will be appreciated that a variety of alternative cutting apparatuses may be used to cut the fabric.
- the elevator 915 In a fabric 15 receiving position, the elevator 915 is generally level with the covering table 905 .
- the elevator 915 includes a vacuum that secures the fabric 15 across the elevator.
- a photo eye is provided approximately two inches past the elevator 915 to detect if the fabric 15 does not come within view. In the event that fabric 15 is not detected, the system is stopped for troubleshooting.
- the elevator 915 and fabric 15 are raised beneath the bottom core material 10 of the raised magazine assembly 911 .
- the magazine dispenser control apparatus 920 such as a moveable cylinder with retractable stabbers 925 , releases a core material article 10 .
- moveable cylinders include hydraulic cylinders, pneumatic cylinders, electric actuators and the like.
- the elevator 915 is lowered with the core material 10 and fabric 15 , and the stack 910 adjusts so that the next article 10 in the magazine assembly 911 is engaged by the stabbers 925 until the next cycle.
- a photo eye is positioned on the magazine assembly 911 to detect if there are not at least two core materials 10 in the magazine. Because of the ease of loading before the magazine is completely empty, the system will not initiate if there are less than two articles detected. The switch may be bypassed to use all of the articles by covering the photo eye.
- the elevator 915 is lowered beneath the fabric receiving table 905 .
- the edges of the fabric 15 that extend beyond the edges of the core material 10 fold vertically against the sides of the core material 10 and the slot 907 .
- each pincher set 1005 is generally “L” shaped with a horizontal portion 1009 extending over the top of the covered article 10 and a vertical portion 1007 extending along a side of the covered article 10 .
- Each pincher set closes at a respective corner 12 of the covered article 10 so that the vertical portion 1007 of a pincher set 1005 folds the fabric 15 around the sides of the core material 10 and the horizontal portion 1009 folds fabric 15 over a portion of the top of the article 10 .
- the pinchers also hold excess fabric 15 at each corner 12 for trimming.
- a long cylinder with a small gripper 1120 indexes to each of the four corners 12 and the gripper 1120 grabs and holds the excess fabric 15 at the corner 12 .
- a “hot wire” between the jaws of the pinchers sets 1005 is energized while the fabric 15 is being held by the grippers 1120 .
- the “hot wire” cuts the excess fabric 15 from the corner 12 while simultaneously welding the fabric around the corner 12 of the article 10 .
- the long cylinders for the grippers 1120 retract to pull the cut off fabric away from each of the corners 12 .
- a cooling nozzle 1125 is provided at each corner 12 where the pinchers 1005 conduct trimming operations. Pressurized air is provided to the corner 12 following the weld cut and removal of the excess fabric 15 from the corner 12 to cool and strengthen the weld.
- a debris removal air nozzle is also provided at each corner 12 of the trimming station to blow away the excess fabric 15 from the grippers 1120 . After the grippers 1120 retract with the cut excess corner fabric 15 , each gripper 1120 is opened and the debris removal nozzle provides a burst of air to blow away fabric 15 debris from the machine.
- the folding pinchers 1005 are subsequently opened to release the article 10 with fabric folded over the bottom face and side surfaces.
- the elevator 915 is raised up to the height of the covering table 905 until the covered article 10 is beneath the stack 910 of core material 10 in the magazine assembly 911 .
- a pressurized air nozzle subsequently blows air to propel the article 10 out from underneath the magazine 911 and on to a conveyor 1200 for carrying the article 10 to the tucking station 1100 .
- a photo eye is also used to detect if the article 10 does not enter and/or leave the elevator 915 and covering table 905 .
- the cycle restarts for covering and fabric trimming the next article 10 at the bottom of the stack 910 in the magazine assembly 911 .
- the article 10 is carried on a first conveyor belt 1205 ( FIG. 18 ) to the automated tucking station 1100 .
- the tucking station 1100 includes a first set of horizontal automated tucking apparatuses 1105 and a second set of vertical automated tucking apparatuses 1110 .
- a tucking apparatus 1105 and 1110 includes four plungers 1150 and a rolling mechanism 1158 .
- the plurality of plungers 1150 are actuated up and down by a tucking cylinder as the tucking apparatus 1105 and 1110 rolls along the edge in which fabric is being tucked.
- each of the horizontal tucking apparatuses 1105 is actuated forward and/or backward to tuck the loose fabric along the top into and along a horizontal edge of the article 10 .
- the vertical apparatuses 1110 are actuated forward and/or backward to tuck the loose fabric into the article 10 .
- the fabric 15 is first tucked horizontally into opposite edges of the top surface of the article 10 .
- the article 10 is conveyed to vertical tucking station for the vertical tucking operation.
- the sequence of horizontal and vertical tucking may be reversed, and that in other embodiments, the tucking operations may be combined, as with programmable timing logic.
- the article 10 is blown away from the folding station 900 ( FIG. 11 ) on to the conveyor 1205 to the horizontal tucking station.
- a first automated stop 1170 or set of stops is pivoted up from the plane of the first conveyor belt 1205 to block and hold the article for horizontal tucking operations.
- the stop(s) 1170 could be actuated from other positions such that the stop 1170 blocks the path of the article 10 to hold it in place.
- a moveable guide rail 1180 is extended to a side of the article 10 to secure it in place.
