US3767510A - Laminating apparatus - Google Patents

Laminating apparatus Download PDF

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US3767510A
US3767510A US3767510DA US3767510A US 3767510 A US3767510 A US 3767510A US 3767510D A US3767510D A US 3767510DA US 3767510 A US3767510 A US 3767510A
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Prior art keywords
strip
material
rollers
backing element
backing
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E Gustafson
H Gustafson
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Matherson-Selig Co
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Matherson-Selig Co
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • B29C66/435Making large sheets by joining smaller ones or strips together
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/18Handling of layers or the laminate
    • B32B38/1808Handling of layers or the laminate characterised by the laying up of the layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00Layered products
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702For plural parts or plural areas of single part
    • Y10T156/1712Indefinite or running length work
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702For plural parts or plural areas of single part
    • Y10T156/1712Indefinite or running length work
    • Y10T156/1715Means joining indefinite length work edge to edge
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702For plural parts or plural areas of single part
    • Y10T156/1712Indefinite or running length work
    • Y10T156/1722Means applying fluent adhesive or adhesive activator material between layers
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702For plural parts or plural areas of single part
    • Y10T156/1712Indefinite or running length work
    • Y10T156/1722Means applying fluent adhesive or adhesive activator material between layers
    • Y10T156/1727Plural indefinite length or running length workpieces
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702For plural parts or plural areas of single part
    • Y10T156/1712Indefinite or running length work
    • Y10T156/1741Progressive continuous bonding press [e.g., roll couples]

Abstract

Apparatus for laminating two or more strips of web material which may have different flow characteristics to a web backing element in abutting side by side relation. The laminating apparatus includes a drive system for isolating the laminating section from the takeup station and includes a tensionless web guide which compensates for strips of material which may have been cut unevenly and automatically guides them into a tight abutting relation.

Description

llnited States Patent Gustafson, deceased Oct. 23, 1973 LAMINATING APPARATUS Eric Gustafson, deceased, late of Chicago, Ill. Helen Gustafson, executor-elect Assignee: Matherson-Selig Co., Chicago, 111.

Filed: Oct. 27, 1971 Appl. No.: 192,945

lnventor:

U.S. Cl 156/494, 156/324, 156/543, 156/544, 156/547, 156/549, 156/555 Int. Cl. C09j 5/00 Field of Search 156/324, 494, 495, 156/533, 539, 541, 542, 544,545, 586, 549, 550, 552, 555, 562

References Cited UNITED STATES PATENTS 8/1961 Borys 156/545 8/1964 Hannon 156/499 2,527,183 10/1950 Gardner 156/543 2,297,236 9/1942 Nadai et a1 226/196 UX 3,562,067 2/1971 Kuchelk 156/542 3,458,382 7/1969 Buck 156/543 3,352,733 11/1967 Kruce 156/552 X Primary Examiner-Alfred L. Leavitt Assistant Examiner-David A. Simmons Attorney-Gerald M. Newman [57] ABSTRACT Apparatus for laminating two or more strips of web material which may have different flow characteristics to a web backing element in abutting side by side relation. The laminating apparatus includes a drive system for isolating the laminating section from the takeup station and includes a tensionless web guide which compensates for strips of material which may have been cut unevenly and automatically guides them into a tight abutting relation 6 Claims, 6 Drawing Figures PAIENTEDBBI 23 I913 SHEET 2 OF 3 Inner-(1291": Eric Gustafson ONN PAIENTEflnmza I973 37571510 sum 30F 3 InUerzZEr: Eric Gusfcz-Fson- .1 LAMINATING APPARATUS FIELD OF INVENTION This invention relates in general tolaminating apparatus and inparticularrelates to apparatus for laminating two or morestrips of material having different flow characteristics to a backing element which has very little tendency to stretch. -Moreyparticularly,,this invention relates to apparatus for laminating strips of material having substantial flow characteristics in tight, abutting side .by side relation to a backing element.

DESCRIPTION OF THEPRIOR ART Charts or pamphlets, on which samplesof various materials are mounted for comparison or for display to a customer are very popular and arecommonly used to facilitate the sale of many products. Such charts may be employed in the automobile industry for showing apotential customerthe available choice ofseat cover materials, headliner materials and other interior coverings. Such sample charts are also used in the fabric in dustry to show a potential wholesale .or retail buyerthe choice of fabrics. or materials in which a sample of clothing or other articles may be purchased.

In the manufacture of such charts it is, of course, desirable that they be assembled or compiled automatically by machinery capable of accommodating the samples which have previously been cut to a given size and mounting them on the various charts or brochures as may be desired.

Many of the sample patches .of fabric or other material are air permeable, while the apparatus for picking up the samples to mount them on the chart often employs air or suction as the lifting medium.

