US3355073A

US3355073A - Methods of and apparatus for producing shaped products

Info

Publication number: US3355073A
Application number: US225610A
Authority: US
Inventors: Jack L Moore; John A Roming
Original assignee: Individual
Current assignee: Individual
Priority date: 1962-09-24
Filing date: 1962-09-24
Publication date: 1967-11-28
Anticipated expiration: 1984-11-28

Description

Nov. 28, 1967 1 L M0RE ETAL METHODS OF AND APPARATUS FOR PRODUCING SHAPED PRODUCTS 5 Sheets-Sheet l Filed Sept. 24, 1962 lllllllllllll xm umm.. lll

c/a'c Mao/e da/7 f4. fPo/yv/nyl INVENTORJ ATTORNEVJ MODS 0F AND APPARATUS Fon PRODUCING SHAPED PRODUCTS Nov. 28, 1967 1 L MOQRE ErAL 5 Sheets-Sheet 2 Filed Sept. 24, 1962 om@ "OINIHMHUHIO 0 www h Q MQW .lll A f/ R im@ :oja w A l ha.. .m\ l/f. U am f/w/fA/rO/w BY g ik) Y [AAJ Afro/MMX.:

Nov. 28, 19677 v MOQRE ETAL METHODS 0F AND APPARATUS FQR PRODUCIG SHAPED PRODUCTS Filed Sept. 24, 1962 5 Sheets-Sheet 5 www a/m o 0mm uM/n n ,MR EMMA .A.

Nov. 28, 1967 .L L MOORE ET AL METHODS oF AND APPARATUS Fon PRDDUCING SHAPED PRODUCTS 5 Sheets-Sheet 4 .filed sept.

v INVENTORJ BY q gada/JA ATTO/PNEYJ Noir. 28,1967 v .1.1.1. MOOREv ETAL v 3,355,073

METHODS 0F AN APPARATUS FR PRODUCING SHAPED PRODUCTS Filed Sept. 24, 1962 5 Sheets-Sheet 5 A dac/4 Moo/ 4/0/7/7 A. Hom/ng vnvvmv'roks Y ATTO/PNEVJ United States Patent O 3,355,073 METHDS F AND APPARATUS FUR PRDUCING SHAPED PRDUCTS .lack L. Moore and .lohn A. Roming, both of 109 Ave. D, Lawton, Okla. 73501 Filed Sept. 24, 1962, Ser. No. 225,610 21 Claims. (Cl. 223-12) This invention relates to new and useful improvements in methods of and apparatus for producing shaped products. 'Ilhe invention is particularly adaptable for use in forming 4hat bodies and hats from a knitted or woven material.

Various attempts have been made to form shaped articles, such as hat bodies and hats, by placing the knitted or woven material in a mold and forming the article by the application of pressure or heat, or both. Most of such prior attempts have depended primarily upon stretching or shrinking the individual yarn elements of the material to cause the material to conform to the mold shape so that a major change in the individual yarn elements occurs during the mol-ding operation; this change in the yarn elements is undesirable because it creates difficulty in maintaining proper and symmetrical design in the iinished part by reason of the impossibility of accurately controlling the stretch or shrinkage of each individual yarn element. In some instances, attempts |have been made to employ special types of material so that the deformation of the overall yarn pattern will not produce conspicuous irregularities in the fabric pattern but such methods not only increase the cost of production but limit the type of material from which the product is formed.

Regardless of the particular method of the prior art which is employed, all such methods havethe additional major disadvantage of forming the product from a blank of the knitted or woven material which blank must be pre-cut to size and whichl must be independently fed into the molding area. In effect, the prior practice involves a one-step operation with the blank being inserted in the mold and formed into the desired shape, after which the molded product is removed so that another blank may be introduced. This type of one-step operation, as compared to one which may be carried out continuously and automatically without interruption, involves increased costs and labor.

It is, therefore, one object of this invention to provide an improved method of forming shaped products from a fabric comprising knitted or woven material, such as paper or synthetic fibers, wherein the shaping of said product is produced primarily by deforming the normal pattern of the fabric and any stretching or shrinking of the individual yarn elements of the material is minimized, whereby conspicuous irregularities in the final product are obviated.

An important object of the invention is to provide an improved method of forming shaped three-dimensional products from at `fabric material which involves moving a web of fabric material into a forming and molding area, then forming and molding the material into a desired shape while said material remains undetached from the web, and thereafter separating the formed product from the web and removing it from tlhe molding area; all of said steps being carried out in a substantially continuous manner and in repetitive sequence, whereby shaped products may be produced rapidly, economically and in a continuous automatic process.