- the guide rail 1180 is attached to a cylinder and presses the article 10 against a raised edge 1160 along the conveyor belt 1205 on the opposite side of the article 10 to create a tight fit for consistent tucking of all articles 10 .
- the conveyor 1205 is stopped on actuation of the moveable guide rail 1180 .
- the horizontal tucking apparatuses 1105 are positioned opposite of one another on the horizontal tucking station frame 1104 .
- the frame 1104 lowers to position the plungers 1150 ( FIG. 20 ) near the article 10 for plunging.
- the frame 1104 raises to move the tucking apparatuses 1105 away from the article 10 , such as accepting and releasing the article 10 for tucking.
- the horizontal tucking station frame 1104 is lowered to position the tucking apparatuses 1105 along horizontal tuck lines of the loose fabric 15 on the top surface of the article 10 .
- the rolling mechanisms 1158 of the tucking apparatus contact the article 10 when the frame 1104 is lowered.
- the tucking apparatus 1105 moves laterally by pneumatic actuation along the frame 1104 as the frame 1104 acts as a track to maintain the tucking apparatus 1105 and plungers 1150 on the tuck line.
- the plungers 1150 are actuated by cylinders to move rapidly up and down to tuck the fabric 15 into the top surface of the article 10 .
- the horizontal stop 1170 is retracted upward and the conveyor 1205 is turned on.
- a second conveyor belt 1207 is provided to the vertical tucking station. From the first conveyor 1205 , and following retraction of the horizontal stops 1170 , the covered article with horizontal tucks moves to the vertical tucking station.
- a vertical station stop 1185 is actuated to stop the article at the desired position on the second conveyor 1207 at the vertical station.
- the vertical tucking apparatuses 1110 are positioned on a vertical tucking station frame 1106 .
- the set of vertical apparatuses 1110 are positioned perpendicular with respect to the horizontal apparatuses 1005 . Accordingly, the remaining loose fabric 15 on the top surface edges of the article 10 is vertically tucked.
- the vertical tucking operation is identical to the horizontal tucking apparatus operation.
- the vertical station frame 1106 and vertical guide rail 1181 is retracted.
- the second conveyor belt 1207 is then turned on and the vertical station stops 1185 moved from the path of the covered article 10 .
- the second conveyor 1207 transports the covered article 10 from the vertical tucking station for removal from the system, or, alternatively, carries the article 10 on further conveyor(s) for additional processing, such as the application of reinforcing material.
- photo eyes are positioned next to each of the horizontal and vertical station stops.
- the tucking apparatuses will not start unless the pad is detected in the proper position at each station.
- a program switch is also provided that restricts operation of the first conveyor belts from the folding and trimming station to the horizontal tucking station until at least one cycle of the automated tucking and trimming station occurs.
- another program switch is also provided to prevent propulsion of the article following trimming from the elevator area to the horizontal tucking station if the tucking operations are in process.
- the second belts will not be turned on the article transported from horizontal tucking station to the vertical tucking station if an another program switch senses vertical tucking operations are not complete. In such embodiments, any detected problem must be corrected and the system reset for operations to resume.
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Abstract
Description
- This application is a divisional of U.S. patent application Ser. No. 10/835,246, filed Apr. 29, 2004, which is a continuation-in-part of U.S. patent application Ser. No. 10/234,630, filed Sep. 4, 2002, both of which are relied on and incorporated herein by reference.
- The present invention relates generally to systems and methods for manufacturing covered articles.
- Examples of reinforced materials are well-known in the art, including U.S. Pat. No. 5,728,458 to Sweeney entitled “Light-Weight High-Strength Composite Pad” and U.S. Pat. No. 5,209,968 to Sweeney entitled “Composite Structure With Waste Plastic Core And Method of Making Same,” both of which are incorporated herein by reference. These examples disclose the use of core materials coated with reinforcing layers for multi-use pads, equipment pads, building panels, and other applications.
- Typically, these prior art reinforced layered structures are formed by manual covering processes such as wrapping a core, trimming excess wrapping material, and attaching the material to or into the article with adhesive, physical bindings, or direct insertion into the article core. These manual steps can require a number of individuals, limit the quantity of articles that can be manufactured in a given time frame, and result in inconsistent products. Accordingly there is a need to automate the covering of articles.
- The present invention answers this need by providing a covering apparatus and method that automates the covering process for manufacturing articles.
- The present invention provides an apparatus and method for covering articles. In embodiments of the invention, covering, trimming, and/or tucking of material into a core material is automated.
- In an embodiment of the invention a conveyor system is provided for transporting an article to covering, trimming and/or tucking stations to cover the article.
- In an embodiment of the invention a fibrous fabric is tucked into a core material comprising expanded polystyrene (EPS) foam, moldable into any desired shape. In further embodiments, additional material layers may be applied or injected on and/or beneath the covering material to achieve desired reinforcing characteristics.
- The present invention further provides a system and method for manufacturing reinforced articles with a core material covered with a covering material by injecting a desired compound or mixture between the core material and covering material to create an inner reinforcing layer.
- In another embodiment of the invention, an automated covering station is provided wherein covering material is dispensed for surrounding an article core. In one embodiment, the core material is covered by the dispensed material as the core drops through a slot in a covering table across which the covering material is dispensed.
