CN103826828A - 热成形片材装载设备及方法 - Google Patents

热成形片材装载设备及方法 Download PDF

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CN103826828A
CN103826828A CN201280035987.XA CN201280035987A CN103826828A CN 103826828 A CN103826828 A CN 103826828A CN 201280035987 A CN201280035987 A CN 201280035987A CN 103826828 A CN103826828 A CN 103826828A
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sheet material
insert
vacuum plant
vacuum
attached
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CN103826828B (zh
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滋维·兰普鲍特
查德·E·霍华德
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Nike Innovation LP
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Nike International Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10Forming by pressure difference, e.g. vacuum
    • B29C51/105Twin sheet thermoforming, i.e. deforming two parallel opposing sheets or foils at the same time by using one common mould cavity and without welding them together during thermoforming
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26Component parts, details or accessories; Auxiliary operations
    • B29C51/42Heating or cooling
    • B29C51/421Heating or cooling of preforms, specially adapted for thermoforming
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/002Joining methods not otherwise provided for
    • B29C65/008Joining methods not otherwise provided for making use of electrostatic charges
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022Particular heating or welding methods not otherwise provided for
    • B29C65/028Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841Holding or clamping means for handling purposes
    • B29C65/7847Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841Holding or clamping means for handling purposes
    • B29C65/7852Holding or clamping means for handling purposes using electrostatic forces to hold at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
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    • B29C66/4326Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532Joining single elements to the wall of tubular articles, hollow articles or bars
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/543Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining more than two hollow-preforms to form said hollow articles
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    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61Joining from or joining on the inside
