MXPA97001578A - Expansible and collapable article, method and apar - Google Patents
Expansible and collapable article, method and aparInfo
- Publication number
- MXPA97001578A MXPA97001578A MXPA/A/1997/001578A MX9701578A MXPA97001578A MX PA97001578 A MXPA97001578 A MX PA97001578A MX 9701578 A MX9701578 A MX 9701578A MX PA97001578 A MXPA97001578 A MX PA97001578A
- Authority
- MX
- Mexico
- Prior art keywords
- bar
- unloading
- sheet material
- adhesive
- sheet materials
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 41
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Abstract
A method and apparatus (10) for forming expandable and collapsible articles (20), the method comprising: a horizontally oriented frame (46) receiving one or more rolls of sheet material from a powered mechanism (12a, 12b) a pusher bar (16) having upper (98) and lower (100) fastening members (100) engageable with the sheet material; and a discharging bar (18) having upper (172) and lower (174) discharging members that move between a bend position and a discharge position with respect to the frame (46). One or more linear actuators (134, 136) are provided to move the pusher bar (16) to and in the housing of the unloading bar (18), and the degree of linear movement that these actuators have is adjustable so that they can be made advancing sections of sheet material through the pusher bar (16) into contact with the unloading bar (18), thereby forming fold lines in the sheet material with variable spaces therebetween. An expandable and collapsible product (20) is formed having a folded accordion configuration with an outward facing surface with virtually any contour shape desired
Description
EXPANSIBLE AND COLLAPSABLE ARTICLE, METHOD AND APPARATUS
FIELD OF THE INVENTION This invention relates to a method and apparatus for forming expandable and collapsible articles, and more particularly, to a method and apparatus capable of forming folded and / or cellular units that are used as window treatments, filters and the like, wherein at least one surface is formed by interconnected cellular or folded units that give the appearance of a curved or contoured surface.
BACKGROUND OF THE INVENTION The expandable and collapsible products that are used as window blinds, filter media and the like have been manufactured in a variety of configurations by various methods and apparatus. One of the types of expandable and collapsible products is a folded accordion or zig-zag article comprising a series of interconnected pleats as disclosed for example in U.S. Patent Nos. RE 27,094; 4,181,070; 3,921,432; 4,012,932 and others. Another type of construction is the so-called cellular structure or "honeycomb" wherein the selected folded portions of one or more sheet materials are
P1114 / 97 X interconnect by adhesive or similar, to form hollow, elongated, adjacent channels. Illustrative patents for the expandable and collapsible products of the honeycomb type include U.S. Patent Nos. 4,603,072; 4,631,108; 4,685,986; 4,631,217; 4,676,855; 4,677,012; and 4,677,013. Accordion-type folded articles and the cellular or honeycomb products already mentioned, form a variety of different devices depending on the particular configuration of the desired finished article and how the various folds of the sheet materials that are interconnected are interconnected. form the article. The formation of the folds themselves in the sheet material requires a separate process step within a product manufacturing system, or with a single unit alone, when some other type of the aforementioned articles is formed. One method and apparatus for folding sheet material involves the use of cooperating rollers having meshing teeth. The teeth couple and bend the sheet material between them during their passage through the rollers. Refer, for example, to U.S. Patent Nos. 4,811,873; 4,871,006; and 5,193,601. Another type of folding apparatus employs a pusher bar that moves horizontally towards and in
P1114 / 97MX and - move away from a vertically moving unloading bar. The pusher bar couples one or more sheets of material placed on the top of the frame of the folding device and advances that portion of the material
blade between the pusher bar and the unloading bar, towards the unloading bar against which the blade is folded. The unloading bar moves vertically upwards, after the bend has been made, to allow the fold that has just been formed to move in
downward direction, while the pusher bar returns to its initial position, separated from the unloading bar, preparing for another bending operation. The apparatus of this general type is disclosed, for example, in U.S. Patent Nos. 2,387,163;
, 2495, 130; 4,201,119; 4,871,404; 4,943,454; and 5,205,891. A limit of all these methods and apparatuses described above is that the article folded in the form of an accordion and / or the resulting cellular article has a surface
flat. That is to say, the "peaks" or fold lines of the interconnected folds that form the expandable and collapsible accordion type article are all in the same plane because the height of all the folds is the same. This also applies to expandable cellular articles and
collapsible elaborated from a series of cellular units
P1114 / 97MX interconnected, since the height or transverse dimension of each "cell", for example elongated hollow channel, is the same throughout the article. While expandable and collapsible articles having a flat surface are suitable for certain applications, they have a limited aesthetic interest when used to form different window treatments and the like, and are less desired in a variety of filtering applications.
SUMMARY OF THE INVENTION Therefore, among the objectives of this invention is to provide a method and apparatus for forming an expandable and collapsible article having at least one contoured or curved surface facing outwards, which is capable of forming articles folded in the form of an accordion as well as cellular articles, which is capable of varying or maintaining in a consistent manner the height of the fold or the height of the cell of each of these types of articles, which is, in essence, fully operational automatic and that produces cellular articles or folded of precise dimensions. These objects are achieved in a method and apparatus for forming expandable and collapsible articles comprising a horizontally oriented frame, which receives
P1114 / 97MX one or more rolls of sheet material from a feeder mechanism, a pusher bar having lower and upper fastener members engaging the sheet material, a discharging bar having upper and lower discharging members that move between a fold position and a discharge position relative to the frame, and a pre-marker bar located between the pusher bar and the unloading bar. One or more of the linear actuators are provided to move the pusher bar towards and away from the unloading bar, and the extension of the linear movement of these actuators is adjusted so that different stretches of the sheet material can be advanced by means of the pusher bar, in contact with the unloading bar, thus forming the fold lines in the sheet material with different spaces between them. An expandable and collapsible product is formed in this form with an accordion fold configuration with an outward facing surface having virtually any desired contoured shape. Alternatively, cellular articles may be formed by the apparatus of this invention consisting of a series of adjacent elongated hollow cellular units, which are formed by the same elements used in the manufacture of accordion-bent items, but
P1114 / 97MX adding dispensers of adhesives and welding units. One aspect of this invention is based on the concept of providing an adjustable drive mechanism for the pusher bar, which is capable of varying the position of this in relation to the unloading bar, essentially in any sequence, at any time during operation of the apparatus . In the currently preferred embodiment, linear actuators, such as ball and screw mechanisms, are mounted on opposite ends of the pusher bar and are driven by one or more variable speed step motors, whose operation is controlled by a programmable controller such like a personal computer. Depending on the requirements of a particular application, the linear actuators operate to position the pusher bar essentially at any distance, within a predetermined range, relative to the fixed position of the unloading bar. Accordingly, the length of the sheet material between the pusher bar and the unloading bar may vary as desired, in any given sequence. This capability of the present invention allows the articles to be formed to have a non-planar or contoured outer surface of virtually any configuration. For example, items folded in
P1114 / 97MX accordion or zig-zag have a fold height that is defined as the distance between two adjacent fold lines, ie from "peak to peak". As these linear actuators that move the pusher bar are able to adjust the position of the latter relative to the unloading bar, at the start of each successive bending operation, the distance between the adjacent bends can be adjusted as desired, thus altering the height of the fold from one fold to another, in any sequence within a predetermined height range. The pre-marker bar assists in the bending operation by moving vertically upwards towards engagement with the sheet material, between the pusher bar and the unloading bar, thus forming a camber or pre-marking on the sheet material, immediately in anticipation of movement linear of the pusher bar towards the unloading bar. The "outer surface" of the resulting article, for example the surface defined by adjacent peaks in the series of interconnected pleats, therefore has a contoured or non-planar shape that provides finished products such as window blinds, with an aesthetically distinctive appearance. In the presently preferred embodiment, the linear actuators are also provided for moving at least one of the upper fastening members and
P1114 / 97MX lower of the unloading bar, in relation to the other, in a closed clamping position, where the clamping members couple one or more of the rolls of sheet material between them, in preparation for the movement of the bar unloader in order to form a fold, and a separate position wherein the fastener members uncouple the sheet material allowing the pusher rod to return to an initial contact or clamping position, in preparation for another bending operation. Similarly, linear actuators are employed with the unloader bar to move the upper and lower unloader members in relation to each other, between a closed bend position for engagement with the sheet material and the pusher bar, and a unloading position or separate that allows the cell unit or the fold that has just formed, to pass in downstream along the frame of the apparatus for additional handling. The adjustment of the vertical movement of the lower and upper clamping members of the pusher bar, and the upper and lower unloading members of the unloading bar, is obtained by operation of the linear actuators associated therewith, to adjust the sheet materials of different thicknesses Another aspect of the invention involves the use of the present apparatus to form a cellular product
P1114 / 97MX expandable and collapsible, where a series of interconnected cell units are formed - adjacently, each of which has multiple sides and has an elongated hollow interior or core. The same pusher bar and the same unloading bar are used in the manner already described, additionally with adhesive application dispensers, and one or more laser or ultrasonic welding units carried by the pusher bar. In the currently preferred embodiment, two rolls of the sheet material are fed onto the apparatus frame, one on top of the other, so that each sheet has an exposed surface. A first adhesive dispenser applies longitudinally spaced adhesive beads, each extending along the width of the exposed surface of a sheet, and a second adhesive dispenser applies beads of adhesive onto the exposed surface of the sheet. another opposite sheet of the first beads of adhesive. This step of dispensing adhesive is carried out upstream of the pusher bar, where the laser or ultrasonic welding units are mounted. These welding units are activated as the upper and lower clamping members of the pusher bar engage the two rolls of sheet material and form an essentially continuous welding line along the width of the two
P1114 / 97MX adjacent sheets, but separately from the two beads of adhesive, on the exposed surfaces of the sheets. The linear actuators associated with the pusher bar also operate to move this and that portion of the two sheets located between the pusher bar and the unloading bar, in a direction toward the unloading bar. During this movement, an air tube introduces a jet of air between the two sheets, so that they separate from each other before coupling with the unloading bar. A diamond-shaped cell unit is formed each time the pusher bar and the sheet material come into contact with the unloading bar. Each cell unit has opposite fold lines or peaks that define the overall height of the cell unit, and the opposite welding lines, where two sheets are interconnected by laser or ultrasonic welding units. Additionally, each cell unit has first and second surfaces exposed, each carrying adhesive beads applied upstream, as already described. The other two exposed surfaces of each diamond-shaped cell unit do not have an adhesive. In an operation developed downstream of the unloading bar, the two exposed surfaces of a cell unit carrying a bead of adhesive are pushed into engagement with the
P1114-- 97MX two surfaces of an adjacent cell unit that does not have an adhesive. As a result, small "cavities" are formed between adjacent cell units, on either side of the weld line therebetween, each comprising an open and elongated channel extending across the entire width of the sheet material . The interconnection of the adjacent cell units with the adhesive beads adds rigidity to the entire article, and the "cavities" provide a location for the cords to be inserted when the cellular units of this invention are used in the formation of window blinds. or similar expansible and collapsible articles. The cavities effectively hide the laces of sight and thus produce a more aesthetic product. An important advantage of the apparatus and method of the invention, in forming folded accordion and folded articles or cell units as already described, is the fact that the outward facing surface of these articles can be contoured in virtually any configuration desired. As already mentioned, the linear actuators associated with the pusher bar are adjustable and are controlled by a programmable controller, so that the distance between the pusher bar and the unloading bar, in operations of
P1114 / 97 X successive bending, is variable in essentially infinite form. The resulting folded articles may have different fold heights in the case of zigzag or accordion folded articles, or variable cell heights in the case of cellular articles, in essentially any desired sequence depending on the functional or aesthetic requirements of a particular application. At least one outward facing surface is formed in this manner, in any one of the types of articles, which has a "contoured" appearance, wherein the fold lines forming the adjacent peaks of the folds or cell units are left in place. at least two different planes. The two-piece unloader bar and pusher bar, which are employed here, further increase the efficiency of the operation of the system and are adjustable to accommodate different thicknesses of sheet materials.
