WO2007081068A1

WO2007081068A1 - The embossing calender for processing car interior products

Info

Publication number: WO2007081068A1
Application number: PCT/KR2006/000173
Authority: WO
Inventors: Woo Jin Jeon
Original assignee: Woo Jin Jeon
Priority date: 2006-01-11
Filing date: 2006-01-17
Publication date: 2007-07-19
Also published as: KR100679697B1; JP2009523080A; JP4777439B2

Abstract

The present invention relates to an embossing calender in which car interior trimming material passes between an upper heating roll and an intermediate embossing roll or between the intermediate embossing roll and a lower elastic roll, such that the embossments projectedly formed on the outer surface of the embossing roll emboss the interior trimming material, or in which the embossing roll is replaced with another heating roll having a smooth outer surface to form a calender, such that the interior trimming material passing between two rolls can undergo a glazing process. Since an embossing roll can be replaced with other rolls having various shapes, it is possible to manufacture car interior trims having various contours in conformity with customers' tastes. Because the car interior trimming material can pass between two of three vertically arranged rolls to be processed, two types of car interior trimming material can be manufactured.

Description

[DESCRIPTION] [invention Title]

THE EMBOSSING CALENDER FOR PROCESSING CAR INTERIOR PRODUCTS [Technical Field]

The present invention relates to an apparatus for processing car interior trimming material, and more particularly to an embossing calender for processing car interior trimming material, in which car interior trimming material is passed between an upper heating roll and an intermediate embossing roll or between the intermediate embossing roll and a lower elastic roll in a material processing section, such that the embossments projectedly formed on the outer surface of the embossing roll emboss the interior trimming material, or in which the embossing roll is replaced with another heating roll having a smooth outer surface to form a calender, such that the interior trimming material passing between two rolls can undergo a glazing process. [Background Art]

Generally, car interior trim is formed by processing and treating the surface of car interior trimming material.

These days, car interior trim is formed to have embossments on the outer surface thereof rather than have a smooth outer surface. A conventional apparatus for forming embossments on car interior trimming material has a drawback in that its construction is not suitable for mass production.

Also, an apparatus capable of forming various shapes of embossments on car interior trimming material in order to meet customers' various desires and, at the same time, of glazing car interior trimming material in order to provide a smooth surface without embossments has not yet been developed. [Disclosure]

[Technical Problem]

Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide an embossing calender for processing car interior trimming material, in which car interior trimming material is passed between an upper heating roll and an intermediate embossing roll or between the intermediate embossing roll and a lower elastic roll in a material processing section, such that the embossments projectedly formed on the outer surface of the embossing roll emboss the interior trimming material, or in which the embossing roll is replaced with another heating roll having a smooth outer surface to form a calender, such that the interior trimming material passing between two rolls can undergo a glazing process. [Technical Solution]

In order to achieve the above object, according to one aspect of the present invention, there is provided an embossing calender for processing car interior trimming material, comprising a body frame for defining an outer appearance of a body of the embossing calender; an introduction section for feeding interior trimming material while changing feeding directions using a plurality of rolls; a material processing section fitted, at left and right ends thereof, into shaft housing blocks, raised and lowered at a center portion of the body frame by a hydraulic cylinder which is at a lowermost position, and composed of an upper heating roll, an intermediate embossing roll and a lower elastic roll which are driven by a power transmission part; an inner frame plate providing a framework of the material processing section and made of steel; an interior trimming material stacking system including a plurality of rolls for feeding the processed interior trimming material while changing feeding directions, a driving part and a pulling roll for pulling the processed interior trimming material upon driving of a third motor, and a stacking arm for stacking the pulled interior trimming material under the control of a stacking control part; and a control box for controlling the power transmission part, the driving part and the stacking control part, wherein the car interior trimming material passes between the upper heating roll and the intermediate embossing roll or between the intermediate embossing roll and the lower elastic roll to be embossed or glazed on a surface thereof.

According to another aspect of the present invention, thickness adjustment means is installed between the shaft housing blocks of the embossing roll and the upper heating roll to adjust thickness of the interior trimming material; and the thickness adjustment means comprises an upper block having flanges, which are formed at both ends of the upper block to be coupled to the shaft housing block of the upper heating roll, and an inclined surface which has a predetermined inclination angle; a guide rail block coupled to an upper end of the shaft housing block of the embossing roll; a movable block fitted into the guide rail block and having an inclined surface having the predetermined inclination angle; and a thickness adjustment element having a threaded rod which is threadedly coupled through a front end of the movable block and a rotation handle which is fastened to an end of the threaded rod; whereby, with the threaded rod of the thickness adjustment element threadedly coupled through the movable block, when the rotation handle is rotated, the movable block is moved forward and rearward to adjust thickness between the embossing roll and the upper heating roll. According to another aspect of the present invention, the power transmission part of the material processing section comprises a first motor secured to the lower end of the inner frame plate; a clutch fixedly maintained above the first motor and having a shaft to which a first helical gear is coupled; a second helical gear having a shaft which is fitted into the inner frame plate to be meshed with the first helical gear, the second helical gear being connected with a shaft of the embossing roll; a third helical gear having a shaft which is fitted into the inner frame plate to be meshed with the second helical gear, the third helical gear being connected with a shaft of the lower elastic roll; a second motor installed on an upper end of the inner frame plate and having integrally formed therewith a clutch portion; and a timing pulley positioned below the second motor, having a shaft which is fitted into the inner frame plate, and connected with a shaft of the upper heating roll, wherein a belt is wound on the shaft of the first motor and a pulley which is fastened to an end of the shaft of the clutch such that, when the first motor is driven, the second and third helical gears meshed with each other are rotated in opposite directions to thereby rotate the embossing roll and the lower elastic roll, and wherein a shaft of the second motor formed integrally with the clutch portion and the timing pulley are connected with each other by a timing belt such that, when the second motor is driven, the upper heating roll is rotated. According to still another aspect of the present invention, the driving part of the stacking system comprises a third motor fastened to an upper end of the stacking system of the body frame; a clutch fixedly maintained at a predetermined separation from the third motor; and a pulling roll connected via a bearing to a horizontal extension frame which projects from an upper end of the body frame, whereby a pulley which is formed on a shaft of the third motor and a pulley which is formed on a shaft of the clutch are connected with each other by a belt, and the pulley of the clutch and a pulley which is formed on an end of the pulling roll are connected with each other by a belt, such that, when the third motor is driven, the pulling roll is rotated to pull the interior trimming material. According to yet still another aspect of the present invention, the stacking control part of the stacking system comprises a motor attached to the upper end of the body frame and having, formed on a shaft thereof, a pulley; a brake clutch connected with the pulley of the motor by a belt at a preset separation from the motor; a rotation plate rotatably locked to the horizontal extension frame which projects from the body frame; a movable stacking arm coupled to an end of the horizontal extension frame by a hinge; and a connection arm connecting the rotation plate and the movable stacking arm with each other, whereby movement limits of the movable stacking arm are sensed by a sensor which is fixedly positioned adjacent to an upper part of the rotation plate, to control a cycle time required for stacking the interior trimming material.