- In a further embodiment of the present invention, an automated tucking station is provided on a conveyor system for tucking one or more portions of the covering material into the core material. In some embodiments, the tucking apparatus includes parallel pairs of horizontal and vertical tucking apparatuses for plunging covering material into the core.
- In another embodiment of the present invention, a corner trimming station with an automated pincher and welder is provided for trimming excess fabric at the corners of the covered core material by pulling and welding the excess corner fabric.
-
FIG. 1 is a cross-sectional view of a reinforced article in an embodiment of the present invention. -
FIG. 2 is a perspective view of a bottom surface of a core material in a stack of core materials with receiving channels being burned at a receiving channel burning station in an embodiment of the present invention. -
FIG. 3 is a top perspective view of a core material and covering material being positioned thereon at a covering material template table in an embodiment of the present invention. -
FIG. 4 is a top perspective view of a covering material tucking station in an embodiment of the present invention. -
FIG. 5 is a perspective view of a tucking apparatus including an automated tucking needle and plunger in an embodiment of the present invention. -
FIG. 6 is a perspective view of an excess fabric weld trimming station including pinchers, weld holders, and weld blade in an embodiment of the present invention. -
FIG. 7 is a top perspective view of a four corner automated weld trimming apparatus in an embodiment of the present invention. -
FIG. 8 is a top perspective view of a reinforcing layer injection station in an embodiment of the present invention. -
FIG. 9 is a perspective partial cut-away view of a covered core material being injected with an inner reinforcing layer mixture in an embodiment of the present invention. -
FIG. 10 is a texturizing station in an embodiment of the present invention. -
FIG. 11 is a top perspective view of a core material covering, trimming and tucking conveyor apparatus in an embodiment of the present invention. -
FIG. 12 is a top perspective view of an automated covering station in an embodiment of the present invention. -
FIG. 13 is a top perspective view of a magazine cylinders apparatus of an automated covering station in an embodiment of the present invention. -
FIG. 14 is a partial perspective view of a core material and fabric lowered beneath a fabric table of an automated covering station in an embodiment of the present of the invention. -
FIG. 15 of the is a partial perspective view of the trimming apparatus of an automated covering station prior to trimming the corner of a covered core material in an embodiment of the present invention. -
FIG. 16 is a partial perspective view of the trimming apparatus of an automated covering station during trimming of the corner of a covered core material in an embodiment of the present invention. -
FIG. 17 is a top perspective view of a horizontal tucking apparatus station in a conveyor apparatus with retracted tucking cylinders in an embodiment of the present invention. -
FIG. 18 a the top perspective view of a horizontal tucking apparatus station in a conveyor apparatus with tucking cylinders in lowered operation in an embodiment of the present invention. -
FIG. 19 is a top perspective view of a vertical tucking apparatus station in a conveyor apparatus with retracted tucking cylinders in an embodiment of the present invention. -
FIG. 20 is a top perspective view of a vertical tucking apparatus station in a conveyor apparatus with tucking cylinders in lowered operation in an embodiment of the present invention. - The present invention provides a reinforced article and system and method for making the same. Those of ordinary skill in the art will appreciate that an embodiment described herein including an expanded polystyrene (EPS) foam core material with a fabric covering material and cement mixture reinforcing layer is by way of example only, and a variety of alternative materials could be used. In this regard, exemplary covering materials may include fabric, fibrous wrap, webs, mesh, glass mats, paper, and any other types of synthetic or natural fibrous material that is pregnable by a desired reinforcing layer. Core materials include foamable materials such as polyurethane, polyisocyanurate, EPS, other rigid foams, plastics, corks, wood, synthetic polymers, and similar rigid core materials. Those of ordinary skill in the art will further appreciate that such core materials may be molded into virtually any shape or size as may be desired for the reinforced article. The reinforced mixture layer may include mixtures of concrete, plaster, epoxy, synthetic resins, polymers, paint, waterproofing compounds, glues, foams, and similar mixtures or materials capable of injection between a core material and covering material. In this regard, “injection ” may include the deposit of the reinforcing material by injection entirely through a core material at any desired angle, or, alternatively, with an appropriate injection head, through the covering material, so as to deposit the reinforcing layer between the covering material and core material.