A further object is to provide a method, of the character described, in which the forming and molding of the product are effected by initially moving the material into the mold form by a simple ydrawing or pulling action so 3,355,073 Patented Nov. 28, 1967 ICC that a rearrangement of the overall pattern of the material, as distinguished from any substantial stretching, elongation or change of the individual yarn elements, is accomplished to cause the material to conform to the mold elements, after which pressure or heat, or both, is applied to said material to permanently set said material into the desired shape.

A further object is to provide an improved apparatus for forming shaped products from a web of knitted or woven material, such as paper, which includes means for moving the web material into a forming and molding area on a substantially continuous basis and which also includes a mold having movable forming elements constructed in a manner to form and mold said material into a desired shape while said material is still attached and forms part of the web, after which the formed product is removed from the molding area; the movement of the web material and the operation of the mold being so interrelated that automatic, rapid and economical production of said products on a continuous basis may be accomplished.

Another object is to provide an apparatus, of the character described, including a forming and molding device through which web material is fed, together with tension means arranged to act upon the web material adjacent the forming and molding device, -whereby desired tension is applied to said web or said web is relieved of tension at the proper periods, all in relation to the operation of the forming and molding device to thereby permit said device to form and mold the material While said material is still integral with the main web.

A particular object is to provide a method and apparatus, of the character described, which is particularly adapted for use in forming molded hat bodies constructed of knitted or woven material and which lends itself to combination with subsequent steps, whereby a complete finished hat may be produced.

The construction designed to carry out the invention will be hereinafter described, together with other features thereof.

The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown, and wherein:

FIGURE 1 is a diagrammatic perspective illustration of an apparatus for producing shaped products;

FIGURE 2 is a diagrammatic view in elevation of the shaping or forming apparatus illustrating particularly the travel of the web material through such apparatus;

FIGURE 3 is a schematic diagram showing one type of drive mechanism for the shaping or forming apparatus;

FIGURE 4 is a cross-sectional view of a device for forming and molding hat bodies;

FIGURES 5 through 7 are diagrammatic illustrations of the forming and molding device shown in FIGURE 4 illustrating the manner of operation of such device;

FIGURE 8 is a diagrammatic plan view of an apparatus for forming a hat body into a nal hat;

FIGURES 9 through 11 are partial elevation views of the hat body during the forming thereof into the final hat; and

FIGURE l2 -s a view illustrating the contour shape of the brim yforming die.

In the drawings, the numeral 10 designates a supporting frame which includes spaced side bars 11 and support legs 12 (FIGURE 1). The frame is of considerable longitudinal extent and has a supply roll A of web 4material 13 mounted at one end thereof. The web material is formed of a knitted or woven fabric which is preferably knitted or Woven paper. As is clearly shown in FIGURE 3 1, the web of material 13 is adapted to move longitudinally between the side bars 11 of the frame 10 and various spaced driving rollers are arranged at appropriate points to effect the movement of the web in the proper manner.

Upon leaving the roll, the material 13 passes over driven rollers 14 and 15 and is confined against said driven rollers by idler rollers 16 and 17. The web is then directed downwardly around driven rollers 18 and 19 which are disposed within a sizing or other treatment vat or tank 20. A weighted roller 21, which is supported on the web material between rollers 18 and 19, maintains proper tension in the web material. As the web material moves through the tank 20, it is properly treated with a suitable sizing or other material.

The web material, after leaving the sizing tank 20, passes upwardly over a driven roller 22, being maintained in contact therewith by an idler 23, and the web 13 then passes horizontally 4beneath a blower housing 24. A fan 25 in said blower housing directs air over the web to remove any excess sizing which remains on the web after leaving the tank 2t); it is noted that the blower is preferably disposed over one end of the tank 20 (FIGURE 2) so that the excess sizing material is removed and returned to said tank.

After passing beneath the blower housing 24, the web 13 extends over another drive roller 26 and is retained in contact therewith by an idler roller 27. The web then passes around an idler 28 and moves upwardly into a controlled heat tower 29. As clearly shown in FIGURES 1 and 2 the web material moves over

idlers

30 and 31 within the tower 29 and then passes downwardly around a lower idler 32 which brings the web 13 back into horizontal alignment with the frame. The interior of the tower may contain any type of heating unit such as heating coils 29a and the applied heat is for the purpose of partially drying the particular sizing or treating material which has been previously applied to the web. Any suitable type of heating means may be employed.

Upon leaving the heating tower 29 and passing around the idler roller 32, the web material is passed over another drive roller 33 and is maintained in contact therewith by a pressure or idler roller 33a. From drive roller 33, the web material is directed beneath and around a tension roller 34, which is mounted in a horizontal bracket 35, which bracket is supported by the piston rod 36 of a hydraulic piston 37 mounted within a hydraulic cylinder 3S. By reason of this mounting, the tension roller 34 may be raised and lowered with respect to the main frame and therefore, with respect to the web material, whereby a. predetermined tension may be maintained in the web material.