[Advantageous Effects] As is apparent from the above descriptions, the embossing calender for processing car interior trimming material according to the present invention operates fully automatically and conducts an embossing process or a glazing process for the surface of the car interior trimming material.

Also, in the present invention, since an embossing roll can be replaced with other rolls having various shapes, it is possible to manufacture car interior trims having various contours in conformity with customers ' tastes . Moreover, in the present invention, because the car interior trimming material can pass between two of three vertically arranged rolls to be processed, two types of car interior trimming material can be manufactured.

[Description of Drawings] FIG. 1 is a front view illustrating an embossing calender for processing car interior trimming material in accordance with an embodiment of the present invention;

FIG. 2 is a view similar to FIG. 1, illustrating a state in which a stacked-type car interior trimming material is used in the embossing calender in accordance with the embodiment of the present invention; FIG. 3 is a rear view illustrating the embossing calender for processing car interior trimming material in accordance with the embodiment of the present invention;

FIG. 4 is a side view of the embossing calender for processing car interior trimming material in accordance with the embodiment of the present invention;

FIG. 5 is a perspective view illustrating a sensor box for sensing a seamed portion of the car interior trimming material in the embossing calender in accordance with the embodiment of the present invention;

FIGs. 6 and 7 are enlarged front views illustrating a material processing section in the embossing calender in accordance with the embodiment of the present invention;

FIG. 8 is an exploded perspective view illustrating thickness adjustment means in accordance with the embodiment of the present invention;

FIG. 9 is an assembled perspective view illustrating the thickness adjustment means in accordance with the embodiment of the present invention; FIG. 10 is a side view illustrating the operation of the thickness adjustment means in accordance with the embodiment of the present invention;

FIG. 11 is a front view illustrating the operation of a power transmission part in accordance with the embodiment of the present invention; FIGs . 12 through 14 are front views illustrating a stacking system in accordance with the embodiment of the present invention;

FIG. 15 is an exploded perspective view illustrating a coupling relationship between a shaft housing block and a housing locking block in accordance with the embodiment of the present invention;

FIG. 16 is an assembled perspective view illustrating a coupled state of the shaft housing block and the housing locking block in accordance with the embodiment of the present invention;

FIG. 17 is a cross-sectional view independently illustrating the housing locking block in accordance with the embodiment of the present invention; and FIG. 18 is cross-sectional views illustrating the coupled state of the shaft housing block and the housing locking block in accordance with the embodiment of the present invention.

100: body frame 111: first roll

112: second roll 113: third roll

114: fourth roll 120: vertical bar

130: guide roll 200: introduction section 231: stepping plate and bogie 232: space 234: tension adjustment roll 300: material processing section 301: upper heating roll 302: intermediate embossing roll 303: lower elastic roll 310, 311: shaft housing blocks 370: thickness adjustment means

[Best Mode]

The present invention relates to a processing apparatus for processing car interior trimming material.

Describing the construction of the present invention with reference to FIGs. 1 through 14, an embossing calender for processing car interior trimming material in accordance with an embodiment of the present invention comprises a body frame 100 which defines the outer appearance of the body of the embossing calender, and an introduction section 200 which feeds interior trimming material 'A' while changing feeding directions using a plurality of rolls.

The embossing calender further comprises a material processing section 300 which is fitted, at left and right ends thereof, into shaft housing blocks 310, 311 and

312. The material processing section 300 is raised and lowered at a center portion of the body frame 100 by a hydraulic cylinder 350 which is at a lowermost position, and is composed of an upper heating roll 301, an intermediate embossing roll 302 and a lower elastic roll 303 which are driven by a power transmission part 330.

The embossing calender further comprises an inner frame plate 400 and a material stacking system 500. The inner frame plate 400 provides a framework of the material processing section 300 and is made of steel. The material stacking system 500 includes a plurality of rolls which feed the processed interior trimming material A while changing feeding directions, a driving part 510 and a pulling roll 526 which pulls the processed interior trimming material A upon driving of a third motor 511, and a stacking arm 531 which stacks the pulled interior trimming material A under the control of a stacking control part 530.

The embossing calender further comprises a control box 600 which controls the operation of the power transmission part 330, the driving part 510 and the stacking control part 530.

Therefore, the car interior trimming material A passes between the upper heating roll 301 and the intermediate embossing roll 302 or between the intermediate embossing roll 302 and the lower elastic roll 303 to be embossed or glazed on a surface thereof.

Roughly describing the operation of the embossing calender according to the present invention, the interior trimming material A is first introduced from the introduction section 200 into the material processing section 300 which is formed in the body frame 100.

At this time, the feeding of the interior trimming material A into the material processing section 300 is effected through rotation of the plurality of rolls.

In order to ensure easy processing of the interior trimming material A, the interior trimming material A may be fed in a state in which it is wound on a roll or is paid off and stacked into multiple layers . Also, in order to avoid interruption of the operation of the embossing calender according to the present invention, instead of processing only one piece of interior trimming material A, it is preferred that a number of pieces of interior trimming material A be seamed with one another to have an increased length.

Therefore, the interior trimming material A having the increased length is fed through the plurality of rolls and is introduced into the material processing section 300.

The material processing section 300 according to the embodiment of the present invention includes three processing rolls 301, 302 and 303.