- Referring to
FIG. 1 , a cross section of reinforcedarticle 5 is shown. Acore material 10 is surrounded by coveringmaterial 15. In an embodiment of the invention, coveringmaterial 15 includes fabric woven or non-woven. An innerreinforcing mixture layer 20, including a cement mixture in one embodiment, is provided between thecore material 10 and the coveringmaterial 15. - Covering
material edges 19 are tucked intotucking grooves 30 in thecore material 10. Thetucked edges 19 keep the coveringmaterial 15 tightly surrounding the core material. Further, thetucked edges 19 and tuckinggroove 30 maximize retention of innerreinforcing mixture layer 20 betweencore material 10 and coveringmaterial 15. - In alternative embodiments, tucking of
edges 19 may be replaced or augmented by gluing or other adhesives, taping, stapling, sewing, heat binding, and like methods for adheringedges 19 to thecore material 10. - In an embodiment of the invention, the inner
reinforcing mixture layer 20 is injected between thecore material 10 and coveringmaterial 15 after the coveringmaterial 15 is secure withtucked edges 19 intucking groove 30. As described subsequently, a needle head with a dispersion hole may be used for depositing the innerreinforcing mixture layer 20. - In an embodiment of the invention, the inner reinforcing
mixture layer 20 is injected as a slurry mixture, such as a cement mixture, concrete mixture, plaster mixture, epoxy mixture, synthetic resin mixture, polymer mixture, paint mixture, or waterproofing mixture and the like, depending on the desired end use of the reinforced article. Such mixtures are preferably metered to deposit such amounts as are necessary to create a desired thickness and characteristics of the reinforcinglayer 20 and reinforcedarticle 5. Accordingly, depending on the properties of the mixture deposited for the inner reinforcingmixture layer 20, such mixture is cured to provide the desired reinforcing characteristics of the mixture used. - In alternative embodiments of the invention, one or more outer reinforcing mixture layers 25 may be provided in reinforced
article 5.Outer layer 25 may be the same or a different substance frominner layer 20. In an embodiment of the present invention where the reinforcedarticle 5 is an equipment pad, both theinner layer 20 andouter layer 25 are cured cement mixtures. However, optionalouter layer 25 may comprise one or multiple layers that include any materials with desired characteristics for reinforcedarticle 5. In embodiments of the present invention, the outer reinforcingmixture layer 25 includes concrete, plaster, epoxy, synthetic resins, polymers, paint, waterproofing compounds, cement, glues, and the like. It will be understood that this is only an exemplary list, and further appreciated that the curing of any applied mixtures, such as slurry mixtures, may be desirable to achieve desired characteristics of the outer reinforcingmixture layer 25. - In another embodiment of the present invention, an outer reinforcing
layer 25 includes a texture layer 50 (FIG. 10 ). In one embodiment of the present invention, thetexture layer 50 includes a solid substance, such as sand 710 (FIG. 10 ), but may include virtually any solid with desired texture and binding characteristics withouter layer 25. - In embodiments of the present invention where covering
material 15 is a fabric or other fibrous material,inner layer 20 and optionalouter layers 25 andtexture layer 50, at least in part, impregnate the coveringmaterial 15 to bind and create the desirable reinforced surface layers surroundingcore material 10 of reinforcedarticle 5. - Referring to
FIG. 2 , in an embodiment of the present invention,core material 10 includes inner reinforcinglayer receiving channels 40. Wherecore material 10 is EPS foam, the receivingchannels 40 are burned at a receivingchannel burning station 100. - The receiving channel burning station includes
hot wire burners 105 on which thecore material 10 is placed to burn the receivingchannel 40. - The receiving
channels 40 are burned on any surface of the core material which will contact the inner reinforcingmixture layer 20 and be surrounded by coveringmaterial 15. For instance, the receiving channels may be burned along all surfaces of thecore material 10, or along side surfaces 15, or top surfaces and side surfaces, or any combinations thereof. - The receiving
channels 40 permit greater deposition of the inner reinforcingmixture layer 20 than a mere flat surface. Accordingly, the depths of the receivingchannels 40 may be increased or decreased for the desired purpose of the reinforcedarticle 5 and reinforcing characteristics of theinner layer 20. - As shown in
FIG. 2 , the core material may be stacked as a plurality of core materials to burn receiving channels on multiple core materials' 10 surfaces at once. The stack is rotated to each desired receiving channel burning surface for burning onhot wires 105. In this embodiment, it will be appreciated that front and back surfaces may be burned with receivingchannels 40 by separating eachindividual core material 10 from the stack to burn the desired surface. - Further, depending on the properties and material of the
core material 10, receivingchannels 40 may be formed by alternative methods such as cutting, drilling and boring. - In an embodiment of the present invention for manufacturing a reinforced pad, the receiving
channels 40 are preferably burned into a top surface (not shown) and side surfaces of acore material 10 made of EPS foam. - Referring again to
FIG. 1 , with continuing reference toFIG. 2 , the inner reinforcingmixture layer 20 of cement mixture forms a layer on the top and side surfaces of the core material and between the coveringmaterial 15. In this embodiment, the covering material is preferably pregnable fibrous fabric and the tucked ends 19 sustain the inner reinforcinglayer 20 around the top and side surface of thecore material 10 to also promote deposition of the inner reinforcingmixture layer 20 into the receivingchannels 40 of the top and side surfaces. In this embodiment, the receivingchannels 40 are preferably ⅛″ wide by ¼″ deep. - Referring to
FIG. 3 , a coveringmaterial application station 200 is shown. In embodiments whereoptional receiving channels 40 are utilized, thecore material 10 is covered with coveringmaterial 15 after forming the receivingchannels 40. Alternatively, where receivingchannels 40 are not desired, the covering material is applied prior to injection of inner reinforcingmixture layer 20. - In an embodiment of the present invention, the covering material application station provides proper alignment of