The serious problem of lifting and conveying samples of air permeable materials by applying a suction or vacuum is clearly pointed out and defined in US. Pat. No. 2,797,010 issued June 25, 1957 to Adolph P. Neer, entitled Sample Chart and Method of Fabricating the Same," said patent being assigned to the same assignee as the subject application. In accordance with the teaching of the Neer patent the problem is solved by attaching an air impervious layer or backing to one surface of the fabric and then applying the suction or vacuum to the impervious layer to thereby pick up the air permeable fabric and place it in its proper position on the chart.

Although the patent to Neer solved the problem of picking up samples of air permeable fabric and materials, there still existed the problem of attaching or otherwise securing the air impervious layer to the air permeable fabric. v

Fabric or other air permeable material is typically supplied to the chart maker in strip form rolled into a coil from which the sample swatches are then cut. Prior to this invention, when following the teachings of Neer the strip material was manually glued to the air impervious layer or backing. When performing this manual operation it was extremely important to glue the strip material on the backing very carefully so as to have a neat appearing producnWhile this was difficult when laying only one strip on a, backing the difficulty increased multi-fold when laying two or more strips on the same backing as is necessary when itis desirable to show two or more coordinated colors or materials which a prospective purchaser may wish to. choose. For instance, in an. automotive fabric sample chart it is desirable to display to a prospective purchaser a sample of the material which may be used to upholster the seat and a coordinated material which may be used to cover the headliner or other interior surfaces.

When displaying two ormore coordinated materials it is desirable to lay them onthe backing in a tight, abutting, side by side relation so that there are no loose threads or fuzzy edges exposed to thereby give the color chart a neat, desirable appearance.

When, in the prior art such strips were manually laid on the backing there was a high rejection rate due to the materials being placed unevenly on the backing, which led to a great'waste of both material and labor.

SUMMARY OF THE INVENTION The normal difficulty of placing the strip material evenly on the backing is increaseddue to the fact that various strip materials have different flow characteristics and the backing typically had a flow characteristic different than any of the strip materials. By the term :flow characteristic" is meant that the different materials stretch to different degrees when a given tension is applied. The different flow characteristics can cause the material to bunch,,gather or warp after being glued tothe backing if care is not taken to eliminate all tension on the strip material as it is being glued.

This invention obviates the above mentioned problems and difficulties encountered in laying one or more strips of material on a backing element, particularly when the strip materials have flow characteristics which differ from one another and when the flow characteristics of the strip materials differ from the flow characteristics of the backing element. The invention also obviates the problem of placing strip materials on a backing in a neat, straight manner, and causes the material to be adhered more tightly to the backing than was practical by the hand method.

In accordance with the invention, a laminating apparatus is provided, including a supply for the backing material and separate supplies for any number of strip materials. The backing element and the strip materials are trained along independent paths to a point whereat the strip materials are applied or laid on a surface of the backing element which has previously been coated with an adhesive. The strip material and backing are then trained through the nip formed by a pair of smooth, hard surfaced laminating rollers which combine the strip material having the greatest thickness, with the backing element. From the laminating rollers the material and backing are fed through the nip formed by a pair of cushioned surfaced drive rollers which combined or press each of the strip materials onto the backing element. The cushioned drive rollers are driven by a variable speed motor which directly controls the rate of speed of the laminating apparatus. The drive rollers also isolate the combining or laminating portion of the apparatus from the take-up station at which the laminated strip material and backing element are re-wound.

The-laminating apparatus also includes a novel guide station located adjacent to the region whereat the strip materials are applied to the backing element. The guide station includes means for independently, tensionlessly, laterally guiding each of the strips onto the backing element so that they are placed in a tight, abutting, sideby-side relation.

In some instances the edge of one strip material may be placed on the backing in slightly overlapping relationship to the edge of an adjacent strip. The overlap is eliminated as the strip materials pass through the nips of the hard, smooth surfaced laminating rollers which tightlly squeeze the strip material and the backing and cause the overlapping material to shift in a lateral direction to form a tight, abutting edge seam.

Accordingly, the primary object of this invention is to provide laminating apparatus for laminating strip material to a backing element.

Another object of this invention is to provide laminating apparatus for laminating two or more strip materials having different flow characteristics to a backing element which has an entirely different flow characteristic.

An additional object of this invention is to provide laminating apparatus for laminating one or more strips of material in a straight, uniform, neat appearing manner to a backing element.

Another object of this invention is to provide, in a laminating machine guide means for compensating for slight tolerances in the width of strip material being laminated to a backing element and to tensionlessly guide said strip material so that adjacent edges thereof are in tight, abutting relation.

It is a further object of this invention to provide apparatus for laminating a first strip material having a thready or fuzzy edge and second strip material which has a clean edge to a backing element, so that the thready or fuzzy edge of the first material is substantially covered by the clean edge of the second material.