The upper heating roll 301 is at an uppermost position, and the embossing roll 302 is positioned below the upper heating roll 301. The lower elastic roll 303 is positioned below the embossing roll 302. Accordingly, in the present invention, the interior trimming material A can pass between the upper heating roll

301 and the embossing roll 302 as shown in FIG. 2 to be embossed, or can pass between the embossing roll 302 and the lower elastic roll 303 as shown in FIG. 1 to be embossed.

The interior trimming material A which is processed while passing through the material processing section 300 is fed into the stacking system 500 and is then stacked into multiple layers. At this time, the component elements which function to pull the interior trimming material A are the driving part 510 and the pulling roll 526, and the component element which functions to stack the pulled interior trimming material A into multiple layers is the stacking control part 530.

Of course, these operations are conducted fully automatically and are controlled by the control box 600 as shown in FIG. 4.

In the above-described construction of the embossing calender according to the embodiment of the present invention, the detailed structure and function of the introduction section 200 will be described below.

The introduction section 200 comprises horizontal frames 110 which are fastened to the front and rear ends of the body frame 100, front and rear vertical bars 120 which are fastened to the ends of the horizontal frames 110, two- staged guide rolls 130 which are horizontally installed on the vertical bars 120, a first roll 111 which is installed on the upper ends of the horizontal frames 110 to feed the interior trimming material A, and a second roll 112 which is spaced apart from the first roll 111 by a predetermined distance.

The introduction section 200 further comprises a third roll 113 which is rotatably fastened to the lower end of the body frame 100, and a fourth roll 114 which is attached to the lower end of the inner frame plate 400.

Therefore, the interior trimming material A is guided in a manner such that it passes over the two-staged guide rolls 130 of the vertical bars 120, over the first roll 111 and the second roll 112, and then over the third roll 113 and the fourth roll 114 which are positioned at the lower end of the body frame 100, to be fed into the material processing section 300.

That is to say, as shown in FIGs. 1 through 3, the interior trimming material A which is wound on a roll or is stacked into multiple layers in the introduction section 200 is pulled toward the material processing section 300.

At this time, the interior trimming material A is upwardly fed over the two-staged guide rolls 130 which are installed on the vertical bars 120. Then, the interior trimming material A is continuously fed over the outer surfaces of the first roll 111 and the second roll 112 which are installed on the horizontal frames 110.

Thereafter, as the feeding direction of the interior trimming material A is changed, the interior trimming material A is fed over the third roll 113 which is attached to the lower end of the body frame 100 and then over the fourth roll 114 which is attached to the lower end of the inner frame plate 400 and is spaced apart from the first roll 111 by the predetermined distance, to be fed into the material processing section 300.

In other words, in the present invention, the introduction section 200 functions to precisely guide and feed the interior trimming material A to the material processing section 300 and to form a path for the movement of the interior trimming material A.

Meanwhile, in the present embodiment of the present invention, as shown in FIGs. 3 and 4, between the third roll 113 and the fourth roll 114, there are arranged an elongate stepping plate 231 on which a worker can stand to check the feeding and processing state of the interior trimming material A, and casters 233 which are secured to the four corners of the stepping plate 231 so as to define a space 232 below the stepping plate 231.

Further, a tension adjustment roll 234 projects out of the lower surface of the stepping plate 231 to adjust the tension of the interior trimming material A passing between the third roll 113 and the fourth roll 114.

Thus, the tension of the interior trimming material A fed between the third roll 113 and the fourth roll 114 can be adjusted by the tension adjustment roll 234, and the worker can freely move onto the stepping plate 231.

Concretely speaking, when the embossing calender according to this embodiment of the present invention operates, since the interior trimming material A is continuously fed over the rolls, it may be difficult for the worker to gain free access to the embossing calender and work therein.

In consideration of this, the stepping plate 231 comprising a bogie is provided between the third roll 113 and the fourth roll 114 under which the interior trimming material A passes, such that the worker can stand and move on the stepping plate 231 and the stepping plate 231 can be used as transportation means when mounting and dismounting the rolls. The interior trimming material A of this embodiment has substantial length due to the fact that a number of pieces of interior trimming material A are seamed with one another.

Therefore, the seamed portion 120a where two pieces of interior trimming material A are connected with each other has a thickness which is greater than that of a single piece of interior trimming material A.

The seamed portion 120a having the increased thickness also passes between two of the three-staged rolls 301, 302 and 303 in the material processing section 300.

The gaps between three-staged rolls 301, 302 and 303 are set such that only one ply of the interior trimming material A can pass through the gaps to be embossed.

Therefore, if the seamed portion 120a passes between two rolls, excessive load is applied to the rolls.

As a consequence, in order to prevent the excessive load from being applied to the embossing calender, separate means is provided according to the present invention.

Namely, as shown in FIGs. 1 through 3 and 5, a sensor box 110 is provided at a position on the body frame 100 where the interior trimming material A passes, to sense the seamed portion 120a of the interior trimming material A.

That is to say, the interior trimming material A always passes through the sensor box 110. If the seamed portion 120a is sensed by the sensor box 110, the control box 600 controls the hydraulic cylinder 350 such that the hydraulic cylinder 350 is lowered in FIG. 6a to increase the gap between two rolls, for example, the embossing roll 302 and the lower elastic roll 303. Then, after the seamed portion 120a passed through the increased gap, the control box 600 again controls the hydraulic cylinder 350 such that the hydraulic cylinder 350 returns to its original position to decrease the gap between the embossing roll 302 and the lower elastic roll 303.

In this regard, the distance between the sensor box 110 and a virtual contact point between the embossing roll

302 and the upper heating roll 301 or the lower elastic roll

303 is precisely measured based on the rpm of the rotating rolls 301, 302 and 303. Therefore, at the time when the rolls are rotated through a predetermined number of revolutions after the seamed portion 120a is sensed by the sensor box 110, the hydraulic cylinder 350 is lowered to increase the gap between the rolls .

When the seamed portion 120a passed through the increased gap between the rolls, the hydraulic cylinder 350 is raised again to decrease the gap between the two rolls to allow the interior trimming material A to be continuously embossed.

There are several rolls over which the interior trimming material A passes while being fed from the introduction section 200 to the three-staged rolls 301, 302 and 303 of the material processing section 300.

These rolls will be described with reference to FIGs. 1 through 3.

Upstream of the material processing section 300, front and rear circular plates 350 are mounted at heights between the upper heating roll 301 and the embossing roll 302 and between the embossing roll 302 and the lower elastic roll 303. First, second and third guide rolls 351, 352 and 353 are installed on the circular plates 350.

