CA2048329A1 - Apparatus and method for forming at least one fold line pattern in a rigid plastic material - Google Patents
Apparatus and method for forming at least one fold line pattern in a rigid plastic materialInfo
- Publication number
- CA2048329A1 CA2048329A1 CA002048329A CA2048329A CA2048329A1 CA 2048329 A1 CA2048329 A1 CA 2048329A1 CA 002048329 A CA002048329 A CA 002048329A CA 2048329 A CA2048329 A CA 2048329A CA 2048329 A1 CA2048329 A1 CA 2048329A1
- Authority
- CA
- Canada
- Prior art keywords
- embossing
- pattern
- fold
- grooves
- fold line
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/0044—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping edges or extremities
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
- B29C53/04—Bending or folding of plates or sheets
- B29C53/06—Forming folding lines by pressing or scoring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
- B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
- B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
- B29C66/4722—Fixing strips to surfaces other than edge faces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
- B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
- B29C37/0057—Moulding single grooves or ribs, e.g. tear lines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
- B29C65/1412—Infrared [IR] radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
- B29K2023/06—PE, i.e. polyethylene
- B29K2023/0608—PE, i.e. polyethylene characterised by its density
- B29K2023/065—HDPE, i.e. high density polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2024/00—Articles with hollow walls
- B29L2024/003—Articles with hollow walls comprising corrugated cores
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/02—Other than completely through work thickness
- Y10T83/0333—Scoring
- Y10T83/0385—Rotary scoring blade
Abstract
ABSTRACT
Disclosed is a substantially rigid plastic material having at least one fold line pattern comprising a series of generally parallel grooves, wherein preferably groove depth increases from the outside to the middle of the pattern, and an apparatus and method for making the material. The apparatus includes a frame, a conveyor system for moving the plastic material along a linear path, a feeding means situated at an upstream end of the conveyor system and adapted to position the plastic material on the conveyor system, a heating means situated downstream of the feeding means adapted to heat the area to be embossed with the fold line pattern to a temperature sufficient to form the fold line pattern, and an embossing means comprising a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
Disclosed is a substantially rigid plastic material having at least one fold line pattern comprising a series of generally parallel grooves, wherein preferably groove depth increases from the outside to the middle of the pattern, and an apparatus and method for making the material. The apparatus includes a frame, a conveyor system for moving the plastic material along a linear path, a feeding means situated at an upstream end of the conveyor system and adapted to position the plastic material on the conveyor system, a heating means situated downstream of the feeding means adapted to heat the area to be embossed with the fold line pattern to a temperature sufficient to form the fold line pattern, and an embossing means comprising a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
Description
3~
TITLE- APPARATUS AND METHOD FOR FORMING AT LEAST ONE
FOLD LINE PATTERN IN A RIGID PLASTIC MATERIAL
INVENTOR: GARY W. FETTERHOFF AND
WILLIAM R. BLhKE
BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to a method and apparatus for forming at least one fold line pattern in a material. In another aspect, this invention relates to a method and apparatus ~or forming at least one fold line pattern in corrugated pla~tic sheets. In yet another aspect, this invention relates to a method and lo apparatus for heat scoring at least one fold line pattern in corrugated plastic sheets.
TITLE- APPARATUS AND METHOD FOR FORMING AT LEAST ONE
FOLD LINE PATTERN IN A RIGID PLASTIC MATERIAL
INVENTOR: GARY W. FETTERHOFF AND
WILLIAM R. BLhKE
BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to a method and apparatus for forming at least one fold line pattern in a material. In another aspect, this invention relates to a method and apparatus ~or forming at least one fold line pattern in corrugated pla~tic sheets. In yet another aspect, this invention relates to a method and lo apparatus for heat scoring at least one fold line pattern in corrugated plastic sheets.
2. Description_of the Related ~rt It has long been known that boxes and containers could he produced from substantially ~lat sheets of material having fold lines. U.S. Patent No. ~,102,170, issued December 14, 1937 to Stern, discloses a method and machine for scoring fold lines into paper or cardboard, corrugated or otherwise, to make cardboard or paper boxes. Forming containers from scored plastic sheets is di~closed in U.S. Patent No. 3,292,513 issued December 20, 1966 to Palmer, and in U.S. Patent No.
3,495,594. Furthermore, the use o~ cooperating embossing and flattening roller~ i~ disclosed by Palmer as a means of creating a ~old line in plastic sheet materials. More recently, U.S. 4,g46,430, issued August 7, 1990 to Kohmann, discloses an apparatus and method for forming at least one shallow ~old line (0O15~m) in thin PVC sheet6 by first heating the material and then passing tha heated material between a pair of rollers. The PVC sheets are heated utilizing heated bars. The ~old line is created by the use of a 01676/~ 1/2-26-91 Z~ 3;~
roller which imparts a single substantially "U" shaped groove in the PVC material. See FIG. llA which shows prior art ~old line 31 formed in plastic sheet P
utilizing embossing wheel 36 having a single ridge 37.
While the prior art devices are generally adequate for forming thin fold lines plastic materials comprised of plastics with low melting temperatures, the unique problems created by thicker or multilayer higher temperature ~elting plastic materials render the prior art devices :inadequate for forming fold lines in such materials.
For example, the harder plastic materials are generally slippery and tend to slip on the prior art embossing roller systems, which can disrupt system operations and the accurate placem~nt of the fold line.
A single groove fold line generally~ does not provide a stxucturally sound ~old line for thlicker or multilayer plastic materials comprised of plas~tics with higher melting temperatures. In addition the prior art teaches the use o~ bar heaters which are inadequate for such thicker or multilayer materials. Also, in spite of the prior art teaching that heating only the area to be heat scored will prevent warping, some thicker or ~.
multilayer plastics will warp anyway.
Accordingly, there exists a need for an improved heat score machine and method capable of processing harder plastic material~ without the slippage experienced by the prior art deYices. There also exists a need for an improved machine and method capable of heat scoring thicker or multilayer materials comprised of plastics of higher temperature melting temperatures. In addition, a need exists for an improved fold line pattern that will provide a structurally sound fold line for thicker or multilayer 3 s plastic materials.
Z~3~
~9~305US
SUMM~RY OF THE .INVENTION
According to one embodiment of the present invention there is provided an apparatus for embossing onto a material moving along a linear path at least one fold line pattern comprising a series of generally parallel grooves. Although the grooves may be the same size, preferably, groove depth increases from the outside to the middle of the pattern. Such an apparatus will generally comprise a series of stations all of which are disposed along a conveyor ~ystem and mounted on a frame. The conveyor system moves the material along a linear path past the stations.