fabric covering material 15. Afabric template 205 is sized to the shape of thecore material 10 so that the core material is centered on thefabric covering material 15. Thefabric application station 200 is preferably a light table wherein the fabric template includes a template periphery for aligning thefabric covering material 15. - Once the core material is centered on the
fabric covering material 15, theflaps 17 of the fabric are folded over thecore material 10. - Referring to
FIG. 4 , thecore material 10 including the folded flaps 17 of coveringmaterial 15 is placed in coveringmaterial tucking station 300. - The tucking
station 300 includes aconveyor belt 305 for directing a plurality of covered core materials to atucking apparatus 320. As shown inFIG. 4 , two pairs of tuckingapparatuses 320 are used in one embodiment of the invention to tuckflaps 17 into tucking grooves 30 (FIG. 1 ) as folded edges 19 (FIG. 1 ). - On opposite sides of the
conveyor belt 305, flap rail guides 310 are provided for maintaining the folded flaps 17 in a desired position againstcore material 10. The rail guides 310 terminate atflap folder 315 as the coveredcore material 10 is directed at eachopposite flap 17 to tuckingapparatus 320. - Referring to
FIG. 5 , and continuing reference toFIG. 4 , tuckingapparatus 320 includes agroove perforation needle 325 and tuckingplunger 330. Each of theneedle 325 andplunger 330 are automated so as to actuate a rapid up and down plunging movement. - After the
flaps 17 are directed through theflap folder 315, theneedle 325 perforates theflap 17 andcore material 10 to create a tucking groove 30 (FIG. 1 ) perforation line. Ablunt plunger head 330 follows theperforation needle 325 to tuck covering material edge 19 (FIG. 1 ) into tucking groove 30 (FIG. 1 ). In an embodiment of the invention, a plurality of tuckingapparatuses 320 may be used to reinforce tucking of the coveringmaterial edge 19 into tuckinggroove 30. In other embodiments of the present invention, multiple tucking apparatuses are implemented to form multiple tucked grooves for additional tucking of portions of the coveringmaterial 15 into thecore material 10. - In further embodiments of the invention, where the
core material 10 is square or rectangular shaped, the coveredcore material 10 is rotated 90 degrees following initial tucking onopposite flaps 17. Unfolded opposite flaps 14 are folded and the covered core material similarly placed onconveyer 305 of the tuckingstation 300 to tuckflaps 14 with tuckingapparatus 320. In such embodiment, the top and four side surfaces of thecore material 10 are completely covered by coveringmaterial 15 and all four edges of thefabric covering material 15 are tucked into thebottom surface 11 of thecore material 10. - Referring to
FIG. 6 , in an embodiment of the invention withfabric covering material 15 covering acorner 12 of thecore material 10, and adjacent sides of the covering material tucked into a surface of thecore material 10,excess fabric corner 16 will result atcorner 12. - In embodiments of the invention, it is desirable to trim the
excess fabric corner 16 at a corner weld and trimmingstation 500. Thecorner trimming station 500 includes actuatedpinchers 505 that pinchexcess fabric corner 16 and subsequently pull theexcess fabric corner 16 outward from thecore material corner 12.Corner weld holders 510 actuate to pinch and hold theexcess fabric corner 16 at a point near thecore material corner 12. An automatictrim weld blade 515 is actuated toward the pinchedexcess fabric corner 16 and theweld blade 515 welds theexcess fabric corner 16, such as a fibrous woven or non-woven fabric, to create a welded tight, trimmed edge while theexcess fabric corner 16 is burned off and discarded. In some instances, additional trimming, such as by hand, of the fabric welded corner may be necessary to achieve a smooth welded corner edge. - Referring to
FIG. 7 , in an embodiment of the invention wherein the reinforcedarticle 5 is square or rectangular shaped, thecorner trimming station 500 includes four sets ofpinchers 505,weld holders 510, andweld blades 515. In this embodiment, the coveredcore material 10 is placed so that each corner is positioned between each set ofpinchers 505,weld holders 510, andweld blades 515, to allow automatic welding and trimming of all four corners at once. - In a further embodiment, a plurality of covered core materials may be stacked to permit trimming of a plurality of
stacked corners 12 simultaneously. - Referring to
FIG. 8 , a reinforcinglayer injection station 600 is depicted with aninjector 620 connected to amixture supply line 630. - In an embodiment of the present invention, the
injection station 600 includes aconveyor 602 to provide automated injection of a plurality of coveredcore materials 10. - In a further embodiment of the present invention, square or rectangular covered
core materials 10 are stacked at a stackingpartition 605 that aligns the stacked coveredcore material 10 for positioning on theconveyor 602 to theinjector 620. - An
indexer 610 is actuated in the line of conveyor movement toward the bottom coveredcore material 10 in the stack. Theindexer 610 strikes the bottom coveredcore material 10 from the stack to propel it out of the stack and along the conveyor toward theinjector 620. Gravity causes the remaining coveredmaterial 10 in the stack to move downward along thepartition 605 when theindexer 610 retracts in a reverse direction from the movement of theconveyor 602. - It will be appreciated that in an embodiment of the present invention the covered core material propelled from the stack is covered facedown and the reverse face, facing upward, includes the
bottom surface 11 tucked portions. Accordingly, the tucked face is exposed toward theinjector 620. - The
indexer 610 andinjector 620 are in timed synchronization so that the indexer pushes the nextcovered core material 610 forward as theinjector 620 lifts up and down to receive and pin the covered core material in the injector.Metal injector guide 622 preferably holds the covered core material in position for injection. Following injection of the inner reinforcinglayer 20, the injection guides 622 retract upward to permit the next indexed covered material into theinjector 620. - Referring to