Hence, passages through which the interior trimming material A can pass are defined, such that the interior trimming material A can pass through the passages to be fed between the upper heating roll 301 and the embossing roll 302 and between the embossing roll 302 and the lower elastic roll 303. As a result, the first through third guide rolls 351,

352 and 353 serve as guides for moving the interior trimming material A between the upper heating roll 301 and the embossing roll 302 and between the embossing roll 302 and the lower elastic roll 303. The interior trimming material A is passed in a zigzag pattern to be adjusted in tension.

Meanwhile, in the present invention, electric heaters or heating mediums are installed or loaded in the upper heating roll 301 and the embossing roll 302 to heat them to a high temperature. This is because it is the norm that material is formed under a high pressure and a high temperature and it is necessary to heat the interior trimming material A in order to precisely form embossments and intaglios.

In the present invention, the embossing roll 302 is detachably constructed. In other words, due to the fact that the embossing roll 302 is connected to a power source through a universal joint 385, the embossing roll 385 can be removed and replaced with another roll having another configuration as occasion demand.

Therefore, another embossing roll 302 having another embossing shape may be used, or a calendering roll having the same shape as the upper heating roll 301 or the lower elastic roll 303 may be used. At this time, if a smooth heating roll which has no protruding shape on the outer surface thereof is used in place of the embossing roll 302, the interior trimming material A which passes between two rolls can be pressed under a high temperature and pressure to undergo the glazing process on the outer surface thereof.

Namely, with no pattern formed on the outer surface of the interior trimming material A, the texture of the interior trimming material A has increased density and improved durability, and glaze of the outer surface of the interior trimming material A is increased to provide an aesthetically pleasant and clean outer appearance.

In the present invention, it may be often the case that the gaps between the upper heating roll 301, the intermediate embossing roll 302 and the lower elastic roll 303 should necessarily be precisely adjusted. Although the gaps can be primarily adjusted through the actuation of the hydraulic cylinder 350 under the control of the control box 600, required preciseness may not be attained through this adjustment procedure. Hence, in the present invention, in order to cope with this problem, separate means is provided.

The separate means is illustrated in FIGs. 8 through 10 as thickness adjustment means 370. The thickness adjustment means 370 is installed between the shaft housing blocks 311 and 310 of the embossing roll 302 and the upper heating roll 301 to adjust the pressure applied to the interior trimming material A.

Describing in detail, the thickness adjustment means 370 comprises an upper block 373 having flanges 371, which are formed at both ends of the upper block 373 to be coupled to the shaft housing block 310 of the upper heating roll 301, and an inclined surface 372 which has a predetermined inclination angle. The thickness adjustment means 370 further comprises a guide rail block 374 coupled to the upper end of the shaft housing block 311 of the embossing roll 302.

Furthermore, the thickness adjustment means 370 comprises a movable block 376 and a thickness adjustment element 379. The movable block 376 is fitted into the guide rail block 374 and has an inclined surface 375 which has the predetermined inclination angle. The thickness adjustment element 379 has a threaded rod 377 which is threadedly coupled through the front end of the movable block 376 and a rotation handle 378 which is fastened to an end of the threaded rod 377. Thus, with the threaded rod 377 of the thickness adjustment element 379 threadedly coupled through the movable block 376, if the rotation handle 378 is rotated, the movable block 376 is moved forward and rearward to adjust the thickness, that is, the gap, between the embossing roll 302 and the upper heating roll 301.

That is to say, as shown in FIGs. 8 through 10, if the rotation handle 378 of the thickness adjustment element 379 is rotated in one direction, the threaded rod 377 of the thickness adjustment element 379 pushes the movable block 376 threadedly coupled thereto.

Then, the movable block 376 is moved inward through the guide rail block 374. At this time, the upper surface of the movable block 376 is inclined as shown in the drawings to have the predetermined inclination angle. The lower surface of the upper block 373 which is brought into contact with the inclined surface 375 of the movable block 376 is formed as the inclined surface 372 which has the same inclination angle as the inclined surface 375 of the movable block 376. Thus, as the movable block 376 is horizontally moved inward on the upper end of the shaft housing block 311 of the embossing roll 302, due to the surface contact between the inclined surface 375 and the inclined surface 372, the upper block 373 is raised.

At this time, since the upper block 373 is fastened to the shaft housing block 310 of the upper heating roll 301, the upper heating roll 301 is also raised.

As a result, the gap between the upper heating roll 301 and the embossing roll 302 is increased.

If the rotation handle 378 of the thickness adjustment element 379 is rotated in an opposite direction, the above-described operation occurs in an reverse order, and thereby, the gap between the upper heating roll 301 and the embossing roll 302 is decreased.

In this way, the gap between two rolls can be precisely adjusted in conformity with the thickness of the interior trimming material A to be processed.

Hereafter, the power transmission scheme to the upper heating roll 301, the embossing roll 302 and the lower elastic roll 303 will be described. Referring to FIG. 11, the power transmission part

330 functions to transmit power to the rolls. The structure and operation of the power transmission part 330 will be described below.

The power transmission part 330 of the material processing section 300 comprises a first motor 320 secured to the lower end of the inner frame plate 400, a clutch 322 fixedly maintained above the first motor 320 and having a shaft to which a first helical gear 321 is coupled, and a second helical gear 324 having a shaft which is fitted into the inner frame plate 400 to be meshed with the first helical gear 321, the second helical gear 324 being connected with the shaft of the embossing roll 302.

The power transmission part 330 further comprises a third helical gear 326 having a shaft which is fitted into the inner frame plate 400 to be meshed with the second helical gear 324, the third helical gear 326 being connected with the shaft of the lower elastic roll 303.

The power transmission part 330 still further comprises a second motor 329 installed on the upper end of the inner frame plate 400 and having integrally formed therewith a clutch portion 328, and a timing pulley 331 positioned below the second motor 329, having a shaft which is fitted into the inner frame plate 400, and connected with the shaft of the upper heating roll 301.