Additional objects of this invention will become apparent to those versed in the laminating art upon an understanding of the following detailed description of the laminating apparatus of the invention taken in conjunction with the accompanying drawings in which a preferred embodiment of the invention is shown and wherein:

DESCRIPTION OF THE DRAWINGS FIG. 1 is a front elevational view of the laminating apparatus of the invention illustrating the major assemblies and components and their positions relative to each other.

FIG. 2 is a slightly enlarged front elevational view of the laminating apparatus of the invention with the front wall of the frame removed, exposing and clearly illustrating the drive train.

FIG. 3 is a greatly enlarged front elevational view of a portion of the laminating apparatus showing in detail the path of the strip materials through the guide station, the path of the backing element through the gluing station, and the path of the strip materials together with the backing element through the laminating and drive rollers.

FIG. 4 is an enlarged top plan view of one strip material guide element as viewed along lines 4-4 of FIG. 3.

FIG. 5 is an enlarged left side elevational view of three guides for guiding three strips of material in side by side relation illustrating the cooperation between the guide elements and illustrating the path of the strip materials therethrough, as seen along line 55 of FIG. 3.

FIG. 6 is a greatly enlarged sectional elevational view of the cushioned rollers and their cooperation with the strip materials and backing element as seen along lines 66 of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. 1 of the drawings, the laminating apparatus of the invention comprises a main frame generally referred to by reference numeral 10 and includes a supply station 12 of the backing element web and supply stations 14, 16 and 18 of strip materials in web form which are to be placed on the backing element. The laminating apparatus also includes a take-up station 20 at which the laminated strip material and backing are rewound, a glue or adhesive applying station 22, a guide station 24, a pair of hard, smooth surfaced laminating rollers 26 and 28, a pair of cushioned drive rollers 30 and 32 and a variable speed drive motor 34.

As best seen in FIGS. 2, 3 and 4 in addition to FIG. 1, frame 10 is fabricated of spaced apart rigid front and back walls 36 and 38 respectively which are fabricated from heavy plate steel. Many of the various drivers and non-driven members including rollers, shafts and mandrels are mounted in suitable bearings or journals provided in both the front and back walls or are otherwise secured to the walls to lend great stability to the construction. The portion of the frame adjacent drive motor 23 and take-up station 20 is fabricated of angle iron for reduced weight.

To facilitate identification of the strips or webs of materials and the backing element described in connection with this invention, each will be referred to by a letter designation. In accordance therewith, the backing element will be referred to by letter A, and the strip materials carried at supply stations 16, 18 and 20 will be referred to by letters B, C and D respectively.

The coiled supply of the backing element A is secured to a mandrel 40 journaled between side walls 36-38. Mandrel 40 includes an air brake, not shown, which is actuated by an air brake control 37 (FIG. 2) in conjunction with an air cylinder 54 which comprises part of a constant tension control to regulate and control the tension under which the backing element is unwound from the spool.

Backing element A is trained along a path which includes an idler roller 42 journaled on a shaft 44 secured to frame 10. The element is also trained beneath an idler roller 46 journaled on a shaft 48 which is carried at one end of a generally horizontal rocker arm 50 pivotally secured at 52 to the front surface of frame wall 38. The opposite end of rocker arm 50 is coupled to the air cylinder 54. Actuation of the air cylinder causes pivotal movement of arm 50 and corresponding movement of roller 46. The interaction between the air cylinder and air brake control 37 equalizes the tension of backing element A as it is uncoiled from supply station 12.

Backing element A is subsequently trained over an idler roller 56 journaled at 58 to the frame 10 and then passes under a pair of spaced apart rollers 60 and 62 located above the gluing station in generally straddling relation thereto. As the backing element passes over the gluing station the underside of the web engages the surface of a rotating glue applicating roller 64 which, in a well-known manner picks up glue or adhesive from a glue pot 66 and applies it to the web. Conventional doctoring means (not shown) cooperating with the roller are provided for adjusting and controlling the amount of glue or adhesive applied to backing A.

The backing is then trained against a guide 69 comprising a stationary shaft 70 and a pair of guide rollers 71-71. The backing passes between the edges of the guide rollers which may be adjusted inwardly or outwardly to afford lateral adjustment of the backing. Backing A then continues over a large roller 72 journaled on a shaft 74 at which point the strip material is laid onto the backing element in a manner which will be described in greater detail hereinafter.

Element A, along with the strip material which has been applied thereto as will be described hereinafter, is then trained through the nip formed by the pair of hard surfaced, smooth laminating rollers 26-28 and the pair of soft, cushioned drive rollers 30-32 after which the laminated product is rewound at the take-up station 20.