Situated at an upstream end of the conveyor system and adapted to position the material on the conveyor system is the feeding means. The heatiny means situated downstream of the fe~ding means is adapted to heat the area to be embossed with the fold line patt.ern to a temperature suff.icient to form the fold line pattern.
Immediately downstream is the embossing means having a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embo6sing the fold pattern.
According to another embodiment of the present invention there is provided a substantially rigid plastic material having at least one fold line pattern comprising a series of genarally parallel grooves.
Although the groove si~e may be the sam~, preferably, groove depth increases ~rom the outside to the middle of th~ patternO
According to yet another embodiment of this invention there is provided a means for embossing at least one fold line pattern on a length of substantially rigid plastic material moving along a linear path comprising a series of generally parallel grooves, wherein preferably the groove depths are increasing from the outside to the middle of the pattern. In this embodiment the embossing means comprises a knurled flat roller and includes a cooperating embossing roller having a series of ridges suitable for embossing the fold pattern.
According to still yet another embodiment of the present invention there i5 provided a method for embossing onto a length of substantially rigid plastic material moving along a lin~ar path at least one fold line pattern comprising a series of generally parallel grooves. Preferably, the groove depth increases from the outside to the middle of the pattern. The method generally comprises c~nveying the plastic material along a linear path to a heating station where it is heated to a temperature suf~icient to allow the fold pattern to be embossed onto the plastic material. The plastic material is then passed between a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern. .
BRIEF DESCRIPTION OF ~HE DRAWINGS
In order to more fully understand the drawings used in the detailed description of the present invention, a brie~ desc:riptiorl of each drawing i8 presented.
FIG. 1 is a top view of the preferred embodimentO
FIG. 2 is a side view of the preferred embodiment.
FIG. 3 is a partial top view of the present invention.
FIG. 4 is detailed side view of the embossing station of the present invention along line 4-4 of FIG.
3.
FIG. 5 is a detailed side view of the heating station of the present invention.
roller which imparts a single substantially "U" shaped groove in the PVC material. See FIG. llA which shows prior art ~old line 31 formed in plastic sheet P
utilizing embossing wheel 36 having a single ridge 37.
While the prior art devices are generally adequate for forming thin fold lines plastic materials comprised of plastics with low melting temperatures, the unique problems created by thicker or multilayer higher temperature ~elting plastic materials render the prior art devices :inadequate for forming fold lines in such materials.
For example, the harder plastic materials are generally slippery and tend to slip on the prior art embossing roller systems, which can disrupt system operations and the accurate placem~nt of the fold line.
A single groove fold line generally~ does not provide a stxucturally sound ~old line for thlicker or multilayer plastic materials comprised of plas~tics with higher melting temperatures. In addition the prior art teaches the use o~ bar heaters which are inadequate for such thicker or multilayer materials. Also, in spite of the prior art teaching that heating only the area to be heat scored will prevent warping, some thicker or ~.
multilayer plastics will warp anyway.
Accordingly, there exists a need for an improved heat score machine and method capable of processing harder plastic material~ without the slippage experienced by the prior art deYices. There also exists a need for an improved machine and method capable of heat scoring thicker or multilayer materials comprised of plastics of higher temperature melting temperatures. In addition, a need exists for an improved fold line pattern that will provide a structurally sound fold line for thicker or multilayer 3 s plastic materials.
Z~3~
~9~305US
SUMM~RY OF THE .INVENTION
According to one embodiment of the present invention there is provided an apparatus for embossing onto a material moving along a linear path at least one fold line pattern comprising a series of generally parallel grooves. Although the grooves may be the same size, preferably, groove depth increases from the outside to the middle of the pattern. Such an apparatus will generally comprise a series of stations all of which are disposed along a conveyor ~ystem and mounted on a frame. The conveyor system moves the material along a linear path past the stations.
Situated at an upstream end of the conveyor system and adapted to position the material on the conveyor system is the feeding means. The heatiny means situated downstream of the fe~ding means is adapted to heat the area to be embossed with the fold line patt.ern to a temperature suff.icient to form the fold line pattern.
Immediately downstream is the embossing means having a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embo6sing the fold pattern.
According to another embodiment of the present invention there is provided a substantially rigid plastic material having at least one fold line pattern comprising a series of genarally parallel grooves.
Although the groove si~e may be the sam~, preferably, groove depth increases ~rom the outside to the middle of th~ patternO
According to yet another embodiment of this invention there is provided a means for embossing at least one fold line pattern on a length of substantially rigid plastic material moving along a linear path comprising a series of generally parallel grooves, wherein preferably the groove depths are increasing from the outside to the middle of the pattern. In this embodiment the embossing means comprises a knurled flat roller and includes a cooperating embossing roller having a series of ridges suitable for embossing the fold pattern.
According to still yet another embodiment of the present invention there i5 provided a method for embossing onto a length of substantially rigid plastic material moving along a lin~ar path at least one fold line pattern comprising a series of generally parallel grooves. Preferably, the groove depth increases from the outside to the middle of the pattern. The method generally comprises c~nveying the plastic material along a linear path to a heating station where it is heated to a temperature suf~icient to allow the fold pattern to be embossed onto the plastic material. The plastic material is then passed between a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern. .
BRIEF DESCRIPTION OF ~HE DRAWINGS
In order to more fully understand the drawings used in the detailed description of the present invention, a brie~ desc:riptiorl of each drawing i8 presented.
FIG. 1 is a top view of the preferred embodimentO
FIG. 2 is a side view of the preferred embodiment.
FIG. 3 is a partial top view of the present invention.
FIG. 4 is detailed side view of the embossing station of the present invention along line 4-4 of FIG.
3.
FIG. 5 is a detailed side view of the heating station of the present invention.
FIG. 6 is a detailed partial side view of the heating element of the present invention.
FIG. 7 is a partial side view of the conveyor system and fence of the present invention.
SFIG. 8 is a partial top view of the conveyor syste~ of the present invention.
FIG. 9 is a partial side view of a fence roller of tha present invention.
FI~. 10 is a ~ront view showing the heating stations.
FIG. 11 shows in A a prior art scoring wheel, and in B a scoring wheel of one embodiment of the pxesent invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention may generally be used to emboss at lPa~t one fold line pattern on almost any type of plastic material. Such materials include corrugated and multilayer plastic materials, for example, multilayer corrugated polyethylene. .