After passing beneath the tension roller 34, the web material 13 passes over another drive roller 39. Suitable heat lamps or other heating means 41 are provided in the area between the heating tower and the drive roller 39 and such lamps function to maintain the web material in a heated condition after the same leaves the heating tower.

The drive roller 39 is at one end of a forming and molding device which is generally indicated by the letter B and which will be hereinfater described in more detail. Suttice it to say that the forming and molding device B is arranged to form and mold a shaped article or product from the web material 13 as such material is moved into the forming and molding area of said device. As illustrated in FIGURE 1, the web material 13 is adapted to move through the forming and molding device and passes over another drive roller 42 at the discharge side of the molding device.

After its passage over the drive roller 42, the web material passes beneath a second tension roller 34a which is of substantially the same construction and mounting as the tension roller 34. Tension roller 3451 is mounted on a bracket 35a which is supported at its central portion by a piston rod 36a of a piston 37a, said piston being movable within a hydraulic cylinder 38a. The tension roller 34a, like the tension roller 34, may be moved vertically with respect to the frame 10 and relative to the web material 13 and its position controls the application of tension to the web material. It might be noted that normally this tension is applied transversely of the web material 13 so that suicient longitudinal tension is maintained in the web material to assure proper movement through the apparatus.

After passing beneath the second tension roller 34a, the web material is then directed over another drive roller 44, being held in position thereon by idler 45. Another rive roller 46 and idler 47 are disposed just beyond the drive roller 44 and pull the material from the apparatus and over a guide roller 43 onto a discharge tray 49, a portion of which is schematically illustrated in FIG- URE 2.

The passage of the web material through the apparatus in the manner above described in schematically illustrated in FIGURE 2 and from this figure it will be seen that the travel is from the supply roll A, through the sizing vat or tank 20, then beneath the blower housing 24, through the heating tower 29 and finally into the forming and molding area of the device B; after leaving the forming and molding area, the material is discharged on the discharge tray 49.

The various drive rollers are actuated in any desired manner but are preferably driven by the usual sprockets and chains. Stich sprockets and chains are located on the side opposite that shown in FIG. 2 and a schematic diagram of one type of drive mechanism is illustrated. The driving power is preferably obtained from a hydraulic pump S0 which drives a chain 51, such chain passing around the drive roller 44. A suitable timer T controls the hydraulic pump 5t) and, therefore, controls the movement of the web, as will hereinafter appear. A suitable chain 52 and proper sprockets extend the drive action to roller 46. Sprockets and chain 53 transmit motion to the drive roller 42 and from this point an elongate chain 54 provides motive power for the

drive rollers

39, 33 and 26; because of the length of this chain, it is desirable to provide tension sprockets 54a and S413, which are schematically illustrated in FIGURE 3. From a second sprocket on the shaft of drive roller 26, another chain 55 is utilized to drive

rollers

15, 1S, 19 and 22, which rollers move the web material through the sizing tank or vat 20.

In operation, the timer T is set so as to actuate the prime mover or pump 50 in an intermittent manner. The web material moves from the supply roll to move a section, the extent of which is indicated by the letter S, in FIGURE 2, into the forming and molding area of the forming and molding device B. When such section is in position in this area, the timer T stops motion of the web material and, as will be explained, a forming and molding operation occurs. Following completion of the forming and molding operation, the web material 13 again undergoes motion to move the next section of the web material into the forming and molding area. It will be recognized that any suitable timing or control means for controlling the intermittent or step by step movement of the web material may be employed. Also, any suitable drive means and prime mover may be used in lieu of the illustrated sprockets and chain drives and hydraulic pump.

In carrying out the improved method, the web material is moved through the apparatus so as to present successive sections of the web material 13 to the forming and molding device B. As illustrated herein and as will be described in more detail, the forming and molding device is constructed to form a hat body. However, it is apparent that so far as the method is concerned, any shaped article or product formed from the web material may be produced and the invention is not to be limited to the forming ot' hat bodies. The web material 13, controlled by timer T and prime mover 50, moves a section thereof 55 into the forming and molding area. The forming and molding device B is then actuated to form and mold the shaped article. It is noted that during the time that the web material is moving, the

tension rollers

34 and 34a are .in the position shown in full lines in FIGURE 2 and are maintaining desired and proper tension on the web material. When the web material movement is halted with a section within the forming andmolding area, the

tension rollers

34 and 34a are moved to the dotted line positions shown in FIGURE 2, to relieve tension on the web. These rollers are preferably operated hydraulically and a suitable hydraulic control indicated at H in FIG- URE 2 is provided to actuate the pistons 37 and 37a which control the position of said tension rollers to lift said rollers at the proper time. It is also preferable that the forming and molding device B be actuated hydraulically and the control H also controls action of this device so that the movement of the tension rollers may be controlled in proper time sequence to the web movement and also to the operation of the forming and molding device B.