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832Reciprocating joining or pressing tools
    • B29C66/8322Joining or pressing tools reciprocating along one axis
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H3/00Separating articles from piles
    • B65H3/08Separating articles from piles using pneumatic force
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    • B65H3/0816Suction grippers separating from the top of pile
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    • B29C49/00Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2008Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article
    • B29C2049/2013Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article for connecting opposite walls, e.g. baffles in a fuel tank
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C49/00Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2073Means for feeding the inserts into the mould, preform or parison, e.g. grippers
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2791/004Shaping under special conditions
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Abstract

一种制造物品的方法包括用真空装置同时保持彼此重叠且邻接的第一物体和第二物体。该方法还包括同时相对于机器运输第一物体和第二物体。更进一步,该方法包括用机器将第一物体和第二物体附接在一起。

Description

热成形片材装载设备及方法
领域
本公开涉及热成形,且特别地涉及热成形片材装载设备及方法。
背景
热成形是其中物体比如聚合物片材或膜被加热至柔韧、用模具成形为一定形状且然后被冷却的制造工艺。双片材热成形是相关的工艺,其中两个物体被加热,由相应的模具成形,趁热被结合在一起,且然后被冷却以典型地形成中空的物品。用这些工艺,物品可以形成各种各样的形状,且物品可以使用各种材料来有效地生产。
在双片材热成形的情况下,片材常常被独立地装载到热成形炉中,这可能不利地增加制造时间。而且,在一些情况下,片材被各自连接到间隔物(spacer)的相对侧部,且组件被装载到炉中。在该后者的情况下,将片材附接到隔板可能耗费大量的时间,和/或被成形部件通常需要被从间隔物切割,其中的每一个都降低制造效率。此外,在一些情况下,框架、插入件或其他物体有时被插入模具之间以恰当地形成物品,并且将这些部件定位在模具之间可能是额外地费时的且可能负面地影响制造效率。
概述
因此,尽管上面描述的已知装置的改进,仍然存在对于制造物品的方法的需要,该方法包括用真空装置同时保持彼此重叠且邻接的第一物体和第二物体。这种方法还包括相对于机器同时运输第一物体和第二物体。更进一步,该方法包括用该机器将第一物体和第二物体附接在一起。
还公开了一种热成形系统,该热成形系统包括真空装置,该真空装置可操作成同时保持彼此重叠且邻接的第一物体和第二物体。该系统还包括加热第一物体和第二物体、将第一物体和第二物体附接在一起且将第一物体和第二物体成形为热成形物品的热成形机器。
此外,公开了一种制造热成形囊的方法,该方法包括提供具有吸头的真空装置、具有第一真空架和第二真空架的操作装置(handling device),以及具有加热装置和模具的热成形机器。该方法还包括将第一片材、第二片材及插入件设置在支撑表面上的堆栈(stack)中,其中第一片材和第二片材由聚合物制成,其中第一片材和第二片材在堆栈中邻接地分层堆放在彼此之上,且其中第一片材和第二片材在堆栈中堆叠在插入件之上。该方法还包括用真空装置通过用吸头接触第一片材和第二片材中的仅仅一个而从堆栈中同时抓住第一片材和第二片材,并从第一片材和第二片材中的一个悬置第一片材和第二片材中的另一个。此外,该方法包括将第一片材和第二片材同时从支撑表面运输到操作装置。另外,该方法包括通过吸力将第一片材结合到第一真空架并通过吸力将第二片材结合到第二真空架。而且,该方法包括将第一片材和第一真空架移动离开第二片材和第二真空架。而且,该方法包括用真空装置抓住插入件且用真空装置将插入件放置在第一片材和第二片材之间且用加热装置加热第一片材和第二片材。此外,该方法包括将插入件的第一部分附接到第一片材,将插入件的第二部分附接到第二片材,且延伸连接到插入件的第一部分和第二部分的插入件的连接构件。更进一步,该方法包括将第一片材和第二片材附接在一起且使用模具将第一片材和第二片材成形为包括囊的三维弯曲表面。