FIG. 9 , with continuing reference toFIG. 8 , the injector includes aninjection needle 625 and retractingneedle arm 621. As the coveredcore material 10 is received byinjector 620,needle arm 621 andneedle 625 are lowered through thecore material 10 untilinjection needle 625 is positioned so thatinjection hole 628 is positioned between the surface of thecore material 10 and the coveringmaterial 15. The reinforcingmixture 21, such as cement slurry, is provided by amixture feed line 630 connected toinjection needle 625. Themixture 21 is injected in a desired metered amount, depending on the desired characteristics and thickness of the inner reinforcinglayer 20. - Referring again to
FIG. 8 , in an embodiment of the invention, theinjector 620 includes a vacuum base that removes excess water from the mixture 21 (FIG. 9 ) to form inner reinforcinglayer 20 between the coveringmaterial 15 and thecore material 10. In an additional embodiment, the injectedmixture 21 includes a 1:1 cement/water ratio to promote dispersion. The increased water ratio, compared to typical cement mixtures, provides a better dispersion consistency for venting the reinforcinglayer 20. The vacuum action acts to dewater themixture 21 to solidify the injectedcement mixture 21. - Once the desired inner reinforcing
layer 20 is provided by the injection ofmixture 21, the injector, including theinjector guide 622,retractable needle arm 621 andneedle 625, are lifted upward to permit the injectedarticle 5 to be removed. As disclosed, the nextcovered core material 10 is indexed forward and the injector, includinginjector guide 622,needle arm 621 andinjector needle 625, lowered to pin the coveredcore material 10 and repeat the process. - The reinforced article with
inner injection layer 20 may be cured as desired. - In one embodiment, the covered
core material 10 including the injected inner reinforcinglayer 20 is further coated with an outer reinforcing mixture layer 25 (FIG. 1 ). The application of an outer reinforcingmixture layer 25 is well known in the art, and may include automated or by-hand application of a desirable outer reinforcinglayer 25 to the outside of the coveringmaterial 15. - Referring to
FIG. 10 , in another embodiment of present invention, a solid textured layer 50 (FIG. 1 ) is further applied to the outer reinforcingmixture layer 25. Attexturizer station 700 the coveredcore material 10, including inner and outer mixture layers, is moved alongconveyor 701 beneathpad texturizer 705. Sand, or other desired solid texture substance, is disbursed by therotating pad texturizer 705 to create a desired textured surface on reinforced article 5 (FIG. 1 ). - Referring to
FIG. 11 , in an alternative embodiment, core material covering, fabric trimming and fabric tucking operations are automated with computer settings and a conveyor system. - In the exemplary embodiment, a fabric dispenser provides
fabric 15 from afabric roll 815 to anautomated covering station 900 andautomated trimming station 1000.Fabric 15 is provided to thecore material 10 at the covering table 905 and the fabric corners are trimmed beneath the table 905. - After the
fabric 15 is applied to thecore material 10, the coveredcore material 10 is conducted on aconveyor belt 1200 to thetucking station 1100. The tuckingstation 1100 includes a pair ofhorizontal plunging apparatus 1105 and a pair ofvertical plunging apparatus 1110 for automatically tucking thefabric 15 into and along each side of thecore material 10. - With reference to
FIG. 12 , thefabric dispenser 810 includes afabric roll 815 that dispensesfabric 15 across the automated covering table 905. Thefabric dispenser 810 rolls out the desired length offabric 15 based on computer programmable settings. Such programs settings are well known in the art. - The
fabric 15 is dispensed between a raisedstack 910 ofcore material 10 and a trimmingstation elevator 915. A “hot wire” powered by a moveable cylinder is lowered to burn thefabric 15 so it is cut to the desired length. It will be appreciated that a variety of alternative cutting apparatuses may be used to cut the fabric. - In a
fabric 15 receiving position, theelevator 915 is generally level with the covering table 905. Theelevator 915 includes a vacuum that secures thefabric 15 across the elevator. As a safety mechanism, a photo eye is provided approximately two inches past theelevator 915 to detect if thefabric 15 does not come within view. In the event thatfabric 15 is not detected, the system is stopped for troubleshooting. - With reference to
FIG. 13 , theelevator 915 andfabric 15 are raised beneath thebottom core material 10 of the raisedmagazine assembly 911. The magazinedispenser control apparatus 920, such as a moveable cylinder withretractable stabbers 925, releases acore material article 10. It will be appreciated that moveable cylinders include hydraulic cylinders, pneumatic cylinders, electric actuators and the like. - The
elevator 915 is lowered with thecore material 10 andfabric 15, and thestack 910 adjusts so that thenext article 10 in themagazine assembly 911 is engaged by thestabbers 925 until the next cycle. In one embodiment, a photo eye is positioned on themagazine assembly 911 to detect if there are not at least twocore materials 10 in the magazine. Because of the ease of loading before the magazine is completely empty, the system will not initiate if there are less than two articles detected. The switch may be bypassed to use all of the articles by covering the photo eye. - As shown in
FIG. 14 , theelevator 915 is lowered beneath the fabric receiving table 905. As thefabric 15 andcore material 10 pass through theelevator slot 907, the edges of thefabric 15 that extend beyond the edges of thecore material 10 fold vertically against the sides of thecore material 10 and theslot 907. - Referring to
FIG. 15 , theelevator 915 supporting a rectangular coveredcore material 10 stops centered between four sets ofcorner trimming pinchers 1005. Eachpincher set 1005 is generally “L” shaped with ahorizontal portion 1009 extending over the top of the coveredarticle 10 and avertical portion 1007 extending along a side of the coveredarticle 10. Each pincher set closes at arespective corner 12 of the coveredarticle 10 so that thevertical portion 1007 of apincher set 1005 folds thefabric 15 around the sides of thecore material 10 and thehorizontal portion 1009 foldsfabric 15 over a portion of the top of thearticle 10. The pinchers also holdexcess fabric 15 at eachcorner 12 for trimming. - Referring to