FIG. 1 shows a top view and FIG. 2 shows an overhead view of heat scoring apparatu~; A of the present invention ~or forming at least one fold line pattern in a plastic sheat.
Referring now to both FIG5. l and 2 it can be seen that the apparatus generally comprises heating station 100 and heat scoring station 300 both disposed along, above or proximate to conveyor system 200. Conveyor system 200 conveys material, for example a plastic sheet, along a linear path in the direction represented by arrow 50 along a frame 250 from the fPeding or staging area 80 located at the upstream end of conveyor system 200 past heating station 100 toward heat scoring station 300. A positioning system comprising positioning control means 530 and a pair of traversing 3~3 -6~ ~91305US
means 510a and 510b orients the heat scoring skation 300 over the plastic sheet at the desired location.
Frame 250 supports the heat scoring apparatus of the present invention. Referring to FIGS. 1-3, frame 250 is a table having a working surface 251 along which the plastic sheet is conveyed. At the downstream end of the table is knurled cylinder gap 255 which admits knurled cylinder 340 to allow the plastic sheet to be heat scored between knurled cylinder 340 and scoring wheel 330. Frame 250 is sized to accommodate the plastic sheet and to provide space for all of the apparatus elements. Of course, materials of construction and dimensions may vary, and the following materials of construction and dimensions are given as examples, as the present invention is not intended to be limited to certain materials o~ construction or certain dimensions. In the embodiment shown, frame 250 is a metal table, with working suri~ace 251 comprising a 2 1/4" thick plywood top (three stacked pieces of 3/~1'plywood), and spanning about 60 inches long in travel direction 50 and about 121 inches wideO The plywood top is covered with an 1/8" thick sheet of aluminum which serves to reflect heat energy. Gap 255 is si ed to admit knurled cylinder 340 and in the embodiment shown spans about 6 5/8" long by 102 inches wide.
The feeding or staging area 80 comprises a feeding means ~not shown) that is adapted to position the plastic sheet on conveyor system 200. Any manual or automatic means suitable ko position the plastic sheet on conveyor system 200 may-be utilized. Preferably, the discharge o~ a cutting machine, which sizes the plastic material to he heat scored, will discharge the material onto the conveyor system.
.... ~ . .
3~
FIG. 7 is a partial side view of the conveyor system and fence of the present invention.
SFIG. 8 is a partial top view of the conveyor syste~ of the present invention.
FIG. 9 is a partial side view of a fence roller of tha present invention.
FI~. 10 is a ~ront view showing the heating stations.
FIG. 11 shows in A a prior art scoring wheel, and in B a scoring wheel of one embodiment of the pxesent invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention may generally be used to emboss at lPa~t one fold line pattern on almost any type of plastic material. Such materials include corrugated and multilayer plastic materials, for example, multilayer corrugated polyethylene. .
FIG. 1 shows a top view and FIG. 2 shows an overhead view of heat scoring apparatu~; A of the present invention ~or forming at least one fold line pattern in a plastic sheat.
Referring now to both FIG5. l and 2 it can be seen that the apparatus generally comprises heating station 100 and heat scoring station 300 both disposed along, above or proximate to conveyor system 200. Conveyor system 200 conveys material, for example a plastic sheet, along a linear path in the direction represented by arrow 50 along a frame 250 from the fPeding or staging area 80 located at the upstream end of conveyor system 200 past heating station 100 toward heat scoring station 300. A positioning system comprising positioning control means 530 and a pair of traversing 3~3 -6~ ~91305US
means 510a and 510b orients the heat scoring skation 300 over the plastic sheet at the desired location.
Frame 250 supports the heat scoring apparatus of the present invention. Referring to FIGS. 1-3, frame 250 is a table having a working surface 251 along which the plastic sheet is conveyed. At the downstream end of the table is knurled cylinder gap 255 which admits knurled cylinder 340 to allow the plastic sheet to be heat scored between knurled cylinder 340 and scoring wheel 330. Frame 250 is sized to accommodate the plastic sheet and to provide space for all of the apparatus elements. Of course, materials of construction and dimensions may vary, and the following materials of construction and dimensions are given as examples, as the present invention is not intended to be limited to certain materials o~ construction or certain dimensions. In the embodiment shown, frame 250 is a metal table, with working suri~ace 251 comprising a 2 1/4" thick plywood top (three stacked pieces of 3/~1'plywood), and spanning about 60 inches long in travel direction 50 and about 121 inches wideO The plywood top is covered with an 1/8" thick sheet of aluminum which serves to reflect heat energy. Gap 255 is si ed to admit knurled cylinder 340 and in the embodiment shown spans about 6 5/8" long by 102 inches wide.
The feeding or staging area 80 comprises a feeding means ~not shown) that is adapted to position the plastic sheet on conveyor system 200. Any manual or automatic means suitable ko position the plastic sheet on conveyor system 200 may-be utilized. Preferably, the discharge o~ a cutting machine, which sizes the plastic material to he heat scored, will discharge the material onto the conveyor system.
.... ~ . .
3~
Referring still to FIG. 2 and additionally to FIGS. 3 and 7-9, the conveyor system 200 is designed to convey the plastic sheet along the working surPace 251 from the feeding or staging area to and also beneath :~
the heating station 100 and then toward the heat scoring station 300. Conveyor system 200 generally comprises an endless loop conveyor belt 217 which is powered by conveyor motor 280 around sprockets 212(a~-(d), referred to collectively as sprockets 212.
Endless loop conveyor belt 217 is made of chain links 2~9 having sharp pointed fingers 214. The fingers 214 engage the plastic sheet to move it along working surface 251.
Conveyor system 200 is genera].ly disposed along one side of the working curface 251 with fingers 214 extending slightly above the working surface 251. Also positioned along side of conveyor belt 217 is fence 230 which functions as a guide or refexence point for the plastic sheet in its travel. Disposed along the length of fence 230 are a multiplicity of spring loaded fence --roll~rs 237. Each fence roller 237 is connected t~
~ne end of a fence roller arm 235. The other end o~
each fence roller arm 235 is connected to a fastener 235b, that connects ~ence roller arm 235 to ~nce 230 Each fence roller arm 235 pivots on the fastener 235b to allow roller 237 to be movably engaged with the plastic sheet. Torsion spring 238 is mounted on a torsion sprin~ msunt bolt 231 affixed to f~nce 230 by ~astener 231a. End 238a of torsion spring 233 is anchored to the L-shaped fence spring anchor 239, and end 238b of torsion spring`238 is anchored to roller spring anchor 235b. Torsion spring 238 acts to bias ~ence roller arm 235 downward toward the plastic sheet so that fence roller 237 engages the plastic sheet which in turn forces the plastic sheet into engagement -8- A~1305US
with sharp pointed fingers 214 to help prevent undue slippage of the plastic sheet as it is conveyed along.