A belt 334 is wound on the shaft of the first motor 320 and on a pulley which is fastened to an end of the shaft of the clutch 322, such that, when the first motor 320 is driven, the second and third helical gears 324 and 326 meshed with each other are rotated in opposite directions to thereby rotate the embossing roll 302 and the lower elastic roll 303. The shaft of the second motor 329 formed integrally with the clutch portion 328 and the timing pulley 331 are connected with each other by a timing belt 336, such that, when the second motor 329 is driven, the upper heating roll 301 is rotated.

First describing the operation of the upper heating roll 301, if the second motor 329 as shown is driven, the rotational velocity of the second motor 329 is reduced by the clutch portion 328 which is integrally coupled to the end of the shaft of the second motor 329.

The rotational force having reduced rotation velocity is transmitted by the timing belt 336 to the timing pulley 331.

That is to say, the rotational force of the timing belt 336 rotates the timing pulley 331 which is coupled to the end of the shaft of the upper heating roll 301, and as a result, the upper heating roll 301 is rotated.

At this time, in order to ensure that the embossing process is performed for the interior trimming material A which passes through the upper heating roll 301 and the embossing roll 302, the embossing roll 302 disposed below the upper heating roll 301 must also be rotated. In this regard, the rotating operation of the embossing roll 302 will be described below.

As shown in the drawing, when the first motor 320 is driven, the clutch 322 positioned above the first motor 320 is operationally connected with the first motor 320 via the belt 334. Of course, it is to be readily understood that the first motor 320 and the clutch can also be operationally connected with each other using a chain and sprocket mechanism. If the belt 334 is rotated, in a state in which the rotational velocity from the first motor 320 is reduced by the clutch 322, the first helical gear 321 coupled to the end of the shaft of the clutch 322 is rotated.

As shown in the drawing, the first helical gear 321 is meshed with the second helical gear 324.

Since the second helical gear 324 is coupled to the end of the shaft of the embossing roll 302, the rotation of the second helical gear 324 causes the rotation of the embossing roll 302. Accordingly, the upper heating roll 301 and the embossing roll 302 are rotated in opposite directions to emboss the interior trimming material A which passes between them.

As shown in the drawing, gear teeth of the second helical gear 324 are meshed with those of the third helical gear 326.

Therefore, the rotation of the second helical gear

324 in one direction causes the rotation of the third helical gear 326 in an opposite direction, by which the third helical gear 326 coupled to the end of the shaft of the lower elastic roll 303 rotates the lower elastic roll 303.

As a result, if the first motor 320 is driven, the embossing roll 302 is rotated in one direction, and the lower elastic roll 303 is rotated in an opposite direction, whereby the interior trimming material A passing between them is embossed.

Meanwhile, in the present invention, as can be readily seen from FIG. 4, the shaft of the embossing roll 302 and the second helical gear 324, the shaft of the lower elastic roll 303 and the third helical gear 326, and the shaft of the upper heating roll 301 and the timing pulley

331 are respectively connected with each other by universal joints 385, such that the universal joints 385 can be rotated while absorbing vertical displacement of the rolls

301, 302 and 303.

This is because the rolls can be easily replaced by using the universal joints 385 and the vertical displacement of the rolls during rotation can be easily absorbed by the universal joints 385.

In the present invention, another part to be controlled by the control box 600 is the driving part 510 of the stacking system 500 as shown in FIGs. 12 through 14.

The structure of the driving part 510 will be described below. The driving part 510 of the stacking system 500 comprises a third motor 511 fastened to the upper end of the stacking system 500 of the body frame 100, and a clutch 512 fixedly maintained at a predetermined separation from the third motor 511.

The driving part 510 of the stacking system 500 further comprises the pulling roll 526 connected via a bearing to a horizontal extension frame 130 which projects from the upper end of the body frame 100. A pulley 514 which is formed on the shaft of the third motor 511 and a pulley 515 which is formed on the shaft of the clutch 512 are connected with each other by a belt 516, and the pulley 515 of the clutch 512 and a pulley 516 which is formed on an end of the pulling roll 526 are connected with each other by a belt 517, such that, when the third motor 511 is driven, the pulling roll 526 is rotated to pull the interior trimming material A.

That is to say, the driving part 510 functions to rotate the pulling roll 526 and to thereby pull the interior trimming material A.

If the third motor 511 is driven, the rotational force generated from the third motor 511 rotates the pulley 514 which is formed on the shaft of the third motor 511.

Because the pulley 514 is connected with the pulley 515 formed on the shaft of the clutch 512 by the belt 516, the driving of the third motor 511 causes the rotation of the shaft of the clutch 512. The clutch 512 reduces the rotational velocity transmitted from the third motor 511, and thereby, the output shaft of the clutch 512 rotates at a reduced velocity. Therefore, due to the fact that the shaft of the clutch 512 is connected with the pulley 516 formed on the end of the pulling roll 526 by the belt 517, the pulling roll 526 is rotated.

As the pulling roll 526 is rotated, the interior trimming material A is pulled by the pulling roll 526.

The plurality of rolls for feeding the processed interior trimming material A while changing feeding directions in the stacking system 500 are shown in FIGs. 1 through 3. These rolls comprise upper and lower rotation rolls 401 and 402 locked to the inner frame plate 400 beside the upper heating roll 301, the embossing roll 302 and the lower elastic roll 303; a fifth roll 403 locked to the inner frame plate 400 below the rotation rolls 401 and 402 to feed the processed interior trimming material A, and a sixth roll 404 separated from the fifth roll 403 by a pre-selected distance and locked to the lower end of the body frame 100.

A seventh roll 405 is locked to the upper end of the body frame 100 to guide upwards the interior trimming material A having passed over the sixth roll 404, and an eighth roll 407 is disposed beside the pulling roll 526 to feed the interior trimming material A to the pulling roll 526.

Accordingly, the processed interior trimming material A can be guided over the rolls without being distorted.

In the present invention, the construction of the stepping plate installed in the introduction section 200 as described above is also provided to the lower end of the stacking system 500 as shown in FIGs. 1 through 3 to perform the same function.

Therefore, only the construction of the stepping plate will be described, and the operation and working effects will not be described herein.

As shown in the drawings, between the fifth roll 403 and the sixth roll 404, there are arranged an elongate stepping plate 421 on which a worker can stand, and casters 423 which are secured to the four corners of the stepping plate 421 so as to define a space 422 below the stepping plate 421. Also, a tension adjustment roll 424 projects out of the lower surface of the stepping plate 421 to adjust the tension of the interior trimming material A between the fifth roll 403 and the sixth roll 404.