FIG. 16 , a long cylinder with asmall gripper 1120 indexes to each of the fourcorners 12 and thegripper 1120 grabs and holds theexcess fabric 15 at thecorner 12. A “hot wire” between the jaws of the pinchers sets 1005 is energized while thefabric 15 is being held by thegrippers 1120. The “hot wire” cuts theexcess fabric 15 from thecorner 12 while simultaneously welding the fabric around thecorner 12 of thearticle 10. The long cylinders for thegrippers 1120 retract to pull the cut off fabric away from each of thecorners 12. - In an embodiment of the invention, a
cooling nozzle 1125 is provided at eachcorner 12 where thepinchers 1005 conduct trimming operations. Pressurized air is provided to thecorner 12 following the weld cut and removal of theexcess fabric 15 from thecorner 12 to cool and strengthen the weld. - In a further embodiment, a debris removal air nozzle is also provided at each
corner 12 of the trimming station to blow away theexcess fabric 15 from thegrippers 1120. After thegrippers 1120 retract with the cutexcess corner fabric 15, eachgripper 1120 is opened and the debris removal nozzle provides a burst of air to blow awayfabric 15 debris from the machine. - The
folding pinchers 1005 are subsequently opened to release thearticle 10 with fabric folded over the bottom face and side surfaces. Theelevator 915 is raised up to the height of the covering table 905 until the coveredarticle 10 is beneath thestack 910 ofcore material 10 in themagazine assembly 911. - A pressurized air nozzle subsequently blows air to propel the
article 10 out from underneath themagazine 911 and on to aconveyor 1200 for carrying thearticle 10 to thetucking station 1100. As a safety precaution, a photo eye is also used to detect if thearticle 10 does not enter and/or leave theelevator 915 and covering table 905. - The cycle restarts for covering and fabric trimming the
next article 10 at the bottom of thestack 910 in themagazine assembly 911. - Referring to
FIG. 17 , as it is being blown from the covering table, thearticle 10 is carried on a first conveyor belt 1205 (FIG. 18 ) to theautomated tucking station 1100. With reference toFIGS. 18 and 19 , the tuckingstation 1100 includes a first set of horizontalautomated tucking apparatuses 1105 and a second set of verticalautomated tucking apparatuses 1110. - Referring to
FIG. 20 , in an embodiment of the invention, atucking apparatus plungers 1150 and arolling mechanism 1158. Along an edge of the top surface of the coveredarticle 10, the plurality ofplungers 1150 are actuated up and down by a tucking cylinder as thetucking apparatus - With further reference to
FIGS. 17-19 , along parallel opposite sides of the top fabric coveredarticle 10, each of thehorizontal tucking apparatuses 1105 is actuated forward and/or backward to tuck the loose fabric along the top into and along a horizontal edge of thearticle 10. Similarly, along parallel opposite vertical sides of the coveredarticle 10, thevertical apparatuses 1110 are actuated forward and/or backward to tuck the loose fabric into thearticle 10. - In the described embodiment, the
fabric 15 is first tucked horizontally into opposite edges of the top surface of thearticle 10. Following the horizontal tucking operation, thearticle 10 is conveyed to vertical tucking station for the vertical tucking operation. Those of ordinary skill will appreciate that the sequence of horizontal and vertical tucking may be reversed, and that in other embodiments, the tucking operations may be combined, as with programmable timing logic. - Referring to
FIG. 18 , in one embodiment, thearticle 10 is blown away from the folding station 900 (FIG. 11 ) on to theconveyor 1205 to the horizontal tucking station. A firstautomated stop 1170 or set of stops is pivoted up from the plane of thefirst conveyor belt 1205 to block and hold the article for horizontal tucking operations. In alternative embodiments, the stop(s) 1170 could be actuated from other positions such that thestop 1170 blocks the path of thearticle 10 to hold it in place. - After reaching the
first stops 1170, amoveable guide rail 1180 is extended to a side of thearticle 10 to secure it in place. Theguide rail 1180 is attached to a cylinder and presses thearticle 10 against a raisededge 1160 along theconveyor belt 1205 on the opposite side of thearticle 10 to create a tight fit for consistent tucking of allarticles 10. Theconveyor 1205 is stopped on actuation of themoveable guide rail 1180. - The
horizontal tucking apparatuses 1105 are positioned opposite of one another on the horizontaltucking station frame 1104. Theframe 1104 lowers to position the plungers 1150 (FIG. 20 ) near thearticle 10 for plunging. Theframe 1104 raises to move thetucking apparatuses 1105 away from thearticle 10, such as accepting and releasing thearticle 10 for tucking. - After the
guide rail 1180 secures the article, the horizontaltucking station frame 1104 is lowered to position the tuckingapparatuses 1105 along horizontal tuck lines of theloose fabric 15 on the top surface of thearticle 10. - With continuing reference to
FIG. 20 , the rollingmechanisms 1158 of the tucking apparatus contact thearticle 10 when theframe 1104 is lowered. Thetucking apparatus 1105 moves laterally by pneumatic actuation along theframe 1104 as theframe 1104 acts as a track to maintain thetucking apparatus 1105 andplungers 1150 on the tuck line. Theplungers 1150 are actuated by cylinders to move rapidly up and down to tuck thefabric 15 into the top surface of thearticle 10. - Following horizontal tucking, the
horizontal stop 1170 is retracted upward and theconveyor 1205 is turned on. In one embodiment asecond conveyor belt 1207 is provided to the vertical tucking station. From thefirst conveyor 1205, and following retraction of thehorizontal stops 1170, the covered article with horizontal tucks moves to the vertical tucking station. - Referring to
FIG. 19 , avertical station stop 1185 is actuated to stop the article at the desired position on thesecond conveyor 1207 at the vertical station. Like thehorizontal tucking apparatuses 1105, thevertical tucking apparatuses 1110 are positioned on a verticaltucking station frame 1106. However, the set ofvertical apparatuses 1110 are positioned perpendicular with respect to thehorizontal apparatuses 1005. Accordingly, the remainingloose fabric 15 on the top surface edges of thearticle 10 is vertically tucked. - Mechanically, the vertical tucking operation is identical to the horizontal tucking apparatus operation.