While the web material is stationary with lthe section S thereof in the forming and molding area, the tension rollers move up to relieve any applied tension to the web material and the forming and molding vdevice B is actuated to form and mold the shaped body with, as has been described, is illustrated as a hat body. The forming and molding operation performed on the section S is performed While this section is integral with the remainder of the web and it is only after the molding is complete that a cutting action occurs which separates the molded hat body or article from the remainder of the web. A suitable ejector w-hich may be in the form of an ejector arm 5d (FIGURE l) is then actuated to remove the molded hat body from the molding area. For example, the shaft 55a, on which ejector arm 56 is mounted, may be rotativeiy mounted and when actuated subsequent to completion of the cutting operation moves the ejector arm 56 through the forming and molding area to push the molded hat body therefrom. Thereafter, the timer again activates the prime mover or pump Sil to lower the

tension rollers

34 and 34a and thereafter again the web material in a direction in the right in FIGURE 2 the proper distance to move the next adjacent section of web material into the molding area; upon the next section being positioned in the forming and molding area the operation is repeated to form the next article. It is noted that the web material is greater in width than the width of the cut-out material of which the molded article is formed so that drive rollers 44 and 461 acting upon the remaining web material assist the other drive rollers in the system to move the next section of web material into position Within the forming and molding area.

It is thus apparent that the method involves the intermittent motion of a web material which is moved successively or by stages into the forming and molding area. The web material remains stationary for a sufficient length of time to permit the forming and molding to occur, after which the operation is repeated. The control of the movement of the web material and the control of the actuation of the molding device B, as well as the control of the tension on the web material, is all automatic, with the result that a substantially continuous method of forming shaped objects from knitted or woven material is provided. It is7 of course, evident that the type of controls, the prime movers and the various actuators in connection therewith are subject to wide variation and any of the well known units now available may be employed. So long as the sequence of operation remains the same, that is, the web material is moved into the -molding and forming area, the tension on the web is relieved, the molding operation is carried out, the shaped object is removed from the forming and molding area, the tension on the web is again applied, and subsequent movement of the web material is accomplished, the method and procedure of this 6 invention is carried out. Although the

movable tension rollers

34 and 34a are one simple means of applying and relieving tension, other tension means may be employed.

It is evident that the particular forming and molding device is variable as to its molding dies which will be constructed to form the particular desired article or product. As has been noted, the device B shown herein is for the purpose of forming and molding hat bodies and one form of device which has been found particularly satisfactory in the performance of the method is illustrated in FIGURES 4 through 7. Referring to FIGURE 4, in which a cross-sectional View of the device is illustrated, said device comprises a base 60 upon which is mounted a stationary die 61. The die 61 is in the form of an annular collar having a central bore 62 and an upper counterbore 63; the counter-bore is surrounded by an upstanding annular flange 64 and at the inner periphery of the flange, there is provided an annular cutting ring 65.

An annular lower brim die 66 is movable within limits in the counter-bore 63 of the stationary die 61 and is supported upon a plurality of coiled springs 67 which are interposed between the base 60 and the underside of said brim die. The springs normally support the movable lower die 66 in its upper position with respect to said stationary die as shown in FIGURE 4. The lower brim die 66 has a central bore or opening 69 extending entirely therethrough and since it is designed to form a hat brim, its upper surface 68 is generally curved or convex in cross-section. Also, since a hat brim which is not truly circular but which will later require shaping and bending of its peripheral edge is being formed, the convex surface is not annular in the sense that all portions thereof lie in the same plane; instead, the convex surface 68 is actually contoured, as shown in FIGURE 12, so that the surfaces of its end portions which form the front and rear of the hat are in different horizontal planes than the surfaces which form the sides of the brim. Viewing the surface 68 in plan, it is somewhat elliptical in shape as distinguished from a true circle, so that said surface is, when a hat brim is to be formed, contoured whereby final shaping is facilitated without creases or folds. Although the contoured conguration is preferable, particularly for a hat brim, it is not essential since the molding or forming of an article can be carried out with the die surface 68 substantially annular, with its entire area lying in substantially the same plane.

An upper brim die 70 having a central bore 70a is adapted to coact with the lower brim die and has its lower surface 71 curved or concave with this surface being complementary to the upper surface of the lower brim die 66. Suitable vapor or steam escape passages 7011 (FIG- URE 4) are provided in this die. The upper brim die is carried by a plate 72 which is secured through a bracket 73 to the lower end of a tubular piston rod 74. As shown in FIGURE 5, the piston rod 74 has its upper end secured to a hydraulic piston 7S which is slidable within a hydraulic power cylinder 76.