The force with which fence roller 237 engages plastic sheet P may be adjusted by loosening fastener 231a and rotating L-shaped anchor 239 until the desired force is achieved.
It i~ generally necessary to engage the plastic sheet with sharp pointed fingers 214 in such a manner as described above because many of ~he plastic materials utilized as the plastic sheet are hard and slippery.
Referring now to FIG. 2, motor 280 of conveyor system 200 powers endless loop conveyor belt 217 in its path around sprockets 212. Motor drive belt 283 connects motor drive pulley 285 with one of the sprocXets 212 to power Pndless loop conveyor belt 217.
Preferably, motor 280 is a variable speed motor or has a variable speed drive to allow for control the length of the heating residence time that the pla~tic sheet is beneath heating station 100.
Again, the following are presented as nonlimiting examples o~ the present Invention. In the embodiment shown, endless loop conveyor belt 217 is a #50 roller chain (a smaller chain such as a #30 roller chain could be utilized) with fingers 214 having a length of about 7/8 inches spaced along endless loop conveyor belt 217 at intervals o~ about 5/8 inches. Fingers 214 are positioned to extend above working surface 251 about 1/16 inch. Motor 280 powers endles~ loop conveyor belt 217 at rates in the range of about 1,2 inches per second to about 3 inches per second, and is generally a 1/3 h.p. motor.
Referring again to FXGS. 1-3 and additionally to FIGS. 5, 6, and 10, heating station 100 is located downstream from the feed or staging area. The purpose 01~76/0/1-1-1/2-26-91 32~
the heating station 100 and then toward the heat scoring station 300. Conveyor system 200 generally comprises an endless loop conveyor belt 217 which is powered by conveyor motor 280 around sprockets 212(a~-(d), referred to collectively as sprockets 212.
Endless loop conveyor belt 217 is made of chain links 2~9 having sharp pointed fingers 214. The fingers 214 engage the plastic sheet to move it along working surface 251.
Conveyor system 200 is genera].ly disposed along one side of the working curface 251 with fingers 214 extending slightly above the working surface 251. Also positioned along side of conveyor belt 217 is fence 230 which functions as a guide or refexence point for the plastic sheet in its travel. Disposed along the length of fence 230 are a multiplicity of spring loaded fence --roll~rs 237. Each fence roller 237 is connected t~
~ne end of a fence roller arm 235. The other end o~
each fence roller arm 235 is connected to a fastener 235b, that connects ~ence roller arm 235 to ~nce 230 Each fence roller arm 235 pivots on the fastener 235b to allow roller 237 to be movably engaged with the plastic sheet. Torsion spring 238 is mounted on a torsion sprin~ msunt bolt 231 affixed to f~nce 230 by ~astener 231a. End 238a of torsion spring 233 is anchored to the L-shaped fence spring anchor 239, and end 238b of torsion spring`238 is anchored to roller spring anchor 235b. Torsion spring 238 acts to bias ~ence roller arm 235 downward toward the plastic sheet so that fence roller 237 engages the plastic sheet which in turn forces the plastic sheet into engagement -8- A~1305US
with sharp pointed fingers 214 to help prevent undue slippage of the plastic sheet as it is conveyed along.
The force with which fence roller 237 engages plastic sheet P may be adjusted by loosening fastener 231a and rotating L-shaped anchor 239 until the desired force is achieved.
It i~ generally necessary to engage the plastic sheet with sharp pointed fingers 214 in such a manner as described above because many of ~he plastic materials utilized as the plastic sheet are hard and slippery.
Referring now to FIG. 2, motor 280 of conveyor system 200 powers endless loop conveyor belt 217 in its path around sprockets 212. Motor drive belt 283 connects motor drive pulley 285 with one of the sprocXets 212 to power Pndless loop conveyor belt 217.
Preferably, motor 280 is a variable speed motor or has a variable speed drive to allow for control the length of the heating residence time that the pla~tic sheet is beneath heating station 100.
Again, the following are presented as nonlimiting examples o~ the present Invention. In the embodiment shown, endless loop conveyor belt 217 is a #50 roller chain (a smaller chain such as a #30 roller chain could be utilized) with fingers 214 having a length of about 7/8 inches spaced along endless loop conveyor belt 217 at intervals o~ about 5/8 inches. Fingers 214 are positioned to extend above working surface 251 about 1/16 inch. Motor 280 powers endles~ loop conveyor belt 217 at rates in the range of about 1,2 inches per second to about 3 inches per second, and is generally a 1/3 h.p. motor.
Referring again to FXGS. 1-3 and additionally to FIGS. 5, 6, and 10, heating station 100 is located downstream from the feed or staging area. The purpose 01~76/0/1-1-1/2-26-91 32~
of heating station 100 is to heat the plastic sheet to a temperature sufficient to score or emboss it at heat `:
scoring station 300.
~eating station 100 is generally wide enough to heat the immediate width around the area to be scored and is genarally oriented longitudinally in direction 50.
Heating station 100 comprises a housing 109 to which is suspended by fasteners 141. Situated within the housing is a that extends longitudinally for most o~ the length of heater housing 109. Heating element 140 i~ generally any heating element capable of imparting suf~icient heat to the sur~ace of the plastic sheet to scored it. Pre~erably, heating element 140 is an infra red heating element, and more preferably, a quartz infra red heating element.
To help concentrate the heat onto a desired area of the plastic sheet, a reflector 142 is suspended above heating element 140. Preferably re~lPctor 142 is an elongated parabolically shaped :reflector and 142 i8 attached to heater housing lO9 by ]bolts 144. When plastic sheet P is a multilayer or corrugated material, it is more di~ficult to heat the material through all of the layers su~ficiently ~or a heat score to be formed to the proper depth without overheating the top surface of plastic sheet P. In addition to being reflected by r~flector 142, infra red energy rebounds from the re~lective wording surface 251 which helps to provide sufficient heating while not overheating the top surface of plastic sheet P.