- Following the vertical tucking operation, the
vertical station frame 1106 andvertical guide rail 1181 is retracted. Thesecond conveyor belt 1207 is then turned on and the vertical station stops 1185 moved from the path of the coveredarticle 10. Thesecond conveyor 1207 transports the coveredarticle 10 from the vertical tucking station for removal from the system, or, alternatively, carries thearticle 10 on further conveyor(s) for additional processing, such as the application of reinforcing material. - As a safety precaution and to increase consistency, in one embodiment of the present invention photo eyes are positioned next to each of the horizontal and vertical station stops. The tucking apparatuses will not start unless the pad is detected in the proper position at each station.
- In another embodiment, a program switch is also provided that restricts operation of the first conveyor belts from the folding and trimming station to the horizontal tucking station until at least one cycle of the automated tucking and trimming station occurs. In this and alternative embodiments, another program switch is also provided to prevent propulsion of the article following trimming from the elevator area to the horizontal tucking station if the tucking operations are in process. Similarly, the second belts will not be turned on the article transported from horizontal tucking station to the vertical tucking station if an another program switch senses vertical tucking operations are not complete. In such embodiments, any detected problem must be corrected and the system reset for operations to resume.
- Accordingly, while the invention has been described with reference to the structures and processes disclosed, it is not confined to the details set forth, but is intended to cover such modifications or changes as may fall within the scope of the following claims.
Claims (51)
Priority Applications (1)
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US11/134,232 US20050269738A1 (en) | 2002-09-04 | 2005-05-20 | Layering process for forming a reinforced article |
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US10/835,246 US6931822B1 (en) | 2002-09-04 | 2004-04-29 | Automated article covering method and apparatus |
US11/134,232 US20050269738A1 (en) | 2002-09-04 | 2005-05-20 | Layering process for forming a reinforced article |
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US11/134,232 Abandoned US20050269738A1 (en) | 2002-09-04 | 2005-05-20 | Layering process for forming a reinforced article |
US11/134,023 Abandoned US20050252606A1 (en) | 2002-09-04 | 2005-05-20 | Process for automatically trimming an excess of corner covering material |
US11/134,050 Abandoned US20050244531A1 (en) | 2002-09-04 | 2005-05-20 | Reinforced article manufacturing system |
US11/134,846 Expired - Lifetime US7232589B2 (en) | 2002-09-04 | 2005-05-20 | Process for dispersing a reinforcing layer in a layered article |
US11/134,240 Expired - Lifetime US7334385B2 (en) | 2002-09-04 | 2005-05-20 | Automated tucking process for covering a penetrable core material |
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US11/134,050 Abandoned US20050244531A1 (en) | 2002-09-04 | 2005-05-20 | Reinforced article manufacturing system |
US11/134,846 Expired - Lifetime US7232589B2 (en) | 2002-09-04 | 2005-05-20 | Process for dispersing a reinforcing layer in a layered article |
US11/134,240 Expired - Lifetime US7334385B2 (en) | 2002-09-04 | 2005-05-20 | Automated tucking process for covering a penetrable core material |
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US8910998B1 (en) * | 2014-03-27 | 2014-12-16 | Srinivas S. Devathi | Systems and methods for altering the color, appearance, or feel of a vehicle surface |
Also Published As
Publication number | Publication date |
---|---|
US20050268575A1 (en) | 2005-12-08 |
US6927183B1 (en) | 2005-08-09 |
US20050252606A1 (en) | 2005-11-17 |
US7232589B2 (en) | 2007-06-19 |
US20050244531A1 (en) | 2005-11-03 |
US7334385B2 (en) | 2008-02-26 |
US20050269029A1 (en) | 2005-12-08 |
US6931822B1 (en) | 2005-08-23 |
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