As will be explained, the ripper bri-rn die is adapted to be moved downwardly when the piston 75 is moved downwardly within its cylinder and is adapted to move into close relationship with the lower brim die 66. Movement of the upper brim die '70 into close relationship to the lower brim die will initially conne the material between said dies and subsequent continued downward movement of the upper brim die will complete the forming operation and by reason of a suitable cutting edge 77 formed on the die 7), which cutting edge coacts with the cutting ring 65 on the stationary die 61, the formed article or hat body may be cut and thereby detached from the remainder of the web material.

An upper crown die 78 is mounted on the lower end of a piston rod 79 which extends upwardly through the tubular piston rod 74 of the upper brim'die. As indicated in FIGURE 5, the piston rod 79 has its upper end attached to a piston 80 which is movable within a power cylinder 81. The lower surface SZ of the upper crown die is, of course, shaped in accordance with the desired shape of the particular hat body. It is evident that movement of the upper crown die 78 is independent of the movement of the upper brim die by reason of each of these dies being controlled by their separate piston and cylinder assemblies.

A lower crown die S3 is adapted to move upwardly through the bore 69 of the lower brim die and the bore 70a of the upper brim die. The lower crown die has its upper surface 84 complementary to the lower surface of the upper crown die and said lower crown die is carried by a downwardly extending tubular piston rod 85. The lower end of the piston rod -is secured to an actuating pistn 86 disposed within a hydraulic power cylinder 87.

All of the dies may be suitably heated and maintained at a desired temperature by electrical elements or coils which are indicated at 88 in the drawings. Also, all of the dies are actuated hydraulically and the particular hydraulic connections and the controls therefor have not been illustrated in detail because such connections and controls are well known in the art. The unit indicated at H in FIGURE 2 properly controls the sequence of operation and movement of the various parts during the forming and molding operation.

From the foregoing it is evident that for the forming of hat bodies, the forming and molding device B comprises the main crown dies 83 and 78 and the auxiliary brim dies 66 and 7i) which surround the main dies. As will be described the brim dies form a peripheral or substantially annular area around the main dies through which the material passes during the forming step accomplished by the main dies.

In FIGURES 5 to 7, the manner of operation of the forming and molding device B is illustrated. Referring to FIGURE 5, when the web material 13 has been halted to locate the section S of said material in the forming and molding area, the hydraulic controls actuate the device B in the sequence shown in this figure, Initially, the

tension rollers

34 and 34a are raised by means of their respective hydraulic pistons; this relaxes any applied tension to the web material. Simultaneously with the upward motion of the

rollers

34 and 34a, the upper brim die 70 and the upper crown die 78 are moved downwardly to the position shown in FIGURE 5. In this position the upper brim die 70 merely touches the web material 13 to closely confine the material between the upper die and the lower brim die 66. At this point motion of the upper brim die is halted.

Substantially simultaneously with the downward movement of the upper brim die 70 and the upper crown die 78, the lower crown die 83 is moved upwardly by its hydraulic piston 85. Because the power applied to the lower die piston is greater than that applied to the upper crown die piston, the lower crown die 83 moves upwardly in the manner shown in FIGURE 6. Such movement of the lower crown die gathers or draws material through the annular space between the upper and lower brim dies and into the space between the lower crown die and the bore 70a of the upper brim die. The material is substantially free of any tension in all directions and as the lower crown die moves upwardly to the position of FIGURE 6, the material is drawn into the area between the dies 66 and 70 and also into the area around the lower crown die. By reason of the material being free of any tension, there is little resistance to this movement and thus the material is moved into position over the lower crown die without any substantial elongation or stretch of the individual yard elements; as the material moves into position over the lower crown die, a slight realignment of the pattern of the material occurs as it conforms to the shape of said lower crown die and the shape of the area between the upper and lower brim dies.

Upon reaching the upper limit of its movement as shown in FIGURE 6, the lower crown die is halted in its movement. Because it has been moving against the resistance of the upper crown die, there is a slight pressing action applied to the surface of the material between the lower die S3 and the upper die 78. However, this is not a final pressing or setting which completes the molding action but is actually a forming or shaping of the hat body crown. After the lower crown die has completed its movement, the hydraulic control H imparts additional downward movement to the upper brim die 70. This movement results in applying pressure and heat to the brim area and at the same time causes a slight stretching of the material in the crown of the hat body being formed which finally molds and sets the hat body. It is noted that this second or subsequent downward movement of the upper brim die 70 is relatively siight and is only sufficient to complete the setting of the final shape. Upon the cutting edge 77 on the upper brim die 70 moving opposite the cutting ring 65, the shaped body is cut and detached from the web material. It is pointed out that as the upper brim die moves downwardly to complete the molding operation and to cut the material, a downward motion of the lower brim die may occur because this lower brim die is supported by the coiled springs 67. By controlling the strength of said springs, the amount of pressure which is applied during final movement of the upper brim die and prior to cutting can be controlled. The nal position of the dies is illustrated in FIGURE 7.