DESCRIPTION OF THE DRAWINGS The structure, operation and advantages of the presently preferred embodiment of this invention will become apparent upon consideration of the following description along with the accompanying drawings, wherein: Figure 1 is an overall perspective view of the apparatus of this invention; invention; Figure 2 is an enlarged view of a portion
P1114 / 97MX of Figure 1 illustrating an adhesive applicator, a pusher bar and a discharge bar, in greater detail; Figure 3 is a partial cross-sectional view taken generally along line 3-3 of Figure 2; Figure 4 is a partial cross-sectional view taken generally along line 4-4 of Figure 2; Figure 5 is a partial cross-sectional view of the drive mechanism associated with the pusher bar; Figure 6 is a view similar to Figure 2, except that it illustrates a pre-marker bar in place of an air jet that is used to form accordion-folded articles; Figure 7 is an enlarged view of the pre-marker bar shown in Figure 6; Figure 8 is a schematic view of a portion of the apparatus herein, downstream of the unloading bar; Figure 9 is a schematic view of a portion of a partially finished cellular article, made according to the present invention; Figure 10 is a view similar to Figure 6
P1114 / 97MX except for the finished cell unit; Figure 11 is a view similar to Figure 6, except that it is an alternative embodiment of a cellular article made according to the method and apparatus herein; Figure 12 is a schematic view of the finished cell article illustrated in Figure 8; Figure 13 is a schematic view of an accordion or zig-zag bent article made with the apparatus of this invention; and Figure 14 is a schematic view of another article made with the apparatus herein, having a contoured outer surface.
DESCRIPTION M nptat.t, ADA OF THE INVENTION Referring to Figures 1 and 2, the apparatus 10 of this invention generally comprises two sheet feeder mechanisms 12a and 12b, an adhesive applicator unit 14, a pusher bar unit 16 and a unloading bar unit 18. The apparatus 10 functions to form accordion or zig-zag bent articles (Figure 10) and cellular items 22a, 22b (Figures 6 to 7), as will be explained in more detail below. The following discussion will describe each of the elements of the system individually, followed
P1114 / 97MX for an explanation of the operation of the apparatus 10 in the formation of articles 20, 22a and 22b.
Sheet Feeder Mechanisms The sheet feeder mechanisms 12a and 12b that are schematically illustrated in Figure 1 do not form part of this invention by themselves and, therefore, the details of operation thereof will not be provided herein. These sheet feeder mechanisms 12a, 12b are commercially obtained and are currently used in other types of apparatus to form expandable and collapsible articles. For purposes of this discussion and in relation to Figure 1, the two blade feeding mechanisms 12a and 12b include support shelves 24a, b, each with a drive roller 26. The drive roller 26 of the support shelf 24a mounts a roll 28 of sheet material 29 and the support shelf 24b of the sheet feed mechanism 12b assembles a roll 30 of sheet material 31. As will be discussed in more detail below in relation to a description of the method of operation of the apparatus 10, one of the sheet materials 29, 31 is used to form the accordion or zig-zag folded articles 20, while the two sheet materials 29, 31 are employed in the formation of cellular articles 22a and 22b.
P1114 / 97MX The drive roller 26 of each support shelf 24a, b is connected in drive relation to a DC driver 32, which in turn is connected by a line 34 to a drive controller 36. The operation of the drive controller 36 is controlled by a programmable system controller 38 such as the Model Catee PSQ-8 which is purchased from Custom Applied Technology Corporation of Sarasota, Florida, an exclusive computer or any other suitable controller system. As described below, the system controller 38 controls all the functions of the apparatus 10 and can be programmed to form virtually any configuration of the items 20, 22a and / or 22b, as desired. The sheet material 29 is unwound from the roll
28, it is fed around the roller 40 of a tension bar 42 and then wound onto a guide roller 44, from which the sheet material 29 extends over the frame 46 of the apparatus 10. The sheet material 31 coming from the roll 30 is Feeds similarly to the frame 46, for example on the roller 48 of a tension bar 50, and then on a guide roller 52 to a position below the sheet material 29 from the roll 28. As discussed below in connection with a description of the formation of the cellular articles 22a and 22b, the
P1114 / 97MX sheet materials 29, 31 are fed one on top of the other, along the frame 46 towards the pusher bar unit 16 and the unloader unit 18. In the formation of an accordion or zig-fold article -zag 20, only one of the sheet materials 29 or 31 is required.
Adhesive Applicator Referring to Figure 2, the adhesive applicator 14 is illustrated in greater detail. As described below, the adhesive applicator 14 is used only in the formation of the cellular articles 22a and 22b. It is not needed when the apparatus 10 functions to form accordion or zig-zag bent articles 20. Accordingly, the discussion of the construction of the adhesive applicator 14 that continues assumes the presence of upper sheet materials 29 and lower sheet materials 31, above the frame 46. In the presently preferred embodiment, a mounting bracket 54 is provided having a pair of support legs 56, 58, each connected to one side of the frame 46, and an upper transverse armature 60 that it extends between the support legs 56, 58 in a position above the frame 46 and the sheet materials 29, 31 thereon. The upper transverse reinforcement 60 mounts
P1114 / 97MX a first ball and screw mechanism 52 extending from the mounting leg 56 towards the center of the transverse frame 60. A second ball and screw mechanism 64 is also mounted to the upper transverse frame 60, so that it encounters the first ball and screw mechanism 62 and extends to the second mounting leg 58. The ball and screw mechanisms 62, 64 are preferably of the type sold as Model No. 2AC with the name "Powerslide" of Thomson Industries, Inc. of Port Washington, New York. The ball and screw mechanisms 62, 64 of this type include a rotating threaded shaft 68 which is mounted on the opposite ends of bearings 70, 72. The threaded shaft 68 is rotated by a reversible motor 74, preferably carried by one of the housings for the bearings 70 or 72. A carriage 76 moves along the threaded shaft 68 in response to rotation thereof, and can slide along one or more guide rods 78 that extend between the housings of bearing. The ball and screw mechanisms 62, 64 mount adhesive dispensers 80 and 81, respectively, each of which has a nozzle placed immediately above or in engagement with the top sheet material 29. The adhesive dispensers 80, 81 to its Once, they connect to a source of fusion adhesive
P1114 / 97MX hot or similar (not shown). In response to the rotation of the threaded shaft 68 of the first and second ball and screw mechanisms 62, 64, by operation of the motors 74, the two adhesive dispensers 80 and 81 can move towards the center of the upper support plate 60, from a position adjacent to the mounting legs 56, 58 of the bracket 54, thereby forming a bead of adhesive 84 that extends across the width of the upper sheet material 29, as illustrated in dotted lines in the Figure 2. When the sheet material 29 is then advanced towards the pusher bar unit 16 in a folding operation described below, the adhesive dispensers 80, 81 are moved by the ball and screw mechanisms 62, 64 in moving away from each other, toward the mounting legs 56, 58, respectively, thereby applying another bead of adhesive (not shown) on the upper sheet material 29, at a longitudinally spaced location from the first bead of adhesive 84. Accordingly, a series of longitudinally spaced adhesive beads 84 are applied to the exposed surface of the upper sheet material 29 across the entire width thereof. The term "longitudinally" in the sense in which it is used herein refers to the direction of movement of the sheet materials 29, 31 along the frame 46, and in the direction
P1114 / 97MX "transverse" or "perpendicular", referring to a direction perpendicular to the movement of the sheet materials 29, 31 along the frame 46. A similar structure is employed to apply a bead of adhesive 86 to the exposed surface of the bottom sheet material 31. Refer also to Figures 9 to 12. Third and fourth ball and screw mechanisms 88, one of which is shown in Figure 2, are mounted to a lower transverse frame 61 in position below the exposed surface of the lower sheet material 31. The lower transverse frame 61 extends between the opposing legs 56, 58 of the mounting bracket 54, and is mounted thereto, in a position below the upper transverse armature 60. ball and screw mechanisms 88 have the same structure as described above in relation to the mechanisms 62, 64 and, therefore, the same reference numbers are used to identify a structure similar. The carriages 76 of the third and fourth ball and screw mechanisms 88 mount the adhesive dispensers 89, one of which is shown in Figure 2, in a position below the bottom sheet material 31, so that the nozzle each dispenser or dispenser 89 is in contact or substantially in contact with the exposed surface of the lower sheet material 31. These dispensers
P1114 / 97MX adhesive 89 moves towards and away from each other in the same manner as described above for the dispensers 80, 81, associated with the ball and screw mechanisms 62, 64, so that separate adhesive beads 86 are applied longitudinally on the lower sheet material 31, directly opposite the adhesive beads 89 on the upper sheet material 29. Refer to Figures 9 to 12. The two sheet materials 29, 31 are therefore transmitted, to the pusher bar unit 16 and the unloading bar unit 18 with adhesive beads 84, 86, longitudinally spaced apart and in alignment, on the exposed surfaces thereof. The operation of the reversible motors 74 associated with each of the ball and screw mechanisms 62, 64 and 88 is controlled by the system controller 38 to ensure that the adhesive beads 84 and 86 are applied at correct intervals throughout the the sheet materials 29, 31, depending on the size or height of the cellular articles 22a or 22b to be formed, as described in more detail below.