Heating of plastic sheet P along a narrow path will cause the plastic sheet P to warp and/or to buckle upwardly toward the heating station 100. Such de~ormation may cause misalignment of the plastic sheet P and move it too close to the heating element 140. To 01676/0/1-l-1/2-26-91 2~ 33~
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prevent this, a series of hold down rollers 103 are provided that hold the plastic sheet P ~lat as it travels beneath heating element 140. Each roller 103 is attached to a hold down bar 107 by an axle 104 upon which each roller 103 rotates. A hold down bar 107 . runs longitudinally on each side of housing 109 and is affixed to the housing by studs 106 in slots 105.
Studs ~06 are generally aligned to allow the bar 107 to angle forward and downward as it is moved.
lo The rollers 103 are moved into engagament with plastic sheet P by a hold down roller engagement system shown generally at 110. In the embodiment shown, the hold down rollex engagement system 110 comprises a pneumatic cylinder 119 mounted atop housing ~09. Back end ll9b of pneumatic cylinder 1~9 is affixed to housing 109 by bracket 112. ~ylinder rod ll9a is connected to yolk 117 by bracket l:L4. Yolk 117 is in turn co~nected to hold down bars 107 on each side of ; housing 109 by brackets 115.
As air is supplied to pneumat:ic cylinder 119, cylinder rod ll9a extends outwardly away from cylinder 119. Yolk 117 is then moved forward with the orientation of studs 106 and slots 105 allowing hold down bar 107 to move at an angle forward and downward from its top position, shown by hold down bar 107a and hold down roller 103a, to a down position with hold down rollers 103 engaging plastic sheet P.
In general the hold down rollers 103 should be disposed along hold down bax 107 at intervals su~ficient to prevent warping. In th~ embodiment shown, hold down rollers I03 are disposed along hold down bar 107 at intervals of about 10 inches.
The plastic material must be heated sufficiently to allow for the fold line pattern to be embossed onto the plastic material this requires that the plastic 01676/0/1-1-1/~-26-91 ~ A91305US
material be heated up at least to its softening point.
The heating t~mperatures will vary with the type of plastic material u~ed~ but for multilayer polyethylene corrugated type materials, the materials must be heatPd at least to a temperature in the range of about 175F
to about 400F.
Referring now to FIGS. 1-4 it can be appreciated that located immediately downstream of heating station 100 is hea~ scoring station 300. Upon departure from heating station 100, plastic sheet P i~ conveyed by conveyor system 200 to heat scoring station 300 where it pass~s between scoring wheel 330 and knurled cylinder 340, which impart to plastic sheet P a longitudinal fold line pattern running in direction 50.
Heat scoring station 300 generally comprises a vertically movable upper section whleel cage assembly, shown generally at 320 which houses~ scoring whPel 330, and a lower section having knurled cylinder 340.
The knurled cylinder 340 has a rough or knurled --surface to allow the plastic sheet P to be gripped and to prevent undue slippage as the plastic sheet P passes between knurled cylinder 340 and scoring wheel 330~
Knurled cylinder 340 generally extends laterally across most of the width of working surface 251 at knurled cylinder gap 255. Again, while the present invention is not intended to be limited to any particular dimensions, knurled cylinder 340 of the embodiment illustrated in the figures, has an outer diameter of about 6 5/8 inches and sxtends laterally across the working surface 251 for about 102 inches.
Knurled cylinder 340 is driven by endless belt 342 coming from jack shaft assembly 3450 Jack shaft assembly 345 is in turn powered by sprocket 341 keyed to one of the sprockets 212 o~ conveyor system 200 with ZQ~ 3~?r9 endless belt 348. Scoring wheel 330 is not directly driven, but instead idles.
Scoring wheel 330 is carried on a static wheel axle 332~ A multiplicity of ball bearings 331 allow scoring wheel 33U to rotate freely on axle 332. Axle 332 is supported by wheel cage housing 325 which in turn is affixed to housing 109 by a pair of vertical rods 310. Rods 310 are each surrounded by a multiplicity o~ linear ball bushings 312 which permit wheel case housing 325 to move in a vertical direction.
Wheel springs 315 are coile~ around rods 310 and are positioned between working sur~ace 251 and wheel cage housing 325 to help keep scoring wheel 330 suspended above working sur~ace 251 when the scoring wheel 330 is not needed.
Affixed to the top of housing 325 is a pneumatic cylinder 323. Suspended rigidly overhead is scoring bridge 350 which extends laterally across working surface 251 above heat scoring station 300. Scoring bridge 350 is suspended overhead by supports 353 and 355, which connect scoring bridge 350 to frame 250.
The gap between scoring wheel 330 and knurled cylinder 340 may be adjusted for different thicknesses of plastic sheet P. This allows for flexibility in utilizing different feed thickness.
To ensage scoring wheel 330 with plastic sheet P, air is ~orced through part 326 into the lower chamber of pneumatic cylinder 323 so as to cause a piston 321 to move upwardly until piston 321 contacts scoring wheel bridge 350. As bridge 350 is fixed, continual air pressure causes wheel cage assembly 325 to depress springs 315, allowing scoring wheel 330 to engage plastic sheet P. Scoring depth can ba adjusted by controlling the air pressure to pneumatic cylindar 323.
once the air pressure is releasedr springs 315 force 01676/0/1-l-1/2-26-91 j:
3~
the wheel cage 325 back up and away from working surface 251. Alternatively, the length of piston 321 may be adjusted so that at full extension of piston 321 scoring wheel 330 is at the proper desired vertical position.
The fold line pattern comprises a series of generally parallel fold lines. The fold lines within a ~old line patt rn may all have the same size and shape.
Prefera~ly, however, to bias the material into folding at or near the middle of khe fold line pattern, the depth of the fold lines increases from the outside to the middle of the pattern, with the middle fold line (or middle two fold lines if there is an even number of fold lines) being the deepest. Likewise, it is also preferable that the width of the fold lines increases from th~ outside to the middle of l:he pattern. The scoring wheel 330 will have ridges suitable for making the desired ~old line pattern.
FIG. llB shows fold line pattern 30 of the preferred embodiment of the present invention. Also shown is scoring or embossing wheel 330 with embossing ridges 337 that form fold line pattern 30. Angle 337a is generally in the range of about 90 to about 160 degrees. Preferably, an71e 337a i5 in the range of about lO0 to 125 degrees. The fold line pattern comprises at least about 3 fold lines. .:
In practice, angle 337a, and the width and the depth of the grooves are all a function of the material utilized and its thickness. These variables must be selected to give an adequate fold line pattern for the given material.