After the hat body has been molded in the manner above described and has been cut so that it is detached from the remaining portion of the web material I3, the hydraulic system operates to return the dies to their initial positions as schematically illustrated in FIGURE 2. Thereafter, the ejector 56 is operated to eject the molded hat body `from the forming and molding area and the timer T again actuatcs the drive mechanism for moving the web so that the next section of web material may move into place, after which the operation is repeated. At the time that the dies of the device B are returned to their original positions, the tension bars 34 and 34a are lowered by their respective pistons to again apply tension to the web material so that proper tension in said material is present during the subsequent travel thereof.

From the foregoing, it will be seen that a substantially continuous operation for forming molded articles or products from a web material is provided. The sequence of operation involves movement of the web material into the forming and molding area followed by a halting of movement of said material for a sufiicient length of time to permit the device B to operate. The device B actually forms and molds the material into the desired shape while said material is integral with the remainder of the web; it is only after the article is completed that a cutting or detachment of the molded object occurs. The forming and molding of the article or product while remaining integral with the web is possible because sufiicient play or looseness of the material in the die area is present to permit the lower crown die to gather or draw the material into the mold to preliminarily form the same. Because relatively close tolerance is held between the upper and lower brim dies 70 and 65, the material is gathered into the device B without wrinkling and without the requirement that there be any substantial stretching or elongation of the individual yarn elements. In the final molding of the product, there may be some slight stretching of certain of the yarn elements but the major action of the material is a realignment of the pattern of the fabric. Such realignment allows the material to assume a three-dimensional shape without the necessity of depending upon stretching or shrinking of individual yarn elements. This is one of the major features of the invention and the manner in which the material is first drawn or gathered into the die to preliminarily form the same, followed by the pressure and heat application which finally sets the product, makes possible the formation of the article While it is still an integral part of the web material.

In FIGURES 1 through 7, the apparatus has been illustrated as forming a hat body. As is well known, the hat body must be subsequently formed into the final hat and the particular method heretofore described lends itself to combination with additional steps which will complete the formation of a finished hat. Referring to FIGURE 8, a conveyor 99 may extend laterally from the forming and molding area formed by device B so that each hat body is ejected onto the conveyor 90. Such conveyor conducts the hat body which has the crosssectional shape shown in FIGURE 9 to a brim cement applicator 91. In the formation of the hat body, the peripheral ed-ge indicated at 92 in FGURE 9 has been turned upwardly by reason of the coaction between the upper and lower brim dies. The cement applicator 91 applies a cement to the area inside of this peripheral upturned area.

The hat body is then conducted through a drier 93 which partially dries the cement and then passes to the next station 94 which deposits a wire ring 9S, as shown in FIGURE l0, at the periphery of the hat within the upturned edge 92. The conveyor then carries the hat to the next station 96 which comprises a brim edge sealer which turns the edge 92 downwardly over the wire ring 95 to complete the edge. If desired, station 96 may be a sewing machine which would stitch the overturned edge 92. This completes the hat except for the attachment of the usual inner sweat band and any outer trim band which may be desired. It is obvious that if the forming and molding device B is constructed to properiy crease the crown and to Igive it any desired shape, the passage of the hat after it leaves this area through the various stations shown in FIGURE 8 will substantially produce the final product.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made within the scope of the appended claims without departing from the spirit of the invention.

What we claim is:

3l. An apparatus for producing shaped articles from a web of material including,

a support structure having means for receiving a supply roll of web material at one end thereof,

means for moving the web of material longitudinally along a horizontal path, a forming and molding device mounted on the frame and spaced from the supply' roll of wab material, whereby sections of the web material may be moved successively into the forming and molding area of said device, said forming and molding device having means for forming a section of the material within the forming and molding area into a desired shape,

and molding the same into said shape while the section of material being formed and molded is integral with the remainder of the web,

means controlling tension in said web of material to maintain a predetermined tension in said web of material as it is moved by said moving means and to relieve longitudinal tension in said web of material during the forming and molding of said material by said forming and molding device,

cutting means associated with the molding device for cutting out the molded article from the web of material, and

means for removing the molded article from the forming and molding area after the molding operation has been completed.

2;. An apparatus as set forth in claim 1 together with means mounted on the support frame between the supply l@ roil and the forming and molding device for applying a sizing to said material, and

means located between said means for applying sizing and said forming and molding device for applying heat to the web material to heat and partially set said sizing material.

3. An apparatus as set forth in claim l wherein sai-d web moving means intermittently moves the web material along its longitudinal path to successively move a section of the webmaterial into the forming and molding device together with,

means for actuating the forming and molding device during the time that the web material is held stationary, and

thereafter said web moving means again moves web material into the molding device after each article has been formed and molded.