Supply webs 14, 16 and 18 of strip materials B, C and D are journaled on mandrels 80, 82 and 84 respectively. Each mandrel is secured to frame 10. The core friction between the spools or coils of each of these materials and their respective shafts may be adjusted in any conventional manner so as to regulate the tension at which the strip materials are uncoiled or unwound from their respective supplies. This adjustment may be necessary due to the fact that the strip materials typically have different flow characteristics, that is, one of the materials may stretch more than another of the materials and may stretch significantly more than the backing element. Since it is desirable to maintain stretch to a minimum, for certain materials the only tension applied is the minimum core friction. In this connection it should be noted that the backing element typically employed is paper or a very light cardboard, although, other air impervious backing elements such as light plastic may be used.

As best seen in FIGS. 1, 3, 4 and 5 strip material B is trained from supply 14, under a small idler roller 86 and through an upper guide generally referred to by reference numeral 88 which comprises a first stationery round bar 90, and a second stationary round bar 92 dis-' posed a slight distance away from the first bar. Bars 90 and 92 each accommodate an outer guide block 94 having an inner surface 96 which defines a guide reference plane. Each bar also accommodates an inner guide block 98. Guide block 98 includes an opening which receives a pin 100 having a tapered end 102 which extends into the open space between the two blocks. 1

As best seen in FIGS. 3 and 5 the path of strip material B passes over shaft 90, under the tapered end 102 of pin 100, then under shaft 92 after which the material is trained onto the glue coated surface of backing element A and thence through the roller nips.

By maintaining a slight tension on strip material B the upper side of one edge engages the under side of tapere'd end 102 and the cooperation between material B and the angle of the taper continually urges the material along the taper and causes the opposite edge of the material to engage and align with reference plane 96. Thus, the material is constantly urged towards this plane to compensate for varying tolerances of strip material.

Each of the other guides, namely, a center guide 104 for strip material C and a lower guide 106 for strip material D are similarly constructed.

Guides 88, 104 and 106 guide strip materials B, C and D in spite of the fact that the materials pass through the guides with very little tension applied thereto. A minimum of tension is important because of the stretch or flow characteristics of the material. In accordance with the invention, guiding with very little tension applied to the strip material is accomplished due to the cooperation of the stationary bars, the taper and the blocks which define the lateral position of the strip material.

As clearly seen in FIG. 3, strip materials B, C and D each contact backing element A at the surface of roller 72, however each of the strip materials form different angles of contact with the backing element. Specifically, it is clearly seen in FIG. 3 that strip D is applied to backing element first, after which strip C is applied and finally strip B is applied to the backing element.

Accordingly, in the event one of the strip materials was fabric having a fuzzy edge or an edge containing loose threads, that strip would be placed on supply spool 18 (designated as strip B) and it would be laid on the backing element first with its fuzzy edge positioned so that it would be covered by the edge of strip C which would be guided so that it slightly overlapped strip B. Similarly, if strip material C had a fuzzy edge or an edge with loose threads, it would be laid down so that the edge containing the loose threads would be covered by the edge of strip D which would then be guided so that it slightly overlapped the fuzzy edge of strip C as will be described hereinafter.

The position and relationship between strip material guides 88, 104 and 106 are shown in detail in FIG. 5 where it can be seen that guide 106 urges material D in the direction of material C, that guide 104 urges material C in the direction of material D, and that guide 88 urges material B in the direction of material C.

Guides 88, 104 and 106 may each be laterally adjusted by loosening binding screws 108 and sliding the blocks along their respective bars. Fine adjustment of the blocks is effected by individual micrometer controls such as control 110 of guide 88 shown in FIG. 4. By means of these controls the exact position of each strip material on the backing element can be accurately controlled and maintained.

Turning now to the nip forming operating rollers, as best seen in FIG. 3 lower roller 28 is journaled on a fixed shaft 112 secured to frame 10 while upper roller 26 is journaled on a shaft 113 secured to one end of a swinging arm 1 14. The other end of arm 114 is secured to the frame 10 on a pivot 116. As best seen in FIG. 2, pivotal movement of arm 114 is controlled by actuation of an air cylinder 118 through an air control valve 120 to thereby regulate the nip pressure between rollers 26 and 28 and to separate the rollers for threading the materials in a manner which will be described in further detail hereinafter.

It will be recalled that the operating surfaces of rollers 26-28 are smooth and hard, accordingly the use of air pressure to regulate nip pressure functions as a safety feature to prevent an operator who may get his fingers caught in the apparatus from being seriously injured.

Turning now to the second pair of nip forming rollers, upper roller 30 is journaled on a shaft 122 secured to one end of a swinging arm 124. The other end of arm 124 is pivotally secured to the frame at 126. Pivotal movement arm 124 is controlled by actuation of an air cylinder 127 through a control valve 129 in a manner similar to that described in connection with rollers 26-28. Rollers 30-32 are covered with a soft, cushioned material having a durometer rating of 4045. The

function and operation of rollers 26-28 and 30-32 will be described in greater detail hereinafter.