The Pusher Bar Unit is referred to in Figures 2, 3 and 5, the pusher bar unit 16 is illustrated in detail. As described below, in relation to a discussion of the operation
P1114 / 97 X of the apparatus 10, the purpose of the pusher bar unit 16 is to advance a selected length of sheet material 29 and / or 31 towards the unloading bar unit 18, against which the bending operation is performed, to form a fold or a cell unit. An important advantage of the apparatus 10 of this invention is that the movement of the pusher bar unit 16 is adjustable, i.e., it can move essentially in any number of contact or start positions along the length of the sheet materials. and / or 31, and thus initiate successive bending operations in different spaced positions, relative to the unloading bar unit 18. In the currently preferred embodiment, the pusher bar unit 16 comprises an upper clamping member 98 and a lower clamping member. 100, which is positioned vertically below the upper fastening member 98. As seen in Figures 2 and 3, the upper fastening member 98 has, in general, an L-shape having a vertical plate 102 connected to a horizontal plate 104, with guide blocks 106, 108 mounted on either side of the horizontal plate 104. These guide blocks 106, 108 each receive a pair of guide rods 110, 112 which they extend down from them to guide the blocks 114, 115, respectively, assembled
P1114 / 97MX on the base plate 116 of the lower fastening member 100. The base plate 116 is connected to a vertical plate 118, which forms the same L-shape, in general, as the upper fastening member 98, and this vertical plate 118 is oriented in alignment with the vertical plate 102 of the upper clamping member 98. The upper clamping member 98 is supported in position above the lower clamping member 100 by a pair of hydraulic or pneumatic cylinders 128, 130 carried by the transverse plate 126 of a bracket assembly 120, which has opposite legs 122, 124 whose upper ends mount the transverse plate 126. The lower ends of the legs 122, 124, are in turn connected to the base plate 116 and the guide blocks 114, 115, associated with the lower clamping member 100. The transverse plate 126 mounts the hydraulic or pneumatic cylinders 128, 130 in position, so that the piston rod 132 of each cylinder 1 28, 130 is connected to the vertical plate 102 of the upper clamping member 98. The cylinders 128, 130 function to extend and retract their associated piston rods 132, which in turn move the upper clamping members 98 towards and away from the member. lower clamping 100. This movement of the clamping members 98, 100 is guided by the guide rods 110, 112, which extend between them, so
P1114 / 97MX that in the extended position of the piston rods 132, the vertical plate 102 of the upper clamping member 98 engages the vertical plate 118 of the lower clamping member 100, through practically the entire width of the pusher bar unit 16 and the frame 46. As discussed in more detail below, in connection with an explanation of the operation of the apparatus 10, the movement of the upper and lower fastening members 98, 100 in engagement with each other, temporarily holds or grasps one of the two sheet materials 29, 31 therebetween to move it towards the unloading bar unit 18 in order to effect a bending operation. The opposite ends of the lower fastening member 100 are mounted on a pair of adjustable linear actuators 134, 136, preferably of the type sold as Model No. RX 102B-12-M55-MC by Industrial Devices Corporation of Novato, California. Referring to Figure 5, each linear actuator 134, 136 includes a threaded shaft 140 carried by bearings 142, 144 at opposite ends, and has a carriage 146 that moves between the bearings 142, 144 in response to the rotation of the arrow threaded 140. The carriage 146 of each linear actuator 134, 136, in turn, is connected to the base plate 116 of the lower fastening member 100, as schematically illustrated in Figure 5 and shown in the Figure
P1114 / 97MX 3. The threaded shaft 140 of the linear actuators 134, 136 each assembles a bevel gear 150, 151, respectively. The bevel gear 150 is connected in drive relationship with a bevel gear 152 mounted on one end of the arrow 153 whose opposite end carries a bevel gear 154 mounted in position to engage a drive gear 155, on the output shaft 156 of a stepper motor 158, preferably of the type sold with Model No. 583-135-MO by The Control Division of Parker Hannifan Corporation of Wadsworth, Ohio. The stepper motor 158 is mounted to the frame 46 approximately in the center thereof, for example halfway along the lower fastening member 100, and is operated by a motor controller (not shown) connected to the system controller 38. The drive gear 155 of the output shaft 156 of the stepper motor 158 is also meshed with a bevel gear 159, carried at one end of an arrow 161. The opposite end of the arrow 161 mounts a bevel gear 163, which in turn, it engages with bevel gear 151 on arrow 140 of linear actuator 136. Preferably, each of arrows 153 and 161 are rotatably supported by a bearing (not shown) at either end.
P1114 / 97MX The output shaft 156 of the stepper motor 158 rotates in both directions, clockwise and counterclockwise, to precisely control the rotation of the threaded arrows 140 associated with each linear actuator 134 , 136, by the drive trains described above. The carriage 146 of each linear actuator 134, 136 and, therefore, the lower clamping member 100, then move in the axial direction with respect to the threaded arrows 140 and longitudinally along the frame 96. As the member upper fastener 98 is connected to the lower fastening member 100 by the mounting bracket 120, the entire pusher bar unit 16 moves towards and away from the unloading bar unit 18, in the form of a unit, in response to the operation of the stepper motor 158. Linear actuators 134, 136 are illustrated in the Figures as ball and screw mechanisms, capable of precise and infinitesimally adjustable linear movement in response to the operation of the stepper motor 158. it is contemplated that other "adjustable" linear actuators could be employed in this invention, for example hydraulic or pneumatic cylinders, as long as the ability to move and locate n precise upper clamping members and
P1114 / 97 X lower 98, 100 with respect to the unloading bar unit 18 is maintained. As described more fully below, an important aspect of this invention is the ability of the apparatus 10 to selectively and accurately vary the spacing between the pusher bar unit 16 and the unloading bar unit 18, by operating the actuators linear 134, 136 so that different sections of the sheet material 29 and / or 31, placed between the pusher bar unit 16 and the unloading bar unit 18, can be bent to produce articles 20, 22a and / or 22b of different sizes . The pusher bar unit 16 also includes the structure required in the manufacture of the cellular articles 22a and 22b, as described in more detail below in connection with a discussion of the method of operation of the apparatus 10. In the currently preferred embodiment, the plate horizontal 104 of upper clamping member 98 assembles a pair of ball and screw mechanisms 162, 164 of the same type as the ball and screw mechanisms 62, 64 that are described above in relation to the discussion of the adhesive applicator 14. In this form , the same reference numbers are used in the description of the mechanisms 62, 64 and in Figure 3 to illustrate the same mechanism structure 162, 164. The ball and screw mechanisms 162, 164 assemble
PU14 / 97 X the welding devices 166, 168, respectively, in position immediately above the exposed surface of the upper sheet material 29. The welding devices 166, 168 are preferably ultrasonic welding apparatuses such as those sold by Branson Ultrasonics Corporation of Danbury, Connecticut. Alternatively, laser welding devices may employ those of the type sold by The Industrial Laser Source of Hopedale, Massachusetts. The welding devices 166, 168 are moved by the ball and screw mechanisms 162, 164 towards each other, and towards the center of the upper clamping member 98, and then away from each other towards the ends thereof. A separate welding line 170 is formed during each of the movements of the welding devices 166, 168 which interconnect the sheet materials 29 and 31. Refer also to Figures 9 to 12. The operation of the ball mechanisms and Screw 162, 164 is governed by the controller 38, so that the welding devices 166, 168 are activated in sequences synchronized with the movement of the sheet materials 29 and 31, along the frame 46. As a result, the lines 170 longitudinally spaced welds are formed along the length of the sheet materials 29, 31 at locations near the
P1114 97MX point where the adhesive beads 84, 86 were applied by the adhesive dispensing unit 14. As discussed below, the individual cellular units of the cellular articles 22a and 22b are formed between adjacent welding lines 170 and a line of adhesive. fold is formed in the sheet materials 29, 31, midway between adjacent welding lines 170.
Unloading bar unit Referring to Figures 1 to 4, the unloading bar unit 18 comprises an upper unloading bar 172 and a lower unloading bar 174 which can both move towards and away from each other between a fold position, wherein the upper and lower unloading bars 172, 174 come into contact with each other (Figure 2), and a discharge position where they separate from each other (Figure 4). The vertical movement of the unloading bars, upper and lower, 172, 174 is achieved with the same type of adjustable linear actuators 134, 136 used in the pusher bar unit 16. A detailed description of the linear actuators used with the bar unit unloader 18 will therefore not be repeated here, and the same reference numerals used in Figures 1 and 3 are used in Figure 4. P1114 / 97MX Lower unloading bar 174 is mounted at either end to the carriage 146 of the ball and screw mechanisms 180 and 182 that, as mentioned before, they are essentially identical to the ball and screw mechanisms 134, 136 of the pusher bar unit 16. The carriage 146 of each ball and screw mechanism 180, 182 moves along the threaded shaft 68. rotatably carried by the bearings 142, 144. The bearings 142, 144 of the ball and screw mechanism 180 are mounted to a support leg 175 of a mounting bracket 177 for unloading bar, and the bearings 142, 144 of another ball mechanism and screw 182 are mounted on the opposing support leg 179 of the mounting bracket 177. The lower end of the support legs 175, 179 mounts to the frame 46 and the upper end thereof carries a transverse armature 181 extending between the legs. same. The threaded shaft 140 of each ball and screw mechanism 180, 182 is connected in drive relation to the output shaft 156 of the stepper motor 158, by arrow 153, 161 in the same manner as described above in connection with a discussion of the actuators 134, 136 and Figure 5. The stepper motor 158 is connected to a motor controller (not shown) which, in turn, is connected to the controller 38 of the system. The mechanisms of
P1114 / 97 X ball and screw 180, 182 function to raise and lower the lower unloading bar 174 relative to the upper unloading bar 172, during the drive of the stepper motor 158 A similar structure is provided to move the upper unloading bar 172 with respect to the lower unloading bar 174. As shown in Figure 4, the upper unloading bar 172 is carried by a pair of ball and screw mechanisms 200, 202, which are mounted to the supporting legs 175, 179 of the bracket assembly 177, in the same manner as the ball and screw mechanisms 180, 182. The ball and screw mechanisms 200, 202 have the same structure and function as the ball and screw mechanisms 180, 182, and are given the same reference numerals of Figure 4, except that another stepper motor 158 is mounted to a transverse armature 181 extending between the support legs 175, 179 of the mounting bracket 177, c In order to drive the ball and screw mechanism 200, 202. In the presently preferred embodiment, each of the arrows 153 and 161 is rotatably supported by a bearing 165 at either end. As illustrated schematically in Figure 1 and discussed in more detail below, the upper and lower unloader bars 172, 174 move toward each other toward a
P111 / 97MX fold position, where they are brought into contact with each other to provide a surface against which the pusher bar unit 18 can be moved to bend the sheet material 29 and / or the sheet material 31. After has completed a bending operation, the upper and lower unloading bars 172, 174 move to a unloading position, spaced apart to allow the folding of the article 20 or of the cellular unit of the article 22, which has just been formed, move away.