本章节提供了对本公开的大体概述,且不是其全部范围或其全部特征的全面公开。另外的适用性领域从本文提供的说明书将变得明显,本概述中的描述和特定例子仅仅意在用于说明的目的且不意在限制本公开的范围。
附图
本文所描述的附图仅仅用于对所选择的实施方案而不是所有可能的实施方案的说明的目的,且不意在限制本公开的范围。
图1是用于热成形物品的热成形系统的一部分的示意图;
图2是图1的热成形系统的示意图;
图3是图1的热成形系统的示意图;
图4是图1的热成形系统的示意图;
图5是图1的热成形系统的示意图;
图6是图1的热成形系统的示意图;
图7是图1的热成形系统的示意图;
图8是图1的热成形系统的示意图;
图9是图1的热成形系统的示意图;以及
图10是图1的系统的示意图;
在附图的全部几个视图中,相应的参考数字表示相应的部分。
详细描述
现在将更充分地参考附图来描述示例性实施方案。
参考图1-10,示意性地图示了用于将第一物体12和第二物体14附接在一起的系统10。在一些实施方案中,系统10可以是热成形系统10且可以用于双片材热成形工艺;然而,应理解,本公开的教导可以应用到其他类型的系统和制造方法,而不偏离本公开的范围。
在热成形系统10的情况下,第一物体12和第二物体14可以被加热、成形并附接以形成物品,比如囊16a、16b(图8-10)。更具体地,如将要讨论的,系统10可以操控和运输第一物体12和第二物体14,可以将插入件17放置在物体12、14之间,且可以以非常有效的方式将物体12、14基本密封在一起以形成多个囊16a、16b。囊16a、16b可以被包含在鞋类物品中、在护胫或其他运动器械中、或在任何其他合适的物件(未示出)内。然而,应理解,系统10可以用于制造除了囊16a、16b以外的任何合适的物品,而不偏离本公开的范围。
如图4中示意性地图示的,系统10可以包括具有一个或多个抽吸构件20(例如,吸头)的真空装置18。系统10还可以包括装载构件22、致动器24及具有一个或多个真空架27a、27b(例如,抽吸构件)的操作装置26。此外,系统10可以包括具有加热装置32、模具28a、28b以及充气装置34的热成形机器30。
通常,物体12、14和插入件17可以被分层堆放且堆放在如图1所示的装载构件22上面。然后,如图2和图3所示,真空装置18的抽吸构件20可以同时抓住(保持、夹持等)第一物体12和第二物体14并将第一物体12和第二物体14抬升或以其它方式运输远离装载构件22。接下来,如图4所示,致动器24可以使得真空装置18的抽吸构件20将第一物体12和第二物体14同时运输到操作装置26,于是物体12、14随后受控于操作装置26(图5)。此外,如图5和图6所示,真空架27a、27b可以分别结合到第一物体12和第二物体14,并将第一物体12和第二物体14分开。接下来,物体12、14可以通过加热装置32加热直至柔韧。随后,如图7所示,插入件17可以被放置在第一物体12和第二物体14之间。然后,如图8所示,当施加热量且充气装置34对物体12、14之间的区域充气时,模具28a、28b可以用于形成物体12、14并将物体12、14附接在一起。接下来,如图9所示,模具28a、28b可以被分开且真空装置18可以从模具28a、28b处移走囊16a、16b。然后,如图10所示,单独的囊16a、16b可以彼此分开,且囊16a、16b可以被单独地修整以除去多余的材料。
如将要讨论的,系统10及其操作方法可以以非常有效的方式制造囊16a、16b。例如,由于第一物体12和第二物体14同时被真空装置18抓住、保持和运输,所以该制造工艺可以相对快速地完成,而不需要多余的操作器械,且物体12、14相对少地准备。而且,一个或多个操作可以部分地或完全地自动化,例如,使用一个或多个机器人。像这样地,囊16a、16b可以相对快速地制成,且16a、16b可以以可重复的方式在高的公差内形成。
现在将更详细地讨论系统10的不同特征。如图1、图2和图4所示,装载构件22可以是具有大体平坦的支撑表面36的稳固平台。装载构件22也可以是移动式的。例如,装载构件22可以包括用于可移动地支撑装载构件22的一个或多个轮38。在一些实施方案中,装载构件22可以手动地移动,但在其他实施方案中,装载构件22可以是机动化的或者以其它方式自动地移动。
如图1所示,第一物体12和第二物体14和插入件17可被布置在支撑表面36上的堆栈40中。例如,第一物体12可以直接地重叠且分层堆放在第二物体14上,使得第一物体12和第二物体14对齐且彼此直接地邻接(例如,邻接地分层堆放)。而且,第二物体14可以直接重叠且分层堆放在插入件17上。另外,堆栈40可以根据真空装置18的抽吸构件20的数量和位置来布置。例如,第一物体12和第二物体14可以定位在表面36上,使得物体12、14的重量可以大体均匀地分布在抽吸构件20之间。而且,如将要讨论的,每个插入件17可以根据抽吸构件20的间隔被隔开,使得每个抽吸构件20能够抓住插入件17中的一个。
而且,尽管图1中所图示的堆栈40只包括在分别的层中的第一物体12、第二物体14及插入件17,但是应理解,堆栈40可以包括一系列第一物体12和第二物体14及插入件17。例如,堆栈40可以包括第一物体12,第一物体12被分层堆放在第二物体14上,第二物体14被分层堆放在插入件17上,插入件17被分层堆放在另一个第二物体14上,另一个第二物体14被分层堆放在另外的插入件17上,以此类推。另外,堆栈40可以通过自动送料机、输送机等手动地或自动地布置。