Turning now to the drive train, as best seen in FIG. 2 drive motor 34 is mounted on a base 131 located at the lower left portion of the apparatus. Drive motor 34 is a DC variable speed motor and includes an output sprocket 130 coupled by a link chain 132 to a sprocket 134 carried on a main jack shaft 136 journaled to the frame. Jack shaft 136 carries a second sprocket 138 which is coupled by a link chain 140 to a sprocket 142 secured to a shaft 143 which is coupled to take-up spool 120 through a variable speed air clutch, not shown, which enables regulation of the spool take-up tension. Jack shaft 136 also has secured thereto a small sprocket 144 which is coupled by a long generally horizontal link chain 146 to a sprocket 150 secured to a secondary jack shaft 148 journaled between frame sides 36-38. Jack shaft 148 also includes a small sprocket 152 which is connected through a chain 154 to a sprocket 156 carried on a shaft 158 having an end which extends through frame side 36. Glue applying roller 64 is secured to the extending end of shaft 158. Proper tension is maintained on link chain 154 by a spring loaded roller 160.

Secondary jack shaft 148 includes additionally an intermediate sprocket 162 connected by a short link chain 164 to a sprocket 166 journaled between frame side walls 36-38.

Jack shaft 126 carries a control arm 170 having a control end 172. The jack shaft is journaled through control arm 170 and is movable independent thereto. Control arm 170 and swinging arm 124 form an articulated support. Shaft 126 also includes a gear 176 which meshingly engages a similar gear 178 carried on shaft 122 journaled to swinging arm 124. Shaft 122 extends through the front of frame wall 36 and carried upper cushioned roller 30.

The dual acting air controlled cylinder 127 is mounted on the frame above control arm 170 and includes a piston actuated rod 184 connected by a link 186 to arm 170. Cylinder 182 is actuated in a downwardly direction to regulate the nip pressure between cushioned rollers 30-32. By use of air pressure to provide the nip pressure between the rollers a safety feature is provided in that the nip opening will yield upon the introduction into the nip of foreign material such as the fingers or limbs of an operator. The air cylinder also functions to lift roller 30 for proper set-up and threading of the webs through the rollers.

The limit of the nip pressure is manually adjusted by a knob 190 and a threaded shaft 192 having an end which cooperates with control end 172.

ln a similar manner the nip pressure of smooth, hard rollers 26-28 is controlled by air cylinder 118 which includes a piston connected to an actuating rod 196 coupled by a link 198 to an arm 200 which is journaled on a shaft 116 secured between the frame side walls. As described above, shaft 116 also carries arm 114 which carries shaft 113 on which roller 26 is journaled. Arms 114 and 200 are articulated in the same manner as described above in connection with arms 124 and 170 and the nip pressure limit is manually adjusted in a manner similar to that described above with respect to rollers 30-32, by a manual adjustment 206.

As shown in FIG. 1, the apparatus of the invention also includes a control panel 210 comprising a number of air gauges 212 and air pressure regulator controls 214. An upper pair of pressure gauges 212 and regulators 214 are coupled by suitable air lines, not shown, to dual acting air cylinder 127 for regulating the up pressure and the nip pressure of rollers 26-28. In regulating the nip pressure, the control regulates the amount of pressure at the nip of rollers 26-28 thereby determining the pressure transferred to the strip material of greatest thickness for laminating it to the backing. The up pressure applied to the cylinder determines how rapidly roller 26 disengages from roller 28. After setting the proper up and down pressures, the up and down movement of the roller may then be controlled by the two way air valve 129 which is coupled by suitable air conduits to air cylinder 127.

Similarly, a set of gauges 218 and accompanying regulators 220 function to regulate the nip pressure and up" pressure of cushioned roller 30 against cushioned roller 32 through air cylinder 118 and two way air control valve 120. In addition, gauge 224 and accompanying regualtor 226 may be adjusted to control the unwind'tension of the backing element supply 12 and a similar pressure gauge 228 and regulator 230 are provided for controlling the take-up tension of rewind or take-up spool 20.

Operationally, the strip material and backing element are threaded through the machine along the path shown in FIG. 1 by raising rollers 26 and 30 through actuation of air control valves and 127 respectively. The backing element is then first threaded through the machine and onto the take-up spool after which the strip materials are threaded through their respective guides and past the respective pressure rollers which are then lowered into place by operation of the air valves. When placing the supplies of strip materials B, C and D on the machine the material which it is desired to lay down first on the backing element should be placed on supply spindle 84, the material which it is desired to lay down second should be placed on supply spindle 82 and the material which it is desired to lay down last should be placed on supply spindle 80. The sequence in which the materials are laid on the backing element is clearly shown in FIG. 3 wherein it may be clearly seen that the angle between material D and the backing element A is substantially less than the angle between material C and backing element A. Similarly, the angle between material B and the backing element is substantially greater than either of the angles just noted.