Pre-marker bar In relation to Figures 6 and 7, the apparatus 10 is shown in a configuration to form articles 20 folded in accordion form. As described in more detail below, the main differences in operation of the apparatus 10, when an article 20 is formed compared to cellular articles 22a or 22b, is that the adhesive applicator unit 14 and the welding devices 166, 168 are not they need, and only a sheet material 29 or 31 is employed. Additionally, an air tube 330 used to form cellular articles 22a, b, is not in operation. Instead, the apparatus 10 is provided with a pre-marker bar 350, placed between the unit
P1114 / 97MX pusher bar 16 and the unloading bar unit 18, which is effective to form an "arch or buckling" in the sheet material 29 or 31 in advance of the bending operation. As best seen in Figure 7, the pre-marker bar 350 is mounted to the frame 46 by a pair of ball and screw mechanisms 352, 354 of the same type as the units 180, 182, shown in the Figure 4, and which are described above in connection with a discussion of the unloading bar unit 18. Therefore, the same reference numerals of Figure 7 are used to illustrate a structure identical to that shown in Figure 4. The ball and screw mechanisms 352, 354, in response to the operation of the stepper motor 158, are effective to move the pre-marker bar 350 upwardly from a position below the sheet materials 29 or 31 , towards a contact position, wherein an arc or buckling is formed in that position of the sheet material 29 or 31, between the pusher bar unit 16 and the unloading bar unit 18. This aids the pusher bar unit 16 to form a fold at length of the article 20 folded into an accordion, as described in more detail below, and may also be used to vary the heights of these folds. Preferably, each of the mechanisms of
P1114 / 97MX ball and screw 352, 354 are mounted to a track or the like (not shown) to allow adjustment of the longitudinal position of the pre-marker bar 350, along the frame 46 and between the pusher bar unit 16 and the marking bar unit 18 depending on the height of the folds to be formed in the finished article 20 folded into an accordion.
Method for forming cellular articles In relation initially to Figures 1-5, 9-12 and 14, the operation of apparatus 10 to form cellular devices 22 is described below. As already mentioned, the apparatus 10 can also be used to form folded accordion or zigzag shaped articles 20 of the type shown in Figures 13 and 14, and an explanation of that operation is given below. The formation of the cellular articles 22 requires the presence of two sheet materials 29 and 31. The sheet feeding mechanisms 12 work as described above to supply the sheet materials 29, 31, one on top of the other, on the frame 46 of the apparatus 10. The details of the sheet feeding and overfeeding device do not form part of this invention and, therefore, will not be specifically described here. However, it must be understood that the
P1114 / 97MX tension rods 42, 50 and other tensioning devices are employed, as well as other sheet feeding controls, to ensure that the sheet materials 29, 31 are supplied to the pusher bar unit 16 at the proper speed and tension. Additionally, although not described in detail here, the frame 46 is provided with heating elements (not shown) upstream of the pusher bar unit 16, to raise the temperature of the sheet materials 29, 31 to a sufficient level of so that they remain "fixed", that is to say they maintain their bent position, when the folding operation is finished. It is contemplated that most of the sheet materials 29, 31 that are worked in the apparatus 10 will include at least certain thermoplastic materials, either in the form of coating or contained within the sheet material, so that the fold lines that are made in them are essentially permanent. These heating elements 47 do not form part of the invention by themselves and, therefore, are not discussed in greater detail. These heating elements are commercially obtained and are commonly used in a variety of pleat forming devices. An important aspect of the method of operation of the apparatus 10 is its ability to form cellular articles
P1114 / 97MX 22a and 22b in different sizes and in different shapes and contours, as desired. Before describing the specific operational steps involved in the formation of Article 22a or 22b, it is useful to consider the completed construction of each one. Initially in relation to Figures 6 and 7, the cell article 22a is illustrated by including a number of diamond-shaped, interconnected, diamond-shaped cell units 226 of the same size and shape. Each cell unit 226 has a first side 228 that receives a bead of adhesive 84, a second side 230 to which a bead of adhesive 86 is applied, and a third and fourth sides 232, 234 that do not receive adhesive. The first and third sides 228, 232 are separated by a fold line 236, while the second and fourth sides 230, 234 are separated by a fold line 238. The overall height or dimension of each cell unit 226 or the dimension " Peak to peak "is constant and is defined by the distance between the fold lines 236, 238. This forms an outward facing surface 227 of the cellular article 22a that has a flat appearance. Referring to Figures 10 and 12, the cell article 22b differs from the article 22a by incorporating first one-dimensional cell units 240 and second cell units 242 of a different dimension. Each first cell unit 240 includes first and second sides
P1114 / 97MX 244, 246 carrying the adhesive beads 84, 86, respectively, and third and fourth sides 248, 250 without adhesive. A fold line 252 separates the sides 244, 248, while a fold line 254 separates the sides 246, 250. The second cell units 242 have the same diamond shape as the cell units 240 but have a peak-to-peak dimension or smaller height between fold lines 256, 258, which separate sides 260, 266 and sides 262, 264, respectively. While the cell article 22b is shown with two cell units 240 and 242, placed in the pattern illustrated in Figures 9 and 10, it will be appreciated that essentially any combination of heights of cell and pattern units can be obtained with the apparatus 10 within predetermined dimensional ranges. It is evident from the study of the cell units 240 and 242 within the cell article 22b of Figures 11 and 12, that the formation thereof depends on the proper location of the adhesive beads 84, 86, the welding lines 170 and the fold lines 252, 254 256 and 258, in relation to each other along the length of the sheet materials 29 and 31. The fold lines 252, 254 must be centered between adjacent welding lines 170 within the units 240 cells, and these 170 welding lines must be sufficiently
P1114 / 97 X to obtain the desired height or peak-to-peak dimension of the cell unit 240. In addition, the adhesive beads 84, 86 should be placed along the sheet materials 29, 31 so that they are located on the suitable sides 244, 246, respectively of the cell unit 240 and equidistantly of an adjacent welding line 170. The same control of the placement of the adhesive beads 84, 86, the welding lines 170 and the fold lines 256 , 258 is required to form the cell unit 242, except that the location thereof is different from that which appears in the cell unit 240. The system controller 38 operates to control the adhesive applicator unit 14, the welding devices 166 , 168 and the pusher bar unit 16 at suitable intervals, based on the speed of movement of the blades 29, 31 along the frame 46, and the arrangement of the desired 240, 242 cell units to obtain a Cellular item 22b, having an outer surface 260 with the desired contour or pattern. As described in greater detail below, the adhesive beads 84, 86 are applied at desired locations along the sheets 29 and 31 by synchronized operations of the adhesive dispensers 80, 81 and the adhesive dispenser 92.
P1114 / 97 X welding devices 166, 168, also in turn are synchronized by the system controller 38 to form welding lines 170 adjacent to the adhesive beads 84, 86. Additionally, the position of the fold lines 252 , 254, 256 and 258 is obtained by controlling the linear actuators 134, 136, so that the pusher bar unit 16 is positioned at the proper distance from the unloading bar unit 18 at the start of a bending operation. The manner in which the system controller 38 operates to obtain the cellular articles 22a and 22b of a desired configuration depends on the particular application. The operator has the option of programming the system controller 32 using a manual keyboard interface (not shown) in order to specify the particular size and sequence of the cellular units within a cell article such as items 22a, 22b. Essentially any sequence of different cell units having a size within the predetermined range and which is limited by the degree of movement of the linear actuators 134, 136, associated with the pusher bar unit 16 can be obtained. Alternatively, the apparatus 10 is provided. with a sensor 261, connected to the controller 38 that functions to produce a signal when a mark or signal 263
P1U4 / 97MX applied to the upper sheet material 29 moves further. This mark or index 263 may be a special mark placed on the sheet material 29 or a portion of a pattern present on the upper sheet material 29. The sensor 261 is located sufficiently upstream from the adhesive applicator 14, the welding devices 166, 168 and the pusher bar unit 16, so that the controller 38 can operate to operate the adhesive dispensers 80, 81 and 89, as well as the welding devices 166, 168, at suitable intervals . In addition, the controller 38 operates the pusher bar 16 in response to that signal, so that the fold lines 252, 254, 256 and / or 258 can be formed along the sheet materials 29, 31 at the required location, depending on where the marks or indicia 263 are detected by the sensor 261. When the foregoing is kept in mind, the individual operations of: (1) applying adhesive beads 84, 86; (2) forming welding lines 170 and, (3) obtaining bends 252, 254, 256 and 258, are described below separately. The sheet materials 29, 31 are advanced to the adhesive applicator 14 where their exposed surfaces receive beads of adhesive 84, 86, respectively. As noted earlier, dispatchers
P1114 / 97 X of top adhesive 80, 81 are moved by the first and second ball and screw mechanism 62, 64 towards and away from each other, in a position immediately above the exposed surface of the sheet material 29. These dispensers of 80,81 adhesive function to apply the bead of adhesive 84 on the sheet material 29, in both directions of movement thereof, while moving each other towards the middle of the mounting bracket 54 and when they move away from each other to mounting legs 56, 58 of the bracket. Similarly, the adhesive dispensers 89 carried by the third and fourth ball and screw mechanism 88 of the adhesive applicator 14, positioned below the bottom sheet material 31, apply the bead of adhesive 86 to the bottom sheet material 31 in direct alignment with the adhesive bead 84. The next step in the operation of the apparatus 10 to form cellular articles 22a or 22b is to interconnect the sheet material 29, 31 at separate locations along the same. The controller 38 functions to form longitudinally spaced welding lines 170, at locations along the sheet materials 29, 31, depending on the points at which the adhesive beads 84, 86 are applied thereto. As illustrated in Figures 9-12, welding lines 170 are formed of
P1114 / 97MX preferably along the length of the sheet materials 29, 31 with a predetermined space "S" from each of the adhesive beads 84 and 86, in the two cellular articles 22a and 22b. The welding lines 170 are formed by operating the welding devices 166, 168 carried by the upper clamping member 98 of the pusher bar unit 16. As already discussed, the ball and screw mechanisms 162, 164 operate by the controller 38 for moving the welding devices 166, 168 towards each other, towards the center of the upper clamping member 98, and then away from each other towards the opposite ends. The welding devices 166, 168 function to heat and essentially melt the thermoplastic material within the sheet materials 29, 31, so that they are joined together along each welding line 170. Like the welding devices 166, 168 are carried by the upper clamping member 98 of the pusher bar unit 16, this welding operation is carried out with the upper and lower clamping members 98, 100 in a clamping position, ie in engagement with the sheet materials 29, 31 placed between them. It is contemplated that the welding operation may be carried out at the same time as the application of adhesive beads 84, 86 to the sheet materials 29, 31, or subsequent to the operation ofP1114 / 97 X Adhesive application, depending on the desired separation between the welding line 170 and the adhesive beads 84, 86 for a given cell unit 226. Once the sheet materials 29, 31 have been secured along welding lines 170 to the desired distance from the adhesive beads 84, 86, the folding operation can proceed. As already mentioned, the fold lines 236, 238 in the cellular units 226 of article 22a must be centered between the adjacent welding lines 170. Similarly, the fold lines 252, 254 of the cell units 240, as well as the lines of fold 256, 258 of the cell units 242 should also be centered between their adjacent welding lines 170, in order to properly form the article 22b. An important advantage of this invention is that the position of the fold lines within the cellular articles 22a, 22b, or any other cellular article, can be varied in practically any desired sequence during the operation of the apparatus 10. The location of each line of fold 236, 238, 252, 254, 256 and 258 is determined by the distance in which the upper and lower fastener members 98, 100 of the pusher bar unit 16 move relative to the unloading bar unit 18, in advance of the fold operation. This distance or separation between the fastener members
P1114 / 97 X upper and lower 98, 100 and the unloading bar unit 18 determines which position or length of the sheet materials 29, 31 is advanced against the upper and lower unloading bars 172, 174 to form the fold lines within of articles 22a and 22b. The precise control of the position of the upper and lower fastener members 98, 100 relative to the unloading bar 18 is obtained by operation of the linear actuators 134, 136, in the manner described in greater detail above. For example, in order to form the cellular article 22a illustrated in Figures 9 and 10, the system controller 38 operates the linear actuators 134, 136 so that the upper and lower fastener members 98, 100 move as a unit with the mounting bracket 120, towards a clamping position or "contact" in relation to the sheet materials 29, 31. This clamping position is spaced a sufficient distance from the unloading bar unit 18, so that the fold lines 236 and 238 can be formed in half between the adjacent fold lines 170 of one of the cell units 226 that forms the article 22a. Once properly located in that fastening position, the controller 38 operates to drive the pneumatic cylinders 128, 130 of the pusher bar unit 16 that
P1114 / 97MX moves the upper fastener member 98 downward to crush or grasp the sheet materials 29, 31 between the upper and lower fastener members 98, 100. At the same time or at about the same time, the controller 38 functions to cause the upper and lower unloader bars 172, 174 move towards the fold position, i.e. toward each other and in contact with each other, to provide a flat surface against which that portion of the sheet materials 29, 31 between the fastening members 98 , 100 and the unloading bars 172, 174 can be bent. The linear actuators 134, 136 are then activated to move the fastener members 98, 100 and the sheet materials 29, 31 toward contact with the unloading bars 172, 174 to form fold lines 236, 238. As schematically illustrated in FIG. Figure 2, an air tube 330 is mounted in the frame 46, in position between the pusher bar unit 16 and the unloading bar unit 18, to introduce an air stream in a direction transverse to the movement of the sheet materials 29 , 31 along the frame 46. This air flow helps separate the sheet materials 29, 31 from each other during the movement of the fastener members 98, 100 toward the unloading bars 172, 174, to facilitate the formation of the lines fold 236, 238 in it.