4. The method of producing shaped articles from a web of material including the steps of,

delivering the material to be formed into a forming and molding area,

engaging said material in an annular area surrounding said forming and molding area sufficiently tight to allow said material to be drawn through said annular area of engagement into said forming and molding area free of wrinkles and creases,

forming and molding the material in the forming and molding area while drawing material from said annular area,

thereafter forming and molding the material in said annular area,

cutting the material around the outer edge of said annular area, and

removing the shaped article from the forming and molding area.

S. The method of producing shaped articles according to claim 4, together with the steps of maintaining a predetermined -longitudinal tension in said web of material as it is undergoing movement, and relieving longitudinal tension in said web of material when its movement is halted and during said steps of forming and molding in said forming and molding area and said annular area whereby the resistance of said web of material to forming is controlled by said confining of said material in said annular area. 6. In an apparatus for producing shaped articles of fabric, a forming and molding device including,

a first annular forming and molding member, a second annular forming and molding member mating with said first annular forming and molding member,

means moving at least one of said annular forming and molding members to coniine the fabric in sliding engagement between said annular forming and molding members,

a central forming and molding member,

means moving said central forming and molding member through said first and second annular forming and molding members to pull a portion of the fabric to be formed by said central forming and molding ember between said first and second annular forming and molding members whereby said portion of fabric pulled through said annular members is maintained free of wrinkles, and

cutting means surrounding one of said annular forming and molding members.

7. In an apparatus for producing shaped articles of fabric, a forming and molding device including,

a base member,

a lower annular forming and molding member resiliently supported by said base member,

an upper annular forming and molding member mating with said lower annular forming and molding member,

il means for moving said upper annular forming and molding member to confine fabric in sliding engage ment between said annular forming and molding members,

a central forming and molding member,

means moving said central forming and molding member through said annular forming and molding members to pull a portion of the fabric to be formed by said central forming and molding member between said first and second annular forming and molding members whereby said portion of fabric pulled through said annular members is free of wrinkles, and

cutting means associated with said annular forming and molding members to cut t-he fabric around the outer edge of said annular forming and molding members.

8. In an apparatus for producing shaped articles of fabric material, a forming and molding device including,

a base member,

a lower forming member,

an actuator connected to said lower forming and molding member for movement of said lower forming and molding member upwardly through said lower annular forming and molding member and said upper annular forming and molding member,

an upper central forming and molding member,

an actuator for said upper central forming and molding member for movement of said upper central forming and molding member downwardly into mating position with said lower forming and molding member,

said actuator connected to said lower forming and molding member having sufcient power to overcome said actuator connected to said upper central forming and molding member,

an actuator on said upper annular forming and molding member,

a cutting edge around said upper annular forming and molding member, and

a cutting edge on said base member mating with the cutting edge on said upper annular forming and molding member.

9. The method of producing shaped articles from a web of fabric including the steps of moving said fabric web to position a section of said fabric web in a molding and forming area, maintaining a predetermined longitudinal tension in said fabric web as it is undergoing movement, halting movement of said fabric web with said section in said molding and forming area,

relieving longitudinal tension in said fabric web when its movement is halted,

forming a portion of said fabric web within said area into a desired shape, molding the same into said shape after forming while the fabric being molded is still integral with the remainder of said fabric web, and while the longitudinal tension on said fabric web is relieved,

thereafter cutting the shaped portion of said fabric from said fabric web, and

finally removing the shaped portion of said fabric from said forming and molding area.

10. The method of producing a shaped article from a web of fabric having a pattern according to claim 9, together with the steps of confining during the forming step that portion of said fabric web which passes through the outer peripheral portion of said forming and molding area to permit the fabric to be drawn through and confined thereby smoothing said fabric and assisting in the realignment of the pattern of said fabric during the forming of the fabric within the central portion of the forming and molding area.

11. The method of producing a shaped article from a web of fabric having a pattern according to claim 9, together with the steps of confining during the forming step that portion of said fabric web which passes through the outer peripheral portion of said forming and molding area to permit the fabric to be drawn through and confined thereby smoothing said fabric and assisting in the realignment of the pattern of said fabric during the forming of the fabric within the central portion of the forming and molding area, and

thereafter molding that portion of the fabric which remains in the outer peripheral portion of said forming and molding area after the drawing of the fabric into the central portion of said area is complete.

12. The method of producing a shaped article according to claim 9, wherein said web of fabric is a web of knitted fabric.

13. The method of producing a shaped article according to claim 9, wherein said web of fabric is a web of woven fabric.

14. The method of producing shaped V'articles from a substantially continuous web of material according to claim 9, together with the steps of moving a new section of web material into said forming and molding area after said shaped .article is removed from said area, and

repeating the steps of forming, molding, cutting and removing while maintaining longitudinal tension in said web material as it is moving and relieving longitudinal tension in said web material when its movement is halted to sequentially produce a plurality of shaped articles in a substantially continuous manner.