Accordingly, the tension of the interior trimming material A fed between the fifth roll 403 and the sixth roll 404 can be adjusted by the tension adjustment roll 424, and the worker can freely move onto the stepping plate 421.

The stacking control part 530 of the stacking system

500 which constitutes a main component part of the present invention is illustrated in FIGs. 1 through 3 and 12 through

14. The structure of the stacking control part 530 will be described below.

The stacking control part 530 comprises a motor 532 attached to the upper end of the body frame 100 and having, formed on the shaft thereof, a pulley 531; and a brake clutch 534 connected with the pulley 531 of the motor 532 by a belt 533 at a preset separation from the motor 532.

The stacking control part 530 further comprises a rotation plate 536 rotatably locked to the horizontal extension frame 130 which projects from the body frame 100, and a movable stacking arm 531 coupled to an end of the horizontal extension frame 130 by a hinge 537.

The stacking control part 530 still further comprises a connection arm 539 connecting the rotation plate 536 and the movable stacking arm 531 with each other.

Movement limits of the movable stacking arm 531 are sensed by a sensor S which is fixedly positioned adjacent to the rotation plate 536, to control the cycle time required for stacking the interior trimming material A into multiple layers. Describing in detail the operation of the stacking control part 530, since the pulley 531 is coupled to the shaft of the motor 532, if the motor 532 is driven, the pulley 531 is rotated. As the pulley 531 is rotated, the shaft of the brake clutch 534 which is connected with the pulley 531 via the belt 533 is rotated.

The brake clutch 534 is constructed such that it can be idly rotated as occasion demands . In other words, even when the motor 532 is driven and the input shaft of the brake clutch 534 is continuously rotated, the output shaft of the brake clutch 534 may be maintained stopped.

This operation is controlled by the control box 600. Since the (output) shaft of the brake clutch 534 is connected with the rotation plate 536 by a belt, the rotation of the output shaft of the brake clutch 534 causes the rotation of the rotation plate 536.

One end of the connection arm 539 is hingedly connected to the rotation plate 536 and the other end of the connection arm 539 is hingedly connected to the movable stacking arm 531.

Therefore, the rotation of the rotation plate 536 results in interlocked reciprocating movement of the movable stacking arm 531. This interlocked reciprocating movement intermittently occurs, and the interior trimming material A which is discharged out of the distal end of the movable stacking arm 531 is continuously stacked into multiple layers.

Referring to FIGs. 1 through 3, as the interior trimming material A is continuously stacked into multiple layers and the thickness of the interior trimming material A gradually increases, the length of the interior trimming material A which is required to form each layer gradually increases too.

This is because the length of each layer gradually increases in the upward direction.

Therefore, in the present invention, as means for solving this problem, the brake clutch 534 and the sensor S are provided such that they are controlled by the control box 600.

The sensor S which is attached to the horizontal extension arm 130 adjacent to the rotation plate 536 senses the arrival of the movable stacking arm 531 to the left movement limit as shown in FIG. 12, at the time of which the operation of the movable stacking arm 531 is interrupted.

Namely, the brake clutch 534 is controlled such that the rotation of the output shaft of the brake clutch 534 can be interrupted. As the rotation of the output shaft of the brake clutch 534 is interrupted, the rotation of the rotation plate 536 which is connected with the brake clutch 534 via the belt is also interrupted, and the movable stacking arm 531 is held at the arrival position.

Therefore, as the interior trimming material A which is pulled through the rotation of the pulling roll 526 is continuously discharged out of the distal end of the movable stacking arm 531, a sufficient length of the interior trimming material A can be stacked on a preceding layer of the stacked interior trimming material A.

Then, after a predetermined time is elapsed, the control box 600 releases a control signal, and the output shaft of the brake clutch 534 and the rotation plate 536 are rotated until the movable stacking arm 531 is moved to the position shown in FIG. 13 which corresponds to the right movement limit.

Of course, at this position, the rotation of the output shaft of the brake clutch 534 and the rotation of rotation plate 536 are again interrupted until a predetermined length of interior trimming material A is discharged out of the distal end of the movable stacking arm

531. In this way, the movable stacking arm 531 is repeatedly operated to stack the interior trimming material A into multiple layers. Accordingly, in the present invention, as the interior trimming material A is gradually stacked high, the interruption time of the brake clutch 534 is gradually lengthened. Finally, in the present invention, roll crossing means as shown in FIGs. 15 through 18 is provided. In the material processing section 300, the interior trimming material A is compressed with high pressure by the rolls to be appropriately processed on the surface thereof, and therefore, the middle portions of the rolls may be slightly bent.

The roll crossing means functions to cross the rolls with one another and to thereby prevent the rolls from being bent. The structure of the roll crossing means will be described below with reference to the drawings.

Each roll crossing means is disposed on the upper end of each of the shaft housing blocks 310, 311 and 312 which are locked to the inner frame plate 400. Each roll crossing means comprises a housing locking block 610 defining on a lower surface thereof a moving space 611 and having a manipulation rod 613 which possesses a threaded portion 612 and is fitted through a hole defined on a wall of the housing locking block 610 and communicating with the moving space 611. Each roll crossing means further comprises a threaded boss 620 projecting upward from the upper end of each of the shaft housing blocks 310, 311 and 312 and inserted into the moving space 311 of the housing locking block 610, and locking plates 630 for locking each of the shaft housing blocks 310, 311 and 312 on stepped portions 615 formed on the housing locking block 610.

The threaded portion 612 of the manipulation rod 613 which is fitted into the housing locking block 610 is threadedly coupled with the threaded boss 620 which is integrally formed on the upper end of each of the shaft housing blocks 310, 311 and 312, such that, when the manipulation rod 613 is rotated, each of the shaft housing blocks 310, 311 and 312 can be moved forward and rearward in the moving space 611 to cross the rolls with one another.

Describing the operation of the roll crossing means in detail, if the manipulation rod 613 is rotated as indicated by the arrow in FIG. 18, the threaded portion 612 is rotated integrally with the manipulation rod 613, and the threaded boss 620 is moved forward and rearward.