P1114 / 97MX After a cell unit 226 has been formed in this manner, the upper and lower unloading bars 172, 174 move away from each other allowing the newly formed cell unit 226 to move further. Preferably, the spring mechanisms (not shown) are provided for the unloader bars 172 and 174 in order to push them in a direction towards the fastening members 98, 100, so that the unloader bars 172, 174 can "dislodge" or move. upstream from the cell unit 226 that has just been formed. The unloading bars 172, 174 are then returned to the bending position, in contact with each other, in preparation for another bending operation. The bending operation continues, as already described, to form a series of adjacent, interconnected cell units 226 of article 22a. As all cell units 226 have the same dimension, the fastener members 98, 100 are returned to the same fastening position at the start of each successive bending operation. The formation of the cellular article 22b proceeds in an identical manner as described above, except that the gripping or contacting positions to which the fastening members 98, 100 come into contact with the sheet materials 29, 31 change depending on whether or not form a cell unit 240 or cell unit 242. How are you
P1114 / 97MX cell units 240, 242 have different dimensions, the clamping members 98, 100 move further away from the unloading bars 172, 174 at the start of a bending operation to form cell units 240, as compared to the clamping position which is required to properly position the fold lines 256 and 258 for the cell units 242. Regardless of the height or size of the cell unit to be formed, the controller 38 operates to activate the linear actuators 134, 136 and locate in Precisely form the fastener members 98, 100 in any contact or fastening position to initiate a bending operation. Accordingly, an article 20c such as that illustrated in Figure 14 can be formed with a contoured outer surface 370, which can vary widely, as desired. Figures 9 and 11 illustrate the cellular articles 22a, 22b, respectively, in the form in which they appear immediately downstream of the unloading bar unit 18. The cellular article 22a includes a series of interconnected and adjacent cellular units 226, defined by adjacent welding lines 170, each having sides 228-234 with the adhesive beads 84 and 86 applied to the first and second side 228 and 230, respectively. The cellular article 22b includes a
P1114 / 97MX alternating pattern of interconnected cell units 240, cell units 242 and then additional cell units 240. An important use of cell article 22a and 22b is the formation of window blinds and similar window treatments. This application requires an expandable and collapsible product where the strings and cords 300 (shown in dotted line) can be used to raise or lower the cellular articles 22a or 22b with respect to the window. In order to improve the aesthetics of these window treatments, it is desired to conceal the laces 300 from view when viewing the outward facing surface 227 of article 22a, or the outward facing surface 260 of article 22b. This is adjusted in the present invention by forming upper and lower cavities 304, 306 between the adjacent cell units 226 illustrated in Figures 10 and 7, and upper and lower cavities 308, 310 in the cell article 22b, between the adjacent cell units 240. , 242. See Figure 9. With reference to Figures 6 and 7, each cavity 304 comprises an open and elongated channel formed between each of the adhesive beads 84 and the welding line 170. The lower cavities 306 are formed immediately by below the upper cavities 304 and
P1114 / 97MX extend from the adhesive bead 86 towards the welding line 170. Each upper cavity 304 is formed by pushing the first side 228 of a cell unit 226 against the third side 232 of an adjacent cell unit 236b, so that the adhesive bead 84 carried on the first side 228 forms a link therebetween. Similarly, each lower cavity 306 is formed immediately below an upper cavity 304, causing the second side 230 of the cell unit 226 to come into contact with the fourth side 234 of the adjacent cell unit 226. These cavities 304, 306 are formed along the entire length of the cellular article 22a, between the adjacent cellular units 226, so that one or more cords 300 may extend along the length of the cellular article 22a. The same training step as mentioned is used to form the upper and lower cavities 308, 310 of the cellular article 22b. When adjacent cell units 240 of article 22b are interconnected, sides 244, 246 of a cell unit 240 carrying beads of adhesive 84, 86 come into contact with sides 248, 250 of an adjacent cell unit 240. A cell unit 240 is connected to an adjacent unit 242 to form upper and lower cavities 308, 310 by engaging the sides 244, 246 of the cell unit 240 with the sides 264 and
P1114 / 97MX 266 of the cell unit 242. The smaller cell units 242 are connected to each other to form cavities 30 ^, 310 by pushing the sides 260, 262 of a cell unit 242 carrying adhesive beads 84, 86, into contact with the sides 264 and 266 of an adjacent cell unit 242. These same sides 260, 262 of a smaller cell unit 242 contact the sides 248 and 250 and are linked to the corresponding ones of a larger adjacent cell unit 240. , to form the cavities 308, 310 between them. It is contemplated that the two cellular units 22a and 22b could be formed with cavities 304, 306 and 308, 310 as described above, deferring the units 22a, 22b between a forming bar 312 that is illustrated schematically in Figure 2, and the unloading bar 172, 174 or by any other suitable compression member. In addition to concealing the cords 300, the cavities 304, 306 of article 22a and the cavities 308, 310 of article 22b provide strength and rigidity to the cell units 226, 240 and 242, and the resulting cell articles 22a, 22b. the welding lines 170 formed by the welding devices 166, 168 may not provide sufficient structural integrity within the cellular articles 22a or 22b, particularly when used in a treatment for
P1U4 / 97MX windows and typically expand and collapse, when the window treatment article is moved up and down. The adhesive beads 84 and 86 make this potential limitation and ensure that the cellular articles 22a and 22b do not separate or fall out of the window treatment article or other application. Referring to Figure 8, the portion of the apparatus 10 downstream of the unloading bar unit is illustrated schematically. This is where the cellular articles 22a or 22b move together and are cured to form the cavities 304, 306 and 308, 310 that were already described. In the presently preferred embodiments, a band 400 formed of stainless steel mesh or similar material, is mounted at either end to the rods 402, 404 in position to contact the uppermost edges or fold lines 236 of the article. 22a and the fold lines 252, 256 of the cellular article 22b placed in the upper part of the frame 46. The weight of the band 400 against the articles 22a, 22b is sufficient to prevent the adjacent cellular units 226, 240 and 242 from separate, and also increase the friction coupling between the cellular units 226, 240 and 242 and the frame 46. In order to help "crush" or push the
P1114 / 97MX adjacent cell units 226 or 240, 242 together, a retainer bar 406 is initially placed in the upper part of the frame 46 against the first formed cell unit 240, 242 (or 226). The retainer bar 406 is connected by a cable 408, directed on pulleys 410, 412 mounted to the frame 46, to a counterweight 414. The purpose of the retainer bar 406 is to exert a force against the placed cellular units 240, 242 (or 226). in downstream of the discharge bar unit 18 to push them together, so that the adhesive beads 84, 86 of a cell unit 240, 242 contact the exposed sides of an adjacent cell unit 240, 242. The weight of the counterweight 414 may vary, depending on the size of the cell units being formed, in order to exert the desired amount of force upstream against the "stack" or group of cellular units that are being formed. The cell unit stack 226 and retainer bar 406 proceeds to an oven 416 of the type commercially obtained from R & K Machine Corp. of Sarasota, Florida. The furnace 416 is effective to heat the beads of hot melt adhesive 84, 86 to a temperature sufficient to form a bond between adjacent cell units 240, 242 (or 226) thereby forming the cavities 308, 310. The cavities 304, 306 of the article 22a cell
P1U4 / 97MX form in the same way. Once the retainer bar 406 reaches the end of the oven 416, it falls into a recess 418 within the frame 46 and extends substantially flush with the upper surface of the frame 46. By this time, a sufficient number of units cell 240, 242 (or 226) have already formed downstream of the unload bar unit 18, so that a force is exerted in a downstream direction against all cell units 240, 242 (or 226) above of the frame 46. In other words, the complete number and frictional engagement of the stack of cell units 240, 242 above the frame 46, with the help of the weight of the band 400, are sufficient to cause the adjacent cell units 226 contact each other as soon as they form and move past the unloading bar unit 18. As a result, the finished cellular articles 22a and 22b shown in Figures 10 and 12 are in the oven 416 and discharged from the end of the frame 46.