15. The method of producing shaped articles according to claim 14, together with the steps of confining during the forming step that portion of said fabric web which passes through the outer peripheral portion of said forming and molding area to permit the fabric to be drawn through and confined thereby smoothing said fabric and assisting in the realignment of the pattern of said fabric during the forming of 'the fabric within the central portion of the forming and molding area, and

16. The method of producing shaped articles according to claim 14, wherein said web of material is a web of knitted fabric.

17. The method of producing shaped articles according to claim 14, wherein said web of material is a web of woven fabric.

18. An apparatus for producing shaped articles from a web of material, comprising means for forming and molding a web of material and defining a forming and molding area, means for delivering a section of the web of material to be formed into said forming and molding area,

means confining said material in an annular area surrounding said forming and molding larea and allowing a portion of said material to be drawn through the confined annular area into said forming and molding area,

means actuating said forming and molding means to form and mold said material in said forming and molding arca while drawing material through said confined annular area,

said confining means molding said material in said annular area to complete the molding of a shaped article after the forming of said material in said forming and molding area, and

means for cutting the shaped article from said web of material.

19. An apparatus for producing shaped articles according to claim 18, including means controlling tension in said Web of material to maintain a predetermined longitudinal tension in said web of material as -it is undergoing movement and to relieve longitudinal tension in said web of material when its movement is halted.

20. An apparatus for producing shaped articles from a web of fabric, comprising means for forming and molding a fabric web and defining a forming and molding area,

means for moving said fabric web to position a section of said fabric web in said forming and molding area,

said forming and molding means having means for forming a section of said fabric web Within said forming and molding area into a desired shaped article and molding the same into said shape While the section of material being formed and molded is integral with the remainder of the fabric web,

means controlling tension in said fabric web to maintain a predetermined longitudinal tension in Vsaid fabric Web as it -is undergoing movement and to relieve longitudinal tension in said fabric web when its movement is halted, and

means for cutting the shaped article from the fabric web.

21. An apparatus for producing shaped articles according to claim 1, including annular molding means surrounding said forming and molding device and adapted t coniine and mold the material in the annular area defined by said annular molding means whereby material is drawn through said annular molding during the forming of said material in said forming and molding device and thereafter the material is molded in said annular area by said annular molding means.

References Cited UNITED STATES PATENTS Ertola et al. 223-12 Katz 264-136 Mallory 18-19 Clapp.

Bronson 18-19 Gross et al. 264-324 Hunter 223-12 Pardee et al. 264-163 Haerther et al. 264-134 X Schneider 264-324 Mumford 18-19 X Menkel 18-19 Gordon 264-134 Theil 18-19 Taylor 18-19 Goldfein 264-134 PATRICK D. LAWSON, Primary Examiner.

G. V. LARKIN, Assistant Examiner.

Claims

1. AN APPARATUS FOR PRODUCING SHAPED ARTICLES FROM A WEB OF MATERIAL INCLUDING, A SUPPORT STRUCTURE HAVING MEANS FOR RECEIVING A SUPPLY ROLL OF WEB MATERIAL AT ONE END THEREOF, MEANS FOR MOVING THE WEB OF MATERIAL LONGITUDINALLY ALONG A HORIZONTAL PATH, A FORMING AND MOLDING DEVICE MOUNTED ON THE FRAME ANS SPACED FROM THE SUPPLY ROLL OF WAB MATERIAL, WHEREBY SECTIONS OF THE WEB MATERIAL MAY BE MOVED SUCCESSIVELY INTO THE FORMING AND MOLDING AREA OF SAID DEVICE, SAID FORMING AND MOLDING DEVICE HAVING MEANS FOR FORMING A SECTION OF THE MATERIAL WITHIN THE FORMING AND MOLDING AREA INTO A DESIRED SHAPE, AND MOLDING THE SAME INTO SAID SHAPE WHILE THE SECTION OF MATERIAL BEING FORMED AND MOLDED IS INTEGRAL WITH THE REMAINDER OF THE WEB, MEANS CONTROLLING TENSION IN SAID WEB OF MATERIAL TO MAINTAIN A PREDETERMINED TENSION IN SAID WEB OF MATERIAL AS IT IS MOVED BY SAID MOVING MEANS AND TO RELIEVE LONGITUDINAL TENSION IN SAID WEB OF MATERIAL DURING THE FORMING AND MOLDING OF SAID MATERIAL BY SAID FORMING AND MOLDING DEVICE, CUTTING MEANS ASSOCIATED WITH THE MOLDING DEVICE FOR CUTTING OUT THE MOLDED ARTICLE FROM THE WEB OF MATERIAL, AND MEANS FOR REMOVING THE MOLDED ARTICLE FROM THE FORMING AND MOLDING AREA AFTER THE MOLDING OPERATION HAS BEEN COMPLETED.