For example, for 5/32 inch multilayer corrugated high density polyethylene materials, the depth of the outer fold lines is generally in the range of about ~.6 mm to about 2.8 mm and the depth of the inner or 3~
-14~ A91305US
deeper fold lines is in the range of about 3.4 mm to about 3.6 mm. The width of the bottom of the outer fold lines is generally in the range of about 1.7 mm to about 2.0 mm, and depending on angle 337a, the width of the top of the outer fold lines is generally in the range o~ about 1.7 mm to about 3.3 mm. The width of the bottom of the inner fold lines is generally in the range of about 2.8 mm to about 3.2 mm, and depending on angle 337a, the width of the top of the outer Eold lines is generally in the range of about 3 mm to about -~
S mm. Of course, the particular dimensions for the ~old lines will vary d~pending on the application, the material utilized, and its thickness, and the above dimensions are presented merely as nonlimiting examples.
In order to provide for scoring at various positions across plastic sheet P, a positioning system is provided to position scoring wheel 330 at various points laterally across knurl~d cylinder wheel 340.
Referrlng to Figures 1~4, the positioning system comprises a positioning control means, shown generally at 530 and a pair of traversing means 510a located at the downstream end of housing 109, and 510b located at the upstream end of housing 109.
Both traversing means 510a and 510b can be described as follows. Baseplate 503 connects open ball bushing 505 to housing lO9. Ball bearings 507 allow ball bushing 505 to slide along traversing rod 511, which is suspended above and across working sur~ace 251. Traversing rod 511 is suspended above and across working surface 251 by vertical rods 533 and 535, which are in turn connected to frame 250. Positioning . :
control means 530 comprises handle 535, rod 537 and tape 531 with positioning read out. Tape 531 is connected to housing 109 by bracket 539. As handle 535 .
2d ~ 8 ~32 ~3 .
is turned, the position of scoring wheel 330 is changed and may be determined by reading tape 531~ The scoring wheel 330 may be locked in place.
In the heat scoring apparatus of the present invention, a multiplicity of heat score fold lines may be created simultaneously by providing multiple sets of heating/scoring stations arranged generally parallel to each other. In the embodiment as shown in the figures, there are 4 parallel heating systems 100 each with its own heat scoring wheel 330, and traversing system.
They all share a co~mon knurled cylinder 340.
The present invention permits the creation of one or more fold line patterns on a plastic sheet P. A~ter th~ fold line patterns an created, plastic sheet P may be manually or automatically folded along the fold lines to form the container or box shape desired.
The descrlption given herein is intended to illustrate the preferred embodiments of the present invention. It is possible for one of ordinary skîll in the art to make various changes to the details of the present invention, including changes in the size, shape and materials, as well as in the details of the illustratQd construction without departing from the spirit of this invention. Therefore, it is intended that all such variations be included within the scope of the present invention as claimed. -01676/0/1-l-1/2-26-91
scoring station 300.
~eating station 100 is generally wide enough to heat the immediate width around the area to be scored and is genarally oriented longitudinally in direction 50.
Heating station 100 comprises a housing 109 to which is suspended by fasteners 141. Situated within the housing is a that extends longitudinally for most o~ the length of heater housing 109. Heating element 140 i~ generally any heating element capable of imparting suf~icient heat to the sur~ace of the plastic sheet to scored it. Pre~erably, heating element 140 is an infra red heating element, and more preferably, a quartz infra red heating element.
To help concentrate the heat onto a desired area of the plastic sheet, a reflector 142 is suspended above heating element 140. Preferably re~lPctor 142 is an elongated parabolically shaped :reflector and 142 i8 attached to heater housing lO9 by ]bolts 144. When plastic sheet P is a multilayer or corrugated material, it is more di~ficult to heat the material through all of the layers su~ficiently ~or a heat score to be formed to the proper depth without overheating the top surface of plastic sheet P. In addition to being reflected by r~flector 142, infra red energy rebounds from the re~lective wording surface 251 which helps to provide sufficient heating while not overheating the top surface of plastic sheet P.
Heating of plastic sheet P along a narrow path will cause the plastic sheet P to warp and/or to buckle upwardly toward the heating station 100. Such de~ormation may cause misalignment of the plastic sheet P and move it too close to the heating element 140. To 01676/0/1-l-1/2-26-91 2~ 33~
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prevent this, a series of hold down rollers 103 are provided that hold the plastic sheet P ~lat as it travels beneath heating element 140. Each roller 103 is attached to a hold down bar 107 by an axle 104 upon which each roller 103 rotates. A hold down bar 107 . runs longitudinally on each side of housing 109 and is affixed to the housing by studs 106 in slots 105.
Studs ~06 are generally aligned to allow the bar 107 to angle forward and downward as it is moved.
lo The rollers 103 are moved into engagament with plastic sheet P by a hold down roller engagement system shown generally at 110. In the embodiment shown, the hold down rollex engagement system 110 comprises a pneumatic cylinder 119 mounted atop housing ~09. Back end ll9b of pneumatic cylinder 1~9 is affixed to housing 109 by bracket 112. ~ylinder rod ll9a is connected to yolk 117 by bracket l:L4. Yolk 117 is in turn co~nected to hold down bars 107 on each side of ; housing 109 by brackets 115.
As air is supplied to pneumat:ic cylinder 119, cylinder rod ll9a extends outwardly away from cylinder 119. Yolk 117 is then moved forward with the orientation of studs 106 and slots 105 allowing hold down bar 107 to move at an angle forward and downward from its top position, shown by hold down bar 107a and hold down roller 103a, to a down position with hold down rollers 103 engaging plastic sheet P.
In general the hold down rollers 103 should be disposed along hold down bax 107 at intervals su~ficient to prevent warping. In th~ embodiment shown, hold down rollers I03 are disposed along hold down bar 107 at intervals of about 10 inches.
The plastic material must be heated sufficiently to allow for the fold line pattern to be embossed onto the plastic material this requires that the plastic 01676/0/1-1-1/~-26-91 ~ A91305US
material be heated up at least to its softening point.
The heating t~mperatures will vary with the type of plastic material u~ed~ but for multilayer polyethylene corrugated type materials, the materials must be heatPd at least to a temperature in the range of about 175F
to about 400F.
Referring now to FIGS. 1-4 it can be appreciated that located immediately downstream of heating station 100 is hea~ scoring station 300. Upon departure from heating station 100, plastic sheet P i~ conveyed by conveyor system 200 to heat scoring station 300 where it pass~s between scoring wheel 330 and knurled cylinder 340, which impart to plastic sheet P a longitudinal fold line pattern running in direction 50.
Heat scoring station 300 generally comprises a vertically movable upper section whleel cage assembly, shown generally at 320 which houses~ scoring whPel 330, and a lower section having knurled cylinder 340.