Method for Shaping Accordion Folded Articles The accordion or zig-zag folded articles 20 and 20a illustrated in Figures 13 and 14 are formed in essentially the same manner as described above in
P1114 / 97MX relates to the cellular articles 22a and 22b, except that the adhesive beads 84, 86 and the welding lines 170 are removed. In addition, only one sheet material 29 or 31 is required and, preferably, the pre-marker bar 350 is used to assist in the bending operation. As already mentioned, the pre-marking bar 350 is positioned between the pusher bar 16 and the unloading bar unit 18 and is effective to move upwards in contact with a sheet material 29 or 31, in advance of the movement of the upper and lower fastener members 98, 100, in contact with the unloading bars 172, 174, so that a pre-bend or "arch" is formed in the sheet material 29 or 31, before the fold line is formed. The operation of the apparatus 10 in other directions is similar, including the movement of the upper and lower fastener members 98, 100 of the pusher bar unit 16 and the movement of the unloading bars 172, 174 of the unloading bar unit 18. As illustrated schematically in Figures 13 and 14, the resulting accordion or zig-zag folded article 20 is formed with a series of adjacent pleats 316, 318, or a variety of different folds as in article 20a having the same or a different variety of heights in virtually any predetermined sequence. This sequence is either programmed in
P1114 / 97MX the system controller 38, or is determined by marks or indicia 263 as described above, so that the controller 38 operates the linear actuators 134, 136 to locate the upper and lower clamping members. 100 of the pusher bar unit 16 in the desired contact or fastening position at the start of each successive bending operation. Accordingly, an accordion-bent article 20 or 20a can be produced with an outwardly facing surface 320 or 370 having essentially any type of outer contour, or a flat outer surface, as desired. It is also contemplated that an article 20, 20a be bent into accordion or the like, the heights of the folds varying by using only the pre-marker bar 350, or in combination with the pusher bar unit 16. As the pre-marker bar 350 can move in response to the operation of the ball and screw mechanisms 352, 354, its vertical position with respect to a sheet material 29 or 31 that moves above them, can vary as desired. With the upper and lower unloader bars 172, 174 in contact with each other, thereby holding and grasping a sheet material 29 or 31 therebetween, the upper and lower clip members 98, 100 of the bar unit
P1114 / 97MX pusher 16 separated from each other, move the pre-marker bar 150 vertically upward causing an "arch" that is formed in the sheet material 29 or 31 and that pulls or pulls out a larger section of sheet material 29 or 31 between the pusher bar unit 16 and the unloading bar unit 18, which would be present if the sheet material 29 or 31 were in planar form therebetween. In other words, a portion of the sheet material 29 or 31 is pulled or pulled sufficiently downstream towards the unloading bar unit 18 due to the arc formed by the pre-marking bar 350. The portion or length of the sheet material 29 or 31 extracted downstream is variable, depending on the degree of vertical movement of the pre-marker bar 350, as dictated by the ball and screw mechanisms 352, 354. Consequently, when the pusher bar unit 16 is subsequently operated to hold the sheet material 29 or 31 and move it into contact with the pusher bar unit 18, different heights of fold sizes can be formed depending on the degree of vertical movement of the pre-marker bar 350 and, therefore, the length or amount of sheet material 29 or 31 that is pulled or extracted downstream by the pre-marker bar 350. It is further contemplated that the above described method of varying the height of the folds within e an article
P1114 / 97MX accordion folding, adjusting the vertical movement of the pre-marker bar 350, could be done independently or in combination with the variable movement of the pusher bar unit 16. That is, variable heights of the fold can be obtained by varying the degree of vertical movement of the pre-marking bar 350, while moving successively to the pushing bar unit 16 to the same holding position relative to the unloading bar unit 18, or alternatively, varying both the position of the pre-marking bar 350 as the contact position of the pusher bar unit 16, along the sheet material 29 or 31, as described above. In any case, an accordion-folded article having variable fold heights is produced. While the invention has been described in relation to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and different equivalent elements thereof may be substituted, without departing from its spirit and scope. In addition, many modifications may be made to suit a particular situation or material, without thereby departing from the essential scope of the teachings of this invention. For example, the pusher bar unit 16 illustrated in the Figures is shown with the members
P1114 / 97MX upper and lower fasteners 98, 100. However, it is contemplated that a fastening member 98 or 100 could be removed, so that a single fastening member or a single plate would be used to advance one or both of the sheet materials 29, 31 towards coupling with the unloading bars 172, 174, if desired. Additionally, the unloader bar unit 18 could also be formed with a single upper or lower unloader bar 172, 174, without departing from the scope of the invention. Furthermore, while the two unloading bars 172, 174 with movement capability in a vertical direction have been described, it is contemplated that the lower unloading bar 174, for example, could be held in a fixed position while only the upper unloading bar 172 is it would move vertically with respect to this one. It is also contemplated that the adhesive beads 84 and 86 applied by the adhesive applicator unit 14 could be continuous or discontinuous across the width of the sheet materials 29, 31, as desired, as long as the resulting articles 22a and 22b retain their structural integrity. Also, while the welding devices 166, 168 are shown in the Figures mounted to the pusher bar unit 16, it is contemplated that they could be mounted on a structure
P1114 / 97MX separated and / or in the adhesive applicator unit 14, as desired. It is also considered within the scope of the invention to employ the apparatus 10 only as a bending device for cellular articles, without the operation of the adhesive applicator unit 14 or of the welding devices 166, 168. It is contemplated that the materials of Sheet 29 and 31 could be interconnected along the welding lines 170 and provided with adhesive beads 84, 86, in a separate piece of equipment and then collected in rolls. These rolls would then be mounted to the feeder mechanism 12 of the apparatus 10, and the folds would be formed by the operation of the sensor 261 which picks up a mark or mark on the sheet materials 29 or 31, such as the adhesive bead 84, so that the controller 38 would operate as a pusher bar unit 16 consistently, in the manner already described. Therefore, it is understood that the invention is not limited to the particular mode disclosed as the best way contemplated to carry out the invention, but that the invention will include all the modalities that fall within the scope of the appended claims.
P1114 / 97MX
Claims (100)
- NOVELTY OF THE INVENTION Having described the present invention, it is considered as a novelty and, therefore, what is claimed as property is contained in the following CLAIMSt 1. An apparatus for forming an expandable and collapsible product, from a sheet material , comprising: a frame along which the sheet material can move; a unloader bar that can move relative to the frame between a fold position proximate the frame, and a separate unloading position of the frame; a pusher bar moving towards and away from the unloading bar, the pusher bar is effective to contact the sheet material in a contact position separate from the unloading bar and to move a portion of the sheet material in a direction towards the unloading bar, so that the sheet material comes into contact with the unloading bar in that fold position; a drive mechanism, associated with the pusher bar, which includes at least one drive member that is adjusted to selectively vary the location of the contact position, wherein the bar P1114 / 97MX 'pusher is contacted with the sheet material so that a variety of different lengths of sheet material can be moved into contact with the unloading bar.
- 2. The apparatus according to claim 1, wherein the driving member is a linear actuator. The apparatus according to claim 2, further including a programmable controller that is effective to control the operation of the linear actuator, so that the location of the contact position can be varied as desired. The apparatus according to claim 2, wherein the linear actuator is a ball and screw mechanism. The apparatus according to claim 1, further including a second driving mechanism, associated with the unloading bar, including at least one driving member operating to vary the unloading position of the unloading bar relative to the frame. The apparatus according to claim 5, wherein the driving member of the second driving mechanism operates to vary the bending position of the unloading bar relative to the frame. The apparatus according to claim 5, wherein the second drive includes at least one P1114 / 97MX linear actuator that works to move the unloading bar in a direction practically perpendicular to the direction of movement of the sheet material, along the frame. The apparatus according to claim 7, wherein the linear actuator is a ball and screw mechanism. 9. The apparatus according to claim 1, further including a pre-marker bar positioned between the pusher bar and the unloading bar, the pre-marker bar is effective to contact the sheet material and move it in a generally perpendicular direction. to the movement of the sheet material along the frame, during the movement of the pusher bar towards the unloading bar. 10. An apparatus for forming an expandable and collapsible product from sheet material, comprising: a frame along which the sheet material can move; a unloader bar that can be moved relative to the frame between a folding position proximate the frame and a separate unloading position of the frame; a pusher bar that can move towards and P1114 / 97MX away from the unloading bar, the pusher bar has a upper clamping member and a lower clamping member, at least one of which can move relative to the other in a direction practically perpendicular to the direction of movement of the sheet material along the frame, the upper and lower clamping members are effective for holding the sheet therebetween in a separate clamping position of the unloading bar and for moving a portion of the sheet material in a direction towards the unloading bar, so that the sheet material comes into contact with the unloading bar in the fold position; a drive mechanism, associated with the pusher bar, which includes at least one drive member that is adjustable to selectively vary the location of the fastening position, wherein the upper and lower fastening members are brought into contact with the fastener material so that a variety of different sections of sheet material can be moved into contact with the unloading bar. The apparatus according to claim 10, wherein the pusher bar includes a mounting bracket that extends between the upper and lower fastening members, the mounting bracket supports the upper fastening member in a position vertically above the P1114 / 97MX lower support member. The apparatus according to claim 11, wherein the mounting bracket carries at least one linear actuator which is effective to move the upper fastening member towards and away from the lower fastening member. The apparatus according to claim 12, wherein the at least one linear actuator is a pneumatic cylinder. The apparatus according to claim 10, wherein two rolls of sheet material, one above the other, move along the frame, at least one of the upper and lower fastening members of the pusher bar mounts a device accessory for interconnecting the two rolls of sheet material at selected locations along the length thereof. 15. The apparatus according to claim 14, wherein the accessory device is an ultrasonic welding device. The apparatus according to claim 14, further including a ball and screw mechanism that operates to move the accessory device along the upper fastener means in a direction generally perpendicular to the direction of movement of the fastener material. P1114 / 97MX blade along the frame. 17. The apparatus according to claim 10, wherein the driving member is a linear actuator. The apparatus according to claim 17, further including a programmable controller that is effective to control the operation of the linear actuator, so that the location of the clamping position can be varied as desired. 19. The apparatus according to claim 17, wherein the linear actuator is a ball and screw mechanism. The apparatus according to claim 10, wherein the unloading bar is formed with an upper unloading member and a lower unloading member, at least one of the upper and lower unloading members can move relative to each other, between the unfolded position and the discharge position. The apparatus according to claim 20, wherein a linear actuator for moving at least one of the upper and lower clamping members relative to the other, in a direction essentially perpendicular to the direction of movement of the sheet material along the frame. 22. The apparatus according to claim 21, wherein the unloading bar includes a mounting bracket P1114 / 97MX extending between the upper and lower unloading members, the mounting bracket supports the upper unloading member in a position vertically above the lower unloading member. 23. The apparatus according to claim 22, wherein the mounting bracket carries at least one linear actuator that is effective to move at least one of the upper and lower discharging members towards and away from the other. 24. The apparatus according to claim 23, wherein the linear actuator is a ball and screw mechanism. 