Accordingly, should it be desired to laminate a material having a thready or loose edge, that material is placed on spindle 84 with the loose edge inward of the apparatus so that it is laid on the backing element first. In this manner, as seen in FIG. 6, the strip material C which is laid down second can be laid so that its edge adjacent the thready edge of material D slightly overlaps the thready edge thereby covering any threads which would be otherwise exposed. Similarly, in the event material C contained an edge which is thready or loose that edge should be placed inwardly of the apparatus so that material B can be laid slightly overlapping it.

As the strip materials and backing element pass through the nip of rollers 26-28 the nip pressure of the roller acts primarily on the material having the greatest thickness, to firmly press that material against the adhesive coating previously applied to backing element A. In so pressing the material against the coating of backing A, the overlapping edge of material B is firmly pressed against the adjacent, thready edge of material C to cover that edge and present a product having a desirable appearance.

After passing through the nip of rollers 26-28 the material then passes through the nip of cushioned rollers 30-32. These rollers further compress the strip material B and also, due to the soft cushioned covering, firmly engage strip materials C and D to firmly press those materials against the adhesive coated backing element. In so compressing the materials, since the adhesive applied to backing material A has not fully dried, the strip material may shift along the adhesive coating of the backing element so that the strip materials are firmly pressed into place with the adjacent edges in abutting relationship.

In the disclosed embodiment, a backing element of given width is shown with three strip materials laid thereon. It should be noted that the machine may be used with two strip materials, or, alternatively additional guides and material supplies may be added so as to enable the lamination of four or more segments of strip material onto a backing element of sufficient width.

The location at which the strip material is laid on the backing element may be accurately adjusted by means of micrometer adjustments similar to adjustment 110 of guide 88. Similar adjustments are provided for guides 102 and 104. By means of these micrometer controls the exact amount of overlap may be accurately set.

An important aspect of the invention is the adaptability of the apparatus to guide materials which have substantial flow characteristics and at the same time guide the material upon which the flowable materials are being laminated but which in itself does not readily flow. In this connection it should be noted that the strip materials B, C and D are substantially tensionlessly guided, and depend upon the core friction against the mandrel as the sole tension. On the other hand, a definite tension is placed on the backing element.

Also, it is important to note the function of the rubber drive rollers. It is these rollers which maintain and control the laminating speed of theapparatus. Due to their cushioned surfaces, these rollers isolate or separate the tension of the rewind or take-up spool from that of the laminating section of the apparatus, thereby enabling lamination of strip materials and a backing element, each of which have different flow characteristics.

It is obvious that-upon study by those skilled in the art, the disclosed invention may be altered or modified both in physical appearance and construction without departing from its inventive concept. Therefore, the scope of protection to be given this invention should not be limited by The embodiment described above, but should be determined by the essential descriptions thereof which appear in the appended claims.

I claim:

1. Apparatus for laminating strip material to a backing element comprising: a drive motor; a frame including means carrying a web supply of said backing element and a web supply of said strip material; a first pair of nip forming rollers journaled on said frame; a second pair of nip forming rollers having outer surfaces fabricated of resilient material journaled on said frame and coupled to said motor; said second pair of nip forming rollers controlling the rate of speed of said strip material and said backing element; means applying adhesive to one one side of said backing element; means forming a path along which said backing element is trained past said adhesive applicator and through the nips of each of said roller pairs, means guiding said strip material through the nips of said first and second roller pairs whereat the strip material is pressed against said backing element and is laminated thereto; and motor driven take-up means for receiving and rewinding the strip material laminated to the backing element.

2. The apparatus as set forth in claim 1 including additionally; means forming a path for said strip material from the supply through said guide means to the first roller pair and wherein said guide means include a reference plane and fixed means continuously urging the strip material in the direction of said reference plane.

3. The apparatus as set forth in claim 2 wherein said guide means further include a pin having a taper at one end extending in the direction of said reference plane and located at a given distance which is slightly larger than the nominal width of said strip material; means for adjusting the given distance between said 'pin and said reference plane, and wherein said strip material is drawn against said taper and continuously urged against said reference plane.

4. Laminating apparatus for laminating two or more webs of strip material of differing thickness in side-byside relation to a backing element comprising: a frame: a first pair of nip forming idler rollers having hard surfaces journaled on said frame; a second pair of nip forming driving rollers having cushioned operating surfaces journaled on said frame and coupled to a drive motor; means for controlling the nip pressure of the idler rollers and the driving rollers; an adhesive applying station for applying adhesive to one side of said backing element; means defining a path for said backing element from a supply thereof through said adhesive applying station and through the nips of said idler rollers and said cushioned driving rollers; means defining separate paths for said strip materials from respective supplies thereof through the nips of said idler rollers and said cushioned driving rollers including means guiding said strip material in substantiallyside-by-side relation with the edge of one strip overlapping the adjacent edge of an adjacent strip; said idler rollers pressing the strip material of greatest thickness against the adhesive coated surface of said backing and said cushioned rollers pressing each of said strips against the glue coated surface of said backing material, whereby the pressure of said idler rollers against said strip materials causes shifting of one strip material on the backing relative to the other to effect edge-to-edge contact of said strip materials.