The knurled cylinder 340 has a rough or knurled --surface to allow the plastic sheet P to be gripped and to prevent undue slippage as the plastic sheet P passes between knurled cylinder 340 and scoring wheel 330~
Knurled cylinder 340 generally extends laterally across most of the width of working surface 251 at knurled cylinder gap 255. Again, while the present invention is not intended to be limited to any particular dimensions, knurled cylinder 340 of the embodiment illustrated in the figures, has an outer diameter of about 6 5/8 inches and sxtends laterally across the working surface 251 for about 102 inches.
Knurled cylinder 340 is driven by endless belt 342 coming from jack shaft assembly 3450 Jack shaft assembly 345 is in turn powered by sprocket 341 keyed to one of the sprockets 212 o~ conveyor system 200 with ZQ~ 3~?r9 endless belt 348. Scoring wheel 330 is not directly driven, but instead idles.
Scoring wheel 330 is carried on a static wheel axle 332~ A multiplicity of ball bearings 331 allow scoring wheel 33U to rotate freely on axle 332. Axle 332 is supported by wheel cage housing 325 which in turn is affixed to housing 109 by a pair of vertical rods 310. Rods 310 are each surrounded by a multiplicity o~ linear ball bushings 312 which permit wheel case housing 325 to move in a vertical direction.
Wheel springs 315 are coile~ around rods 310 and are positioned between working sur~ace 251 and wheel cage housing 325 to help keep scoring wheel 330 suspended above working sur~ace 251 when the scoring wheel 330 is not needed.
Affixed to the top of housing 325 is a pneumatic cylinder 323. Suspended rigidly overhead is scoring bridge 350 which extends laterally across working surface 251 above heat scoring station 300. Scoring bridge 350 is suspended overhead by supports 353 and 355, which connect scoring bridge 350 to frame 250.
The gap between scoring wheel 330 and knurled cylinder 340 may be adjusted for different thicknesses of plastic sheet P. This allows for flexibility in utilizing different feed thickness.
To ensage scoring wheel 330 with plastic sheet P, air is ~orced through part 326 into the lower chamber of pneumatic cylinder 323 so as to cause a piston 321 to move upwardly until piston 321 contacts scoring wheel bridge 350. As bridge 350 is fixed, continual air pressure causes wheel cage assembly 325 to depress springs 315, allowing scoring wheel 330 to engage plastic sheet P. Scoring depth can ba adjusted by controlling the air pressure to pneumatic cylindar 323.
once the air pressure is releasedr springs 315 force 01676/0/1-l-1/2-26-91 j:
3~
the wheel cage 325 back up and away from working surface 251. Alternatively, the length of piston 321 may be adjusted so that at full extension of piston 321 scoring wheel 330 is at the proper desired vertical position.
The fold line pattern comprises a series of generally parallel fold lines. The fold lines within a ~old line patt rn may all have the same size and shape.
Prefera~ly, however, to bias the material into folding at or near the middle of khe fold line pattern, the depth of the fold lines increases from the outside to the middle of the pattern, with the middle fold line (or middle two fold lines if there is an even number of fold lines) being the deepest. Likewise, it is also preferable that the width of the fold lines increases from th~ outside to the middle of l:he pattern. The scoring wheel 330 will have ridges suitable for making the desired ~old line pattern.
FIG. llB shows fold line pattern 30 of the preferred embodiment of the present invention. Also shown is scoring or embossing wheel 330 with embossing ridges 337 that form fold line pattern 30. Angle 337a is generally in the range of about 90 to about 160 degrees. Preferably, an71e 337a i5 in the range of about lO0 to 125 degrees. The fold line pattern comprises at least about 3 fold lines. .:
In practice, angle 337a, and the width and the depth of the grooves are all a function of the material utilized and its thickness. These variables must be selected to give an adequate fold line pattern for the given material.
For example, for 5/32 inch multilayer corrugated high density polyethylene materials, the depth of the outer fold lines is generally in the range of about ~.6 mm to about 2.8 mm and the depth of the inner or 3~
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deeper fold lines is in the range of about 3.4 mm to about 3.6 mm. The width of the bottom of the outer fold lines is generally in the range of about 1.7 mm to about 2.0 mm, and depending on angle 337a, the width of the top of the outer fold lines is generally in the range o~ about 1.7 mm to about 3.3 mm. The width of the bottom of the inner fold lines is generally in the range of about 2.8 mm to about 3.2 mm, and depending on angle 337a, the width of the top of the outer Eold lines is generally in the range of about 3 mm to about -~
S mm. Of course, the particular dimensions for the ~old lines will vary d~pending on the application, the material utilized, and its thickness, and the above dimensions are presented merely as nonlimiting examples.
In order to provide for scoring at various positions across plastic sheet P, a positioning system is provided to position scoring wheel 330 at various points laterally across knurl~d cylinder wheel 340.
Referrlng to Figures 1~4, the positioning system comprises a positioning control means, shown generally at 530 and a pair of traversing means 510a located at the downstream end of housing 109, and 510b located at the upstream end of housing 109.
Both traversing means 510a and 510b can be described as follows. Baseplate 503 connects open ball bushing 505 to housing lO9. Ball bearings 507 allow ball bushing 505 to slide along traversing rod 511, which is suspended above and across working sur~ace 251. Traversing rod 511 is suspended above and across working surface 251 by vertical rods 533 and 535, which are in turn connected to frame 250. Positioning . :
control means 530 comprises handle 535, rod 537 and tape 531 with positioning read out. Tape 531 is connected to housing 109 by bracket 539. As handle 535 .
2d ~ 8 ~32 ~3 .
is turned, the position of scoring wheel 330 is changed and may be determined by reading tape 531~ The scoring wheel 330 may be locked in place.
In the heat scoring apparatus of the present invention, a multiplicity of heat score fold lines may be created simultaneously by providing multiple sets of heating/scoring stations arranged generally parallel to each other. In the embodiment as shown in the figures, there are 4 parallel heating systems 100 each with its own heat scoring wheel 330, and traversing system.
They all share a co~mon knurled cylinder 340.
The present invention permits the creation of one or more fold line patterns on a plastic sheet P. A~ter th~ fold line patterns an created, plastic sheet P may be manually or automatically folded along the fold lines to form the container or box shape desired.