25. The apparatus according to claim 10, further including a pre-marker bar positioned between the pusher bar and the unloading bar, the pre-marker bar is effective to contact the sheet material and move it in a generally perpendicular direction. to the movement of the sheet material along the frame, during the movement of the pusher bar towards the unloading bar. 26. An apparatus for forming an expandable and collapsible product, from a sheet material, comprising: a frame along which the sheet material can move; P1114 / 97MX a unloading bar that includes a upper discharge member and a lower discharge member, at least one of the upper and lower unloading members may move in a direction substantially perpendicular to the direction of movement of the sheet material, along the frame, between a fold position in which the upper and lower unloading members are close together, and a unloading position in which the upper and lower unloading members are separated from each other; a pusher bar that can move towards and away from the unloading bar, the pusher bar is effective to contact the sheet material in a contact position separate from the unloading bar and to move a portion of the sheet material in a direction towards the unloading bar, so that the sheet material contacts the unloading bar in the fold position; a drive mechanism, associated with the pusher bar, which includes at least one drive member that is adjustable to selectively vary the location of the contact position in which the pusher bar comes into contact with the sheet material, so that a variety of different lengths of sheet material can move towards contact with the bar P1114 / 97MX unloader. 27. The apparatus according to claim 26, wherein the driving member is a linear actuator. The apparatus according to claim 27, further including a programmable controller that is effective to control the operation of the linear actuator, so that the location of the contact position can be varied as desired. The apparatus according to claim 26, which includes a second drive mechanism, associated with the unloading bar, which includes at least one drive member that operates to move at least one of the upper and lower unloader members, so as to vary selectively the bending position and the unloading position. 30. The apparatus according to claim 26, wherein the unloading bar includes a mounting bracket that extends between the upper and lower unloading members, the mounting bracket supports the upper unloading member in a position vertically above the lower unloading member. The apparatus according to claim 30, wherein the mounting bracket carries at least one linear actuator that is effective to move at least one of the upper and lower discharging members towards and in P1114 / 97MX away from the other. 32. The apparatus according to claim 31, wherein the linear actuator is a ball and screw mechanism. 33. The apparatus according to claim 26, further including a pre-marker bar positioned between the pusher bar and the unloading bar, the pre-marker bar is effective to contact the sheet material and move it in a generally perpendicular direction. to the movement of the sheet material along the frame, during the movement of the pusher bar towards the unloading bar. 34. Apparatus for forming an expandable and collapsible cellular product from two rolls of sheet material, comprising: a frame along which the two sheet materials can move one above the other; a unloading bar that can be moved relative to the frame between a folding position proximate the frame and a separate unloading position of the frame; a pusher bar that can move towards and away from the unloading bar, the pusher bar is effective to contact the two sheet materials in a separate contact position of the unloading bar and to move a portion of the two materials P1114 / 97MX in a direction towards the unloading bar, so that the two sheet materials contact the unloading bar in the bending position; a first accessory device that functions to interconnect the two sheet materials at separate locations along the same, in the direction of movement of the two sheet materials along the frame; a second accessory device that is effective to apply a bead of adhesive to each of the two sheet materials at locations close to each point of interconnection between the rolls. 35. The apparatus according to claim 34, wherein the first attachment device is at least one ultrasonic welding device. 36. The apparatus according to claim 35, wherein the first attachment device is mounted to the pusher bar, the first attachment device further includes a ball and ring mechanism that functions to move the ultrasonic welding device along the Pusher bar in a direction generally perpendicular to the direction of movement of the two sheet materials along the frame. 37. The apparatus according to claim 34, wherein the second accessory device comprises at least r :: i4 / 97MX minus a pair of first and second adhesive dispensers, the at least first adhesive dispensing device functions to apply a first bead of adhesive through one of the two sheet materials in a direction transverse to the movement of them, along the frame; and the at least one second adhesive dispenser is effective to apply a second bead of adhesive to the other of the sheet materials, in a manner opposite to the first bead of adhesive. 38. The apparatus according to claim 34, further including a blower device positioned between the pusher bar and the unloading bar, the blower device operates to direct a stream of air between the two sheet materials during the movement of the pusher bar towards the unloading bar in order to separate the two sheet materials in preparation for bending. 39. The apparatus according to claim 34, further including a drive mechanism, associated with the pusher bar and including at least one drive member that is adjustable to selectively vary the location of the fastening position in which the pusher bar is it contacts the two sheet materials, so that a variety of different sections of the two sheet materials can move towards contact with the bar F1114 / 97MX unloader. 40. The apparatus according to claim 39, wherein the driving member is a linear actuator. 41. The apparatus according to claim 40, further including a programmable controller that is effective to control the operation of the linear actuator, so that the location of the clamping position can be varied as desired. 42. The apparatus according to claim 40, wherein the linear actuator is a ball and screw mechanism. 43. The apparatus according to claim 34, wherein the pusher bar includes a mounting bracket that extends between an upper fastening member and a lower member, the mounting bracket supports the upper fastening member in a position vertically above the fastening member lower. 44. The apparatus according to claim 43, wherein the mounting bracket carries at least one linear actuator that is effective to move the upper fastening member toward and away from the lower fastening member. 45. The apparatus according to claim 34, wherein the unloading bar is formed with an upper unloading member and an upper unloading member, for P1114 / 97MX at least one of the upper and lower discharging members may move relative to each other between the bending position and the unloading position. 46. The apparatus according to claim 45, further including a linear actuator for moving at least one of the upper and lower discharging members relative to the other in a direction substantially perpendicular to the direction of movement of the sheet material along the frame. 47. The apparatus according to claim 46, wherein the unloading bar includes a mounting bracket that extends between the upper and lower unloading members, the mounting bracket supports the upper unloaded member in a position vertically above the lower unloading member. 48. The apparatus according to claim 47, wherein the mounting bracket carries at least one linear actuator that is effective to move at least one of the upper and lower unloading members toward and away from the other. 49. The apparatus according to claim 48, wherein the linear actuator is a ball and screw mechanism. 50. An apparatus for forming an expandable and collapsible product from sheet material, which P1114 / 97MX comprises: a frame having a surface along which the sheet material can move; a unloader bar that can move relative to the frame between a fold position proximate the frame, and a separate unloading position of the frame; a pusher bar that can move towards and away from the unloading bar, the pusher bar is effective to contact the sheet material in a contact position separate from the unloading bar and to move a portion of the sheet material in a direction towards the unloading bar, so that the sheet material comes into contact with it in the folded position; a pre-marker bar placed between the pusher bar and the unloading bar in a position below the sheet material and below the surface of the frame, the pre-marker bar can move towards a coupling position in contact with the material of sheet and above the surface of the frame, thus moving a portion of the length of the sheet material in a direction towards the unloading bar; a drive mechanism, associated with the pre-marker bar, which includes at least one drive member that is adjusted to selectively vary the location of the P1114 / 97MX coupling position, where the pre-marker bar comes into contact with the sheet material so that a variety of different lengths of sheet material can be moved to a position between the pusher bar and the unloading bar, to the fold. 51. The apparatus according to claim 50, where the driving member is a linear actuator. 52. The apparatus according to claim 51, further including a programmable controller that is effective to control the operation of the linear actuator, so that the location of the coupling position can be varied as desired. 53. The apparatus according to claim 50, further including a second driving mechanism, associated with the pusher bar, including at least one driving member that functions to selectively vary the location of the contact position in which the pusher bar is puts in contact with the sheet material. 54. The method for forming an expandable and collapsible product from a roll of sheet material, comprising: (a) contacting the sheet material with a pusher bar in a first contact position placed in a first distance from a download bar; P1I14 / 97MX (b) move the pusher bar so that the sheet material between the pusher bar and the unloading bar is forced to engage with the unloading bar to form a fold in the sheet material, with a first height of fold; (c) successively moving the pusher bar towards the selected contact positions relative to the unloading bar, at least some of the selected contact positions are placed at distances, relative to the unloading bar, which are different from the first distance, and then repeat step (b) to form folds in the sheet material having different fold heights. 55. The method according to claim 54, wherein step (a) comprises moving an upper clamping member and a lower clamping member toward each other, so that the sheet material is clamped therebetween. 56. The method according to claim 55, wherein step (a) further comprises actuating at least one linear actuator connected to one of the fastener members, upper and lower, to move at least one of them towards another. 57. The method according to claim 54, wherein step (c) comprises operating at least one linear actuator connected to the pusher bar, the linear actuator. P1114 / 97MX is able to move the pusher bar to different contact positions, at variable distances in relation to the pusher bar. 58. The method for forming an expandable and collapsible cellular product from two rolls of sheet material, comprising: (a) supplying the two sheet materials, one above the other; (b) applying first beads of adhesive on the exposed surface of one of the two sheet materials at longitudinally spaced intervals along them, and applying second beads of adhesive on the exposed surface of the other of the two sheet materials, in opposite locations to the first pearls; (c) joining the two sheet materials together along connection lines close to each location, wherein the first and second beads of adhesive were applied thereto; (d) contacting the two sheet materials with a pusher bar in a contact position that is separate from a unloading bar; (e) moving the pusher bar so that the portion of the two sheet materials between the pusher bar and the unloading bar is forced to engage with the unloading bar to form a F :: I4 / 97MX cell unit; (f) successively repeating steps (d) and (e) to form a series of interconnected cell units having a first side carrying a first bead of adhesive, a second side carrying a second bead of adhesive and a third and fourth sides that do not have adhesive; (g) contacting the first and second sides of each cell unit with the third and fourth sides of an adjacent cell unit to form a cavity extending between each connecting line and each first adhesive bead, and another cavity that it extends between each connection line and each second adhesive bead. 59. The method according to claim 58, wherein step (a) includes advancing the two sheet materials in a direction toward the unloading bar. 60. The method according to claim 58, wherein step (b) comprises applying first and second beads of continuous adhesive on the two sheet materials transversely to the direction of movement of the two sheet materials, and at intervals as far as possible. length thereof which are longitudinally separated in the direction of movement of the two sheet materials. 61. The method according to claim 58, wherein step (c) comprises joining by ultrasonic welding P1I14 / 97MX the two sheet materials together, along weld line that extend in shape. transverse to the direction of movement of the two sheet materials. 62. The method according to claim 58, wherein step (c) comprises laser welding the two rolls of sheet material together along welding lines extending transversely to the direction of movement of the two sheet materials. 