5. The apparatus as set forth in claim 4 including additionally; means for individually adjusting the nip pressure of each of said roller pairs.

6. The apparatus as set forth in claim 4 wherein said strip materials have substantial flow characteristics and wherein said backing element has a relatively small flow characteristic, including additionally; a motor driven take-up station for rewinding the laminated material and wherein said driven cushioned rollers control the rate of speed of said material and backing element and isolate the tension of the strip materials and backing element between the laminating section of the apparatus and the take-up section thereof.

Claims (5)

  1. 2. The apparatus as set forth in claim 1 including additionally; means forming a path for said strip material from the supply through said guide means to the first roller pair and wherein said guide means include a reference plane and fixed means continuously urging the strip material in the direction of said reference plane.
  2. 3. The apparatus as set forth in claim 2 wherein said guide means further include a pin having a taper at one end extending in the direction of said reference plane and located at a given distance which is slightly larger than the nominal width of said strip material; means for adjusting the given distance between said pin and said reference plane, and wherein said strip material is drawn against said taper and continuously urged against said reference plane.
  3. 4. Laminating apparatus for laminating two or more webs of strip material of differing thickness in side-by-side relation to a backing element comprising: a frame: a first pair of nip forming idler rollers having hard surfaces journaled on said frame; a second pair of nip forming driving rollers having cushioned operating surfaces journaled on said frame and coupled to a drive motor; means for controlling the nip pressure of the idler rollers and the driving rollers; an adhesive applying station for applying adhesive to one side of said backing element; means defining a path for said backing element from a supply thereof through said adhesive applying station and through the nips of said idler rollers and said cushioned driving rollers; means defining separate paths for said strip materials from respective supplies thereof through the nips of said idler rollers and said cushioned driving rollers including means guiding said strip material in substantially side-by-side relation with the edge of one strip overlapping the adjacent edge of an adjacent strip; said idler rollers pressing the strip material of greatest thickness against the adhesive coated surface of said backing and said cushioned rollers pressing each of said strips against the glue coated surface of said backing material, whereby the pressure of said idler rollers against said strip materials causes shifting of one strip material on the backing relative to the other to effect edge-to-edge contact of said strip materials.
  4. 5. The apparatus as set forth in claim 4 including additionally; means for individually adjusting the nip pressure of each of said roller pairs.
  5. 6. The apparatus as set forth in claim 4 wherein said strip materials have substantial flow characteristics and wherein said backing element has a relatively small flow characteristic, including additionally; a motor driven take-up station for rewinding the laminated material and wherein said driven cushioned rollers control the rate of speed of said material and backing element and isolate the tension of the strip materials and backing element between the laminating section of the apparatus and the take-up section thereof.
US3767510A 1971-10-27 1971-10-27 Laminating apparatus Expired - Lifetime US3767510A (en)

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US4012276A (en) * 1974-11-11 1977-03-15 Kartonagen-Schertler, Manfred K. Schertler & Co. Apparatus for the manufacture by machine of multilayer corrugated paper material
US4019946A (en) * 1974-02-14 1977-04-26 The Thames Sack And Bag Company Limited Heat sealing apparatus
US4243464A (en) * 1978-01-30 1981-01-06 Potchen Thomas M Laminating method
US4387000A (en) * 1981-02-17 1983-06-07 E. I. Du Pont De Nemours And Company Laminating roll actuating crank mechanism
US4396454A (en) * 1981-06-30 1983-08-02 Brys Lyle E Apparatus for simultaneously joining and laminating lengths of material
US4400230A (en) * 1981-11-23 1983-08-23 Labless, Israel Label indexing and applicator apparatus
US4527319A (en) * 1981-09-28 1985-07-09 Hancor, Inc. Method and apparatus for manufacturing foldable conduit
US4564411A (en) * 1983-12-13 1986-01-14 Gaylord Bros., Inc. Apparatus for producing labels
EP0319252A2 (en) * 1987-11-29 1989-06-07 Brown Gables Holdings Limited Insulating container
US5122212A (en) * 1989-10-27 1992-06-16 American Biltrite, Inc. Method and apparatus for the manufacture of printed and embossed floor covering
US5300166A (en) * 1990-08-17 1994-04-05 Nippon Petrochemicals Co., Ltd. Apparatus for manufacturing a web and method
US5378304A (en) * 1993-12-09 1995-01-03 Doboy Packaging Machinery, Inc. Sealing machine having gap control between heat seal components
US5460672A (en) * 1994-04-26 1995-10-24 Petco, Inc. Apparatus and method for joining a plurality of textile webs together in side-by-side relation
US5466320A (en) * 1994-05-09 1995-11-14 Oscoda Plastics, Inc. Making a cushiony decorative tile or cover product from extruded recycled membrane with discrete fibers randomly dispersed therein
EP0769468A2 (en) * 1995-10-19 1997-04-23 Transprint USA Method and apparatus for splicing heat transfer printing paper
GB2318084A (en) * 1996-10-14 1998-04-15 Tecksom International Limited Laminating apparatus
US6026884A (en) * 1998-01-27 2000-02-22 Maintech, Inc. Laminating device
US20120145327A1 (en) * 2008-03-26 2012-06-14 Polystrand, Inc. Method and apparatus for making sheets of composite material