Due to the fact that the threaded boss 620 is inserted into the moving space 611 defined in the housing locking block 610, the threaded boss 620 can be moved only within the moving space 611. The threaded boss 620 is integrally coupled to each of the shaft housing blocks 310, 311 and 312. Accordingly, as the manipulation rod 613 is rotated, each of the shaft housing blocks 310, 311 and 312 can be moved forward and rearward.

Therefore, in a state in which the rolls are fitted into the center portions of the shaft housing blocks 310,

311 and 312, the rolls can be finely crossed with one another.

Since the shaft housing blocks 310, 311 and 312 locked to the inner frame plate 400 are provided to both left and right ends of the inner frame plate 400, if each of the left shaft housing blocks 310, 311 and 312 is moved forward, each of the right shaft housing blocks 310, 311 and

312 must be moved rearward to precisely cross the rolls with one another . It is preferred that the forward and rearward movement of the shaft housing blocks 310, 311 and 312 be effected within a narrow range of several millimeters .

Consequently, as the rolls are rotated while they are crossed with each other, the middle portions of the rolls are prevented from being bent.

The rolling crossing means 600 may be mounted only to the left and right ends of the uppermost heating roll 301, or may be mounted to the embossing roll 302 or the lower elastic roll 303.

Claims

[CLAIMS] [Claim l]

An embossing calender for processing car interior trimming material, comprising: a body frame (100) for defining an outer appearance of a body of the embossing calender; an introduction section (200) for feeding interior trimming material (A) while changing feeding directions using a plurality of rolls; a material processing section (300) fitted, at left and right ends thereof, into shaft housing blocks (310, 311 and 312) , raised and lowered at a center portion of the body frame (100) by a hydraulic cylinder (350) which is at a lowermost position, and composed of an upper heating roll (301) , an intermediate embossing roll (302) and a lower elastic roll (303) which are driven by a power transmission part (330); an inner frame plate (400) providing a framework of the material processing section (300) and made of steel; an interior trimming material stacking system (500) including a plurality of rolls for feeding the processed interior trimming material (A) while changing feeding directions, a driving part (510) and a pulling roll (526) for pulling the processed interior trimming material (A) upon driving of a third motor (511) , and a stacking arm (531) for stacking the pulled interior trimming material (A) under the control of a stacking control part (530) ; and a control box (600) for controlling the power transmission part (330) , the driving part (510) and the stacking control part (530) , wherein the car interior trimming material (A) passes between the upper heating roll (301) and the intermediate embossing roll (302) or between the intermediate embossing roll (302) and the lower elastic roll (303) to be embossed or glazed on a surface thereof. [Claim 2]

The embossing calender as set forth in claim 1, wherein the introduction section (200) comprises: horizontal frames (110) fastened to front and rear ends of the body frame (100) ; front and rear vertical bars (120) fastened to ends of the horizontal frames (110) ; two-staged guide rolls (130) horizontally installed on the vertical bars (120) ; a first roll (111) installed on upper ends of the horizontal frames (110) to feed the interior trimming material (A) ; a second roll (112) spaced apart from the first roll (111) by a predetermined distance; a third roll (113) rotatably fastened to a lower end of the body frame (100); and a fourth roll (114) attached to a lower end of the inner frame plate (400), whereby the interior trimming material (A) is guided in a manner such that it passes over the two-staged guide rolls (130) of the vertical bars (120), over the first roll

(111) and the second roll (112) , and then over the third roll (113) and the fourth roll (114) which are positioned at the lower end of the body frame (100), to be fed into the material processing section (300) . [Claim 3]

The embossing calender as set forth in claim 2, wherein, between the third roll (113) and the fourth roll (114), there are arranged an elongate stepping plate (231) on which a worker can stand to check a feeding and processing state of the interior trimming material (A) , casters (233) which are secured to four corners of the stepping plate (231) so as to define a space (232) below the stepping plate (231) , and a tension adjustment roll (234) which projects out of a lower surface of the stepping plate (231) to adjust tension of the interior trimming material

(A) between the third roll (113) and the fourth roll (114), whereby the tension of the interior trimming material (A) fed between the third roll (113) and the fourth roll (114) is adjusted by the tension adjustment roll (234), and the worker can move onto the stepping plate (231) . [Claim 4 ]

The embossing calender as set forth in claim 1, wherein, before the material processing section (300) , front and rear circular plates (350) are mounted at heights between the upper heating roll (301) and the embossing roll

(302) and between the embossing roll (302) and the lower elastic roll (303) , and first, second and third guide rolls

(351, 352 and 353) are installed on the circular plates

(350) to provide passages through which the interior trimming material (A) can pass, such that the interior trimming material (A) can be fed between the upper heating roll (301) and the embossing roll (302) and between the embossing roll (302) and the lower elastic roll (303) after passing through the passages. [Claim 5]

The embossing calender as set forth in claim 1, wherein electric heaters or heating media are installed or loaded in the upper heating roll (301) and the embossing roll (302) to heat them to a high temperature. [Claim 6]

The embossing calender as set forth in claim 1, wherein a sensor box (110) through which the interior trimming material (A) passes is provided to the body frame (100) to sense a seamed portion (120a) of the interior trimming material (A) . [Claim 7]

The embossing calender as set forth in claim 1, wherein thickness adjustment means (370) is installed between the shaft housing blocks (311 and 310) of the embossing roll (302) and the upper heating roll (301) to adjust thickness of the interior trimming material (A) . [Claim 8]

The embossing calender as set forth in claim 7, wherein the thickness adjustment means (370) comprises: an upper block (373) having flanges (371) , which are formed at both ends of the upper block (373) to be coupled to the shaft housing block (310) of the upper heating roll (301) , and an inclined surface (372) which has a predetermined inclination angle; a guide rail block (374) coupled to an upper end of the shaft housing block (311) of the embossing roll (302); a movable block (376) fitted into the guide rail block (374) and having an inclined surface (375) having the predetermined inclination angle; and a thickness adjustment element (379) having a threaded rod (377) which is threadedly coupled through a front end of the movable block (376) and a rotation handle