63. The method according to claim 58, wherein step (g) comprises, for each pair of adjacent cell units: (i) contacting the first side of a cell unit carrying the first bead of adhesive with the third side of an adjacent cell unit that does not have adhesive, so as to form a first adhesive bond therebetween which extends in a direction transverse to the movement of the two sheet materials; the first adhesive bond is separated from the connecting line between the two sheet materials, so that a first pocket is formed by the sides of adjacent cell units between the first adhesive bond and the welding line; (ii) contacting the second side of the second cell unit carrying the second bead of adhesive with the fourth side of the adjacent cell unit P1114 / 97MX without adhesive, to form a second adhesive bond between them that extend a direction transverse to the movement of the two sheet materials, the second adhesive bond is separated from the connecting line between the two sheet materials, so that a second cavity is formed by the sides of the adjacent units between the second adhesive link and the connecting line. 64. The method according to claim 58, further including the step of introducing a jet of air between the two sheet materials during the movement of the pusher bar towards the unloading bar. 65. The method according to claim 58, further comprising the steps of: (i) moving at least one of the upper unloader members and a lower unloader member, which collectively form the unloader bar, toward each other in a fold position for coupling with the pusher bar; and (ii) moving the at least one of the upper and lower members away from the other to a discharge position, to allow a formed cell unit to move beyond them. 66. The method for forming an expandable and collapsible cellular product from two rolls of P1114 / 97 X sheet materials, comprising: (a) supplying the two sheet materials, one above the other; (b) applying first beads of adhesive on the exposed surface of one of the two sheet materials at longitudinally spaced intervals along them, and applying second beads of adhesive on the exposed surface of the other of the two sheet materials, in opposite locations to the first pearls; (c) joining the two sheet materials together along connection lines close to each location, wherein the first and second beads of adhesive were applied thereto; (d) contacting the two sheet materials with a pusher bar in a first contact position located at a first distance from the unloading bar; (e) moving the pusher bar so that the sheet material between the pusher bar and the unloading bar is forced to engage with the unloading bar to form a cell unit, from the two sheet materials, having a first height; (f) successively move the pusher bar to select contact positions in relation to the P1114 / 97MX unloading bar, at least some of the selected contact positions are located at distances from the unloading bar that are different from the first distance, and then repeat step (e) to form interconnected cellular units in the two materials of sheet having different heights, each of the cell units has a first side carrying a first bead of adhesive, a second side carrying a second bead of adhesive and a third and fourth sides not wearing adhesive; (g) contacting the first and second sides of each cell unit with the third and fourth sides of an adjacent cell unit to form a cavity extending between each connecting line and each first adhesive bead, and another cavity that it extends between each connection line and each second adhesive bead. 67. The method according to claim 66, wherein step (d) comprises moving an upper fastening member and a lower fastening member, one towards the other, so that the sheet material is held therebetween. 68. The method according to claim 67, wherein step (d) further comprises actuating at least one linear actuator connected to one of the upper and lower clamping members to move them together. P1114 / 97MX 69. The method according to claim 66, further including the steps of: (i) moving at least one of an upper unloader member and a lower unloader member, which collectively form the unloader bar, toward each other in a bend position for coupling with the pusher bar; and (ii) moving said at least one of the upper and lower members away from the other, to a discharge position to allow a formed cell unit to move beyond them. 70. The method according to claim 66, wherein step (b) comprises applying first and second continuous adhesive beads on the two sheet materials transversely to the direction of movement of the two sheet materials, and at intervals as far as possible. length thereof which are longitudinally separated in the direction of movement of the two sheet materials. 71. The method according to claim 66, wherein step (c) comprises joining the two sheet materials together by ultrasonic welding along welding lines extending transverse to the direction of movement of the two materials. of sheet. 72. The method according to claim 66, wherein step (c) comprises the laser welding of the two P1114 / 97MX rolls of sheet material together along weld lines that extend transverse to the direction of movement of the two sheet materials. 73. The method according to claim 66, wherein step (g) comprises, for each pair of adjacent four-sided cell units: (i) contacting the first side of a cell unit carrying the first bead of adhesive with the third side of an adjacent cell unit that does not carry adhesive, to form a first bond of adhesive therebetween which extends in a direction transverse to the movement of the two sheet materials; the first adhesive bond is separated from the connecting line between the two sheet materials, so that a first cavity forms on the sides of the adjacent cell units between the first adhesive bond and the connecting line; (ii) contacting the second side of the second cell unit carrying the second bead of adhesive with the fourth side of the adjacent cell unit without adhesive, in order to form a second bond of adhesive therebetween which extends into a direction transverse to that of the movement of the two sheet materials, the second adhesive bond is separated from the connecting line between the two sheet materials, so that a second cavity is formed by the sides of the sheets. P1114 / 97MX adjacent cell units between the second adhesive link and the connecting line. 74. The method for forming an expandable and collapsible product from a roll of sheet material, comprising: (a) contacting a moveable sheet material with a pre-marker bar placed between a pusher bar and a unloading bar, towards a coupling position which is located at a first distance above the path of movement of the sheet material; (b) moving the pusher bar so that the sheet material between the pusher bar and the unloading bar is forced to engage with the unloading bar, to form a fold of sheet material having a first fold height; (c) successively moving the pre-marker bar to selected coupling positions, at least some of these coupling positions are located at distances, relative to the path of movement of sheet material, which are different from the first distance; (d) successively repeating step (b) to form folds in the sheet material having different fold heights. P1114 / 97MX 75. The apparatus according to claim 74, wherein step (c) comprises moving successively selected portions of the sheet material section in a direction towards the unloading bar and between the pusher bar and the unloading bar. 76. The apparatus according to claim 74, wherein step (b) comprises: (a) contacting the sheet material with a pusher bar in a first contact position located at a first distance from a unloading bar; (b) successively moving the pusher bar towards selected contact portions relative to the unloading bar, at least some of the selected contact positions are placed at distances relative to the unloading bar which are different from the first distance. 77. An expandable and collapsible article comprising: a series of interconnected multi-sided cell units, formed from sheet material, each of the cell units being formed with at least one fold line defining a peak; the peaks of the adjacent cell units collectively form a surface that has P1114 / 97MX an appearance with an outline, where the peaks of the cell units are placed in at least two different planes. 78. The article according to claim 77, wherein each of the cellular units is in diamond form having four exposed sides and first and second exposed fold lines., one of the first and the second fold lines forms the peak. 79. The article according to claim 78, wherein the first and second fold lines form a first peak and a second peak, respectively, the height of the cell of each cell unit is defined by the distance between the first and the second peaks 80. The article according to claim 79, wherein at least some of the cell units have different cell heights, so that the surface collectively formed by the adjacent cell units has a contoured appearance. 81. The article according to claim 77, wherein each of the cell units is formed from two sheet materials, each having a width and a length, each of the cell units being formed by a first connecting line. and a second separate connecting line interconnecting the two sheet materials along the width thereof. P1114 / 97MX 82. The article according to claim 81, wherein each of the cellular units includes at least a first exposed surface and a second exposed surface carrying first and second beads of adhesive, respectively, each of the cellular units has at least one third exposed surface and a fourth exposed surface, adjacent cell units are interconnected, by joining the first and second exposed surfaces and a cell unit, to the third and fourth surfaces of an adjacent cell unit, thus forming cavities between the first connection line and each of the first and second adhesive beads. 83. The article according to claim 82, wherein each of the cavities comprises a closed cavity extending along the width of the sheet materials, and extending outward from one of the first and second lines. of welding towards the junction point between the first and second exposed surfaces of a cellular unit and the third and fourth exposed surfaces, respectively of an adjacent cellular unit. 84. The article according to claim 81, wherein each of the first and second connection lines is an ultrasonic welding line. PU14 / 97MX 85. The article according to claim 81, wherein each of the first and second welding lines is a laser welding. 86. The article according to claim 82, wherein the bead of adhesive on each of the first and second exposed surfaces is essentially continuous along the width of each of the two rolls of sheet material. 87. An expandable and collapsible article comprising: a series of adjacent, multi-sided cellular units, formed of two sheet materials, each having a width and a length, each of the cellular units being formed by a first line of connection and a second separate connecting line interconnecting the two sheet materials along the width thereof, at least one fold line is formed across the width of each of the two sheet materials, in intermediate form to the connecting lines, first and second, adjacent; each of the cell units has at least a first exposed surface and a second exposed surface carrying first and second beads of adhesive, respectively, each of the cell units has at least one third surface P1114 / 97MX exposed and a fourth surface exposed, adjacent cell units are interconnected to join the first and second exposed surfaces of a cell unit to the third and fourth surfaces of an adjacent cell unit, thereby forming cavities between the first connecting line and each of the first second adhesive beads. 88. The article according to claim 87, wherein each of the cellular units is in the form of a diamond having four exposed sides, with a first fold line extending along the width of one of the two sheet materials, and a second fold line extending along the width of the other of the two sheet materials, opposite to the first fold line. 89. The article according to claim 87, wherein each of the cavities comprises a closed cavity extending along the width of the sheet materials, and extending outward from one of the first and second lines. of welding towards the junction point between the first and second exposed surfaces of a cellular unit and the third and fourth exposed surfaces, respectively, of an adjacent cellular unit. 90. The article according to claim 87, in P1114 / 97 X where each of the first and second connecting lines is an ultrasonic welding line. 91. The article according to claim 87, wherein each of the first and second welding lines is a laser welding. 92. The article according to claim 87, wherein the bead of adhesive on each of the first and second exposed surfaces is essentially continuous along the width of each of the two rolls of sheet material. 93. An expandable and collapsible article made from a sheet material, comprising: a series of adjacent, multi-sided cell units, formed of two sheet materials, each having a width and a length, each of Cell units are formed by a first connection line and a second separate connection line interconnecting the two sheet materials, along the width thereof, at least one fold line is formed across the width from each of the two sheet materials intermediate to the adjacent first and second connecting lines; adjacent cell units, each have a unit height defined by the distance between the bend in one of the sheet materials and the fold in P1114 / 97MX the other of the sheet materials within each cell unit, the unit height of at least some of the cell units is different from the unit height of the others, so that the series of adjacent cell units 5 they form, collectively, at least one surface that has a contoured appearance. 94. The article according to claim 93, in -, - where each of the cell units has a diamond shape with four exposed sides, with a first line 10 of fold extending along the width of one of the two sheet materials, and a second fold line extending along the width of the other of the two sheet materials, opposite the first fold line . 15. The article according to claim 93, wherein each of the cellular units includes a first exposed surface and a second exposed surface carrying first and second beads of adhesive, respectively, each of the cellular units having At least third and fourth surfaces exposed without adhesive, the adjacent cell units are interconnected by joining the first and second exposed surfaces of a cell unit to the third and fourth surfaces of an adjacent cell unit, thereby forming 25 cavities between the first connection line and each of P1114 / 97MX the first and second adhesive beads. 96. The article according to claim 95, wherein each of the cavities comprises a closed cavity extending along the width of the sheet materials, and extending outwardly from one of the first and second lines. of connection to the junction point between the first and second exposed surfaces of a cellular unit and the third and fourth exposed surfaces, respectively of an adjacent cellular unit. 97. The article according to claim 93, wherein each of the first and second connection lines is an ultrasonic welding line. 98. The article according to claim 93, wherein each of the first and second welding lines is a laser welding. 99. An expandable and collapsible article comprising: a series of adjacent folded, accordion-shaped folds formed from a length of sheet material, each of the folds having a fold height defined by the distance between two lines of adjacent bends in the sheet material; The fold height of at least some of the folds is different from the fold height of others P1114 / 97 X folds, along the length of sheet material, so that a series of the accordion-folded folds collectively form a surface that has a contoured appearance. 100. An expandable and collapsible article that they comprise comprises: a series of adjacent folded, accordion-shaped folds formed from a length of sheet material, each of the folds having a fold line defining a peak; the peaks of the adjacent folds collectively form a surface having a contoured appearance, wherein the peaks of at least some of the folds are located in at least two different planes. P1U4 / 97MX
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08298496 | 1994-08-30 | ||
| US08/298,496 US5709771A (en) | 1994-08-30 | 1994-08-30 | Method and apparatus for forming an expandable-collapsible article having a contoured surface |
| PCT/US1995/010948 WO1996006731A1 (en) | 1994-08-30 | 1995-08-30 | Expandable-collapsible article, method and apparatus |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| MX9701578A MX9701578A (en) | 1998-03-31 |
| MXPA97001578A true MXPA97001578A (en) | 1998-10-15 |
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