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US3143454A (en) * 1960-01-11 1964-08-04 Laminators Inc Laminating press
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Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4019946A (en) * 1974-02-14 1977-04-26 The Thames Sack And Bag Company Limited Heat sealing apparatus
US4012276A (en) * 1974-11-11 1977-03-15 Kartonagen-Schertler, Manfred K. Schertler & Co. Apparatus for the manufacture by machine of multilayer corrugated paper material
US4243464A (en) * 1978-01-30 1981-01-06 Potchen Thomas M Laminating method
US4387000A (en) * 1981-02-17 1983-06-07 E. I. Du Pont De Nemours And Company Laminating roll actuating crank mechanism
US4396454A (en) * 1981-06-30 1983-08-02 Brys Lyle E Apparatus for simultaneously joining and laminating lengths of material
US4527319A (en) * 1981-09-28 1985-07-09 Hancor, Inc. Method and apparatus for manufacturing foldable conduit
US4400230A (en) * 1981-11-23 1983-08-23 Labless, Israel Label indexing and applicator apparatus
US4564411A (en) * 1983-12-13 1986-01-14 Gaylord Bros., Inc. Apparatus for producing labels
EP0319252A2 (en) * 1987-11-29 1989-06-07 Brown Gables Holdings Limited Insulating container
EP0319252A3 (en) * 1987-11-29 1990-11-14 Brown Gables Holdings Limited Insulating container
US5122212A (en) * 1989-10-27 1992-06-16 American Biltrite, Inc. Method and apparatus for the manufacture of printed and embossed floor covering
JPH0753427B2 (en) * 1989-10-27 1995-06-07 アメリカン ビルトライト,インコーポレーテッド Printing and embossed floor covering manufacturing method and apparatus
US5300166A (en) * 1990-08-17 1994-04-05 Nippon Petrochemicals Co., Ltd. Apparatus for manufacturing a web and method
US5378304A (en) * 1993-12-09 1995-01-03 Doboy Packaging Machinery, Inc. Sealing machine having gap control between heat seal components
US5460672A (en) * 1994-04-26 1995-10-24 Petco, Inc. Apparatus and method for joining a plurality of textile webs together in side-by-side relation
US5466320A (en) * 1994-05-09 1995-11-14 Oscoda Plastics, Inc. Making a cushiony decorative tile or cover product from extruded recycled membrane with discrete fibers randomly dispersed therein
US5560797A (en) * 1994-05-09 1996-10-01 Oscoda Plastics, Inc. Methods of making floor tile and wall covering from extruded hot recycled vinyl thermoplastic membrane having discrete fibers randomly dispersed therein
US5783007A (en) * 1995-10-19 1998-07-21 Transprint Usa Method for splicing heat transfer printing paper
EP0769468A2 (en) * 1995-10-19 1997-04-23 Transprint USA Method and apparatus for splicing heat transfer printing paper
US5660675A (en) * 1995-10-19 1997-08-26 Transprint Usa Method and apparatus for splicing heat transfer printing paper
EP0769468A3 (en) * 1995-10-19 1998-01-07 Transprint USA Method and apparatus for splicing heat transfer printing paper
GB2318084A (en) * 1996-10-14 1998-04-15 Tecksom International Limited Laminating apparatus
GB2318084B (en) * 1996-10-14 1998-09-09 Tecksom International Limited Laminating apparatus
US6026884A (en) * 1998-01-27 2000-02-22 Maintech, Inc. Laminating device
US20120145327A1 (en) * 2008-03-26 2012-06-14 Polystrand, Inc. Method and apparatus for making sheets of composite material
US8763668B2 (en) * 2008-03-26 2014-07-01 Polystrand, Inc. Apparatus for making sheets of composite material
US9333732B2 (en) 2008-03-26 2016-05-10 Gordon Holdings, Inc. Method for making sheets of composite material

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