(378) which is fastened to an end of the threaded rod (377); whereby, with the threaded rod (377) of the thickness adjustment element (379) threadedly coupled through the movable block (376) , when the rotation handle (378) is rotated, the movable block (376) is moved forward and rearward to adjust thickness between the embossing roll (302) and the upper heating roll (301). [Claim 9] The embossing calender as set forth in claim 1, wherein the power transmission part (330) of the material processing section (300) comprises: a first motor (320) secured to the lower end of the inner frame plate (400) ; a clutch (322) fixedly maintained above the first motor (320) and having a shaft to which a first helical gear (321) is coupled; a second helical gear (324) having a shaft which is fitted into the inner frame plate (400) to be meshed with the first helical gear (321) , the second helical gear (324) being connected with a shaft of the embossing roll (302); a third helical gear (326) having a shaft which is fitted into the inner frame plate (400) to be meshed with the second helical gear (324), the third helical gear (326) being connected with a shaft of the lower elastic roll

(303); a second motor (329) installed on an upper end of the inner frame plate (400) and having integrally formed therewith a clutch portion (328); and a timing pulley (331) positioned below the second motor (329), having a shaft which is fitted into the inner frame plate (400), and connected with a shaft of the upper heating roll (301) , wherein a belt (334) is wound on the shaft of the first motor (320) and a pulley which is fastened to an end of the shaft of the clutch (322) such that, when the first motor (320) is driven, the second and third helical gears

(324 and 326) meshed with each other are rotated in opposite directions to thereby rotate the embossing roll (302) and the lower elastic roll (303) , and wherein a shaft of the second motor (329) formed integrally with the clutch portion (328) and the timing pulley (331) are connected with each other by a timing belt (336) such that, when the second motor (329) is driven, the upper heating roll (301) is rotated. [Claim lθ]

The embossing calender as set forth in claim 9, wherein the shaft of the embossing roll (302) and the second helical gear (324), the shaft of the lower elastic roll (303) and the third helical gear (326), and the shaft of the upper heating roll (301) and the timing pulley (331) are respectively connected with each other by universal joints

(385) , such that the universal joints (385) can be rotated while absorbing vertical displacement of the rolls (301, 302 and 303) . [Claim l l]

The embossing calender as set forth in claim 1, wherein the embossing roll (302) is detachably constructed.

[Claim 12] The embossing calender as set forth in claim 1, wherein the driving part (510) of the stacking system (500) comprises : a third motor (511) fastened to an upper end of the stacking system (500) of the body frame (100) ; a clutch (512) fixedly maintained at a predetermined separation from the third motor (511) ; and a pulling roll (526) connected via a bearing to a horizontal extension frame (130) which projects from an upper end of the body frame (100), whereby a pulley (514) which is formed on a shaft of the third motor (511) and a pulley (515) which is formed on a shaft of the clutch (512) are connected with each other by a belt (516) , and the pulley (515) of the clutch (512) and a pulley (516) which is formed on an end of the pulling roll (526) are connected with each other by a belt (517), such that, when the third motor (511) is driven, the pulling roll (526) is rotated to pull the interior trimming material (A) . [Claim 13]

The embossing calender as set forth in claim 1, wherein the plurality of rolls for feeding the processed interior trimming material (A) while changing feeding directions in the stacking system (500) comprise: upper and lower rotation rolls (401 and 402) locked to the inner frame plate (400) beside the upper heating roll (301) , the embossing roll (302) and the lower elastic roll (303); a fifth roll (403) locked to the inner frame plate (400) below the rotation rolls (401 and 402) to feed the processed interior trimming material (A) ; a sixth roll (404) separated from the fifth roll

(403) by a pre-selected distance and locked to the lower end of the body frame (100); a seventh roll (405) locked to the upper end of the body frame (100) to guide upwards the interior trimming material (A) having passed over the sixth roll (404); and an eighth roll (407) disposed beside the pulling roll (526) to feed the interior trimming material (A) to the pulling roll (526) , whereby the interior trimming material (A) can be guided without being distorted. [Claim 14]

The embossing calender as set forth in claim 13, wherein, between the fifth roll (403) and the sixth roll

(404) , there are arranged an elongate stepping plate (421) on which a worker can stand, casters (423) which are secured to four corners of the stepping plate (421) so as to define a space (422) below the stepping plate (421), and a tension adjustment roll (424) which projects out of a lower surface of the stepping plate (421) to adjust tension of the interior trimming material (A) between the fifth roll (403) and the sixth roll (404), whereby the tension of the interior trimming material (A) fed between the fifth roll (403) and the sixth roll (404) is adjusted by the tension adjustment roll (424), and the worker can move onto the stepping plate (421) . [Claim 15]

The embossing calender as set forth in claim 1, wherein the stacking control part (530) of the stacking system (500) comprises: a motor (532) attached to the upper end of the body frame (100) and having, formed on a shaft thereof, a pulley (531); a brake clutch (534) connected with the pulley (531) of the motor (532) by a belt (533) at a preset separation from the motor (532) ; a rotation plate (536) rotatably locked to the horizontal extension frame (130) which projects from the body frame (100) ; a movable stacking arm (531) coupled to an end of the horizontal extension frame (130) by a hinge (537); and a connection arm (539) connecting the rotation plate

(536) and the movable stacking arm (531) with each other, whereby movement limits of the movable stacking arm

(531) are sensed by a sensor (S) which is fixedly positioned adjacent to the rotation plate (536) , to control a cycle time required for stacking the interior trimming material (A) .

[Claim 16]

The embossing calender as set forth in claim 1, wherein roll crossing means (600), each of which is disposed on an upper end of each of the shaft housing blocks (310, 311 and 312) which are locked to the inner frame plate (400), each comprises: a housing locking block (610) defining on a lower surface thereof a moving space (611) and having a manipulation rod (613) which possesses a threaded portion (612) and is fitted through a hole defined on a wall of the housing locking block (610) and communicating with the moving space (611); a threaded boss (620) projecting upward from the upper end of each of the shaft housing blocks (310, 311 and 312) and inserted into the moving space (311) of the housing locking block (610) ; and locking plates (630) for locking each of the shaft housing blocks (310, 311 and 312) on stepped portions (615) formed on the housing locking block (610), wherein the threaded portion (612) of the manipulation rod (613) which is fitted into the housing locking block (610) is threadedly coupled with the threaded boss (620) which is integrally formed on the upper end of each of the shaft housing blocks (310, 311 and 312), such that, when the manipulation rod (613) is rotated, each of the shaft housing blocks (310, 311 and 312) can be moved forward and rearward in the moving space (611) to cross the rolls with one another.