The descrlption given herein is intended to illustrate the preferred embodiments of the present invention. It is possible for one of ordinary skîll in the art to make various changes to the details of the present invention, including changes in the size, shape and materials, as well as in the details of the illustratQd construction without departing from the spirit of this invention. Therefore, it is intended that all such variations be included within the scope of the present invention as claimed. -01676/0/1-l-1/2-26-91
Claims (28)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An apparatus for embossing onto a length of material moving along a linear path at least one fold line pattern comprising a series of generally parallel grooves, the apparatus comprising:
a frame;
a means for moving said material along a linear path;
a means for feeding said material, said feeding means being situated at an upstream end of the conveyor system and adapted to position the said material on the moving means;
a means for heating said material, said heating means being situated downstream of the feeding means and adapted to heat the area to be embossed with the fold line pattern to a temperature sufficient to form the fold line pattern; and a means for embossing said plastic material, said embossing means comprising a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
a frame;
a means for moving said material along a linear path;
a means for feeding said material, said feeding means being situated at an upstream end of the conveyor system and adapted to position the said material on the moving means;
a means for heating said material, said heating means being situated downstream of the feeding means and adapted to heat the area to be embossed with the fold line pattern to a temperature sufficient to form the fold line pattern; and a means for embossing said plastic material, said embossing means comprising a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
2. The apparatus of claim 1 wherein the groove depth increases from the outside to the middle of the pattern
3. The apparatus of claim 2 wherein said moving means comprises an endless loop belt disposed along the frame and adapted to travel in the longitudinal direction and further comprises a fence to guide said material as it travels along the linear path.
4. The apparatus of claim 2 wherein said heating means comprises a heat reflector for directing heat to the desired location and hold down rollers for keeping said material from warping as it is heated.
5. The apparatus of claim 4 wherein the heat reflector is an elongated parabolic reflector.
6. The apparatus of claim 2 wherein the heating means further comprises means for holding down said material.
7. The apparatus of claim 2 wherein said heating means comprises an infra red quartz heating element.
8. The apparatus of claim 2 wherein the fold pattern comprises at least three grooves and the embossing means comprises ridges suitable for making the grooves.
9. The apparatus of claim 2 wherein the frame comprises a table.
10. The apparatus of claim 2 wherein said material comprises a multilayer high density polyethylene corrugated material.
11. The apparatus of claim 10 wherein said material is heated to a temperature in the range of about 175°F to about 400°F.
12. The apparatus of claim 2 wherein said moving means comprises an endless loop belt disposed along the frame and adapted to travel in the longitudinal direction, and a fence to guide said material as it travels along the linear path;
said heating means comprises an infra red quartz heating element and an elongated parabolic reflector for directing heat to the desired location, and hold down rollers for keeping said material from warping as it is heated;
said fold pattern comprises at least three grooves and the embossing means comprises ridges suitable for making the grooves; and said frame comprises a table.
said heating means comprises an infra red quartz heating element and an elongated parabolic reflector for directing heat to the desired location, and hold down rollers for keeping said material from warping as it is heated;
said fold pattern comprises at least three grooves and the embossing means comprises ridges suitable for making the grooves; and said frame comprises a table.
13. An embossing apparatus for embossing onto a length of substantially rigid plastic material moving along a linear path at least one fold line pattern comprising a series of generally parallel grooves with groove depth increasing from the outside to the middle of the pattern, the embossing apparatus comprising a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
14. The apparatus of claim 13 wherein the groove depth increases from the outside to the middle of the pattern.
15. The apparatus of claim 14 wherein the fold pattern comprises at least three grooves and the embossing means comprises at least three ridges suitable for making the grooves.
16. A method for embossing onto a length of material at least one fold line pattern comprising a series of generally parallel grooves, said method comprising the steps of:
heating said material sufficiently so that the fold pattern may be embossed onto said material; and embossing said material between a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
heating said material sufficiently so that the fold pattern may be embossed onto said material; and embossing said material between a knurled flat roller and a cooperating embossing roller comprising a series of ridges suitable for embossing the fold pattern.
17. The method of claim 16 wherein the groove depth increases from the outside to the middle of the pattern.
18. The method of claim 17 wherein the fold pattern comprises at least three grooves and the embossing means comprises ridges suitable for making the grooves.
19. The method of claim 17 wherein the heating step further comprises directing heat to the desired location utilizing a heat reflector.
20. The method of claim 19 wherein the heat reflector is an elongated parabolic reflector.
21. The method of claim 17 wherein the heating step further comprises holding down said material during the heating step to minimize warping of the material.
22. The method of claim 17 wherein said material comprises a multilayer high density polyethylene corrugated material.
23. The method of claim 22 wherein said material is heated to a temperature in the range of about 175°F to about 400°F.
24. A substantially rigid plastic material having at least one fold line pattern comprising a series of generally parallel grooves.
25. The material of claim 24 wherein the groove depth increases from the outside to the middle of the pattern.
26. The material of claim 25 wherein said material comprises a multilayer corrugated material.
27. The material of claim 25 wherein said material comprises a multilayer high density polyethylene corrugated material.
28. The material of claim 27 wherein the fold pattern comprises at least grooves.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/686,036 US5183672A (en) | 1991-04-16 | 1991-04-16 | Apparatus for forming at least one fold line pattern in a rigid plastic material |
US686,036 | 1991-04-16 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2048329A1 true CA2048329A1 (en) | 1992-10-17 |
Family
ID=24754639
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002048329A Abandoned CA2048329A1 (en) | 1991-04-16 | 1991-08-01 | Apparatus and method for forming at least one fold line pattern in a rigid plastic material |
Country Status (4)
Country | Link |
---|---|
US (2) | US5183672A (en) |
AU (1) | AU1876892A (en) |
CA (1) | CA2048329A1 (en) |
WO (1) | WO1992018319A1 (en) |
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1991
- 1991-04-16 US US07/686,036 patent/US5183672A/en not_active Expired - Lifetime
- 1991-08-01 CA CA002048329A patent/CA2048329A1/en not_active Abandoned
-
1992
- 1992-04-16 WO PCT/US1992/003201 patent/WO1992018319A1/en active Application Filing
- 1992-04-16 AU AU18768/92A patent/AU1876892A/en not_active Abandoned
- 1992-07-23 US US07/919,353 patent/US5304056A/en not_active Expired - Fee Related
Also Published As
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AU1876892A (en) | 1992-11-17 |
US5304056A (en) | 1994-04-19 |
WO1992018319A1 (en) | 1992-10-29 |
US5183672A (en) | 1993-02-02 |
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Legal Events
Date | Code | Title | Description |
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EEER | Examination request | ||
FZDE | Discontinued |