物体12、14可以属于任何合适的类型,比如大体平坦的聚合材料片材。例如,物体12、14可以由具有微层结构的聚氨酯材料制成。在一些实施方案中,物体12、14可以由在以下文件中讨论的一种或多种材料制成或包括在以下文件中讨论的一种或多种材料:美国专利第5,952,065号、美国专利第5,713,141号、美国专利申请第08/580,946号、美国专利第6,521,305号、美国专利第6,620,472号、美国专利申请第08/475,276号、专利第6,599,597号、美国专利第6,730,379号、美国专利第7,851,036号、美国专利申请第08/475,275号、美国专利第6,203,868号、美国专利第6,321,465号、美国专利第6,013,340号、美国专利第6,391,405号、美国专利第6,797,215号、美国专利第6,652,940号、美国专利第6,692,803号、美国专利第7,078,091号、美国专利第6,127,026号、美国专利第6,082,025号、美国专利第6,846,534号、和/或美国专利第6,582,786号,其中每个通过引用以其整体并入本文。
插入件17可以由任何合适的材料制成。例如,如图8-10所示,插入件17可以包括第一片材部分42、第二片材部分44及多个连接构件46。插入件17可以包括在2000年9月19日发布的美国专利第6,119,371号中公开的材料,且该美国专利通过引用以其整体并入本文。
另外,真空装置18可以包括任何数量的抽吸构件20。抽吸构件20可以每个被结合到支撑框架47。支撑框架47可以是具有延伸穿过的流体通道的刚性构件,且抽吸构件20可以从支撑框架47的分别的端部悬置。支撑框架47也可以是与真空源48流体连通的。像这样地,抽吸构件20可以在框架47的相应端部处于远离彼此的固定距离,且抽吸构件20可以是通过延伸穿过框架47的通道与真空源48流体连通的。
真空装置18和真空源48也可以被可操作地结合到如图4所示的操作装置26的真空架27a、27b。此外,真空装置18和真空源48也可以被可操作地结合到如图4所示的模具28a、28b。在其他实施方案中,系统10可以包括用于将吸力提供到抽吸构件20、真空架27a、27b及模具28a、28b的分开的独立真空源48。
真空架27a、27b可以是矩形的框架状构件,每个具有分别的开口49。真空架27a、27b还可以包括一个或多个部分50(图4)。在所图示的实施方案中,真空架27a、27b每个包括分别的长形凹槽状口部50。口部50可以与真空源48连通。因此,如将要讨论的,真空架27可以将吸力提供到第一物体12从而夹持第一物体12,且真空架27b可以将吸力提供到第二物体14从而夹持第二物体14。
致动器24可以属于任何合适的类型,比如电驱动的可编程机器人。致动器24也可以包括一个或多个气动驱动的致动器、一个或多个液压驱动的致动器,或任何其它合适类型的致动器24。致动器24可以被可操作地结合到框架47、真空架27a、27b、模具28a、28b或用于致动相同构件的系统10的任何其他部件。应理解,可以存在用于致动不同部件的共用致动器24,或者可以存在用于致动单个部件的多个独立的致动器24。致动器24可以在任何合适的方向上线性地和/或旋转地移动。
此外,致动器24可以提供例如框架47和热成形机器30之间的相对移动。像这样地,当机器30保持静止时致动器24可以移动框架47或反之亦然,或者致动器24可以将框架47和机器30同时相对于彼此移动。致动器24也可以提供系统10的任何部件之间的类似相对移动。
另外,如图4-6所示,模具28a、28b可以是在其中具有一个或多个母型腔52的基本实心的构件。腔52可以根据囊16a、16b的所希望形状而被三维地弯曲。模具28a、28b可以被可操作地结合到致动器24以朝向或远离彼此移动。模具28a、28b还可以包括一个或多个口部51(图4),口部51与真空源48连通,使得模具28a、28b可以将吸力提供到第一物体12和第二物体14,如下面将要讨论的。
如图8所示,模具28a、28b可以朝向彼此移动以在腔52内形成囊16a、16b。此外,如图9所示,模具28a、28b可移开以露出成形的囊16a、16b。在一些实施方案中,模具28a、28b的宽度可以小于真空架27a、27b的开口49的内部宽度(图4)。像这样地,为了将被讨论的目的,模具28a、28b可以被接纳在开口49中且可以移动穿过开口49。应理解,模具28a、28b可以包括用于形成单个囊16a、16b的单个腔52,或如图4-9所示,模具28a、28b可以包括用于同时形成多个囊16a、16b的多个腔52。
更进一步,热成形机器30可以包括加热装置32。加热装置32可以是电阻型加热装置32或任何其他合适的类型。此外,热成形机器30可以包括接纳真空架27a、27b和/或模具28a、28b的室(未特别地示出)。
现在将更详细地讨论囊16a、16b的制造方法。应理解,制造顺序可以以任何合适的方式变化,而不偏离本公开的范围。
从图1开始,堆栈40可以被提供在支撑表面36上。然后,致动器24可以使框架47和被朝向支撑表面36的连接的抽吸构件20致动,直到抽吸构件20直接接触并邻接第一物体12的顶部表面60。如图3所示,抽吸构件20可以将吸力提供到顶部表面60,且抽吸构件20可以被抬升远离从支撑表面36,使得第一物体12被从支撑表面36抬升。而且,因此,第二物体14可以从第一物体12悬置且从支撑表面36抬升,使得第一物体12和第二物体14被抽吸构件20同时抓住、保持并抬升。
应理解,虽然抽吸构件20仅仅直接接触第一物体12,但是第一物体12和第二物体14都可以被保持。第二物体14可以通过静电被保持到第一物体12。而且,如图3所示,一个或多个大体密封的腔(微腔)62可以被界定在第一物体12和第二物体14之间,且当第一物体12由于抽吸构件20提供的吸力而变形时,腔62可以增加容积从而降低腔62中的压力且从而将第二物体14保持到第一物体12。也可以使用这些效果的组合将第二物体14保持到第一物体12。此外,在一些实施方案中,第一物体12和第二物体14之间的静电可以被有意地增加,例如通过应用电离空气,通过拭接第一物体12和/或第二物体14或以任何其他方式。
在另外的实施方案中,第一物体12可以是多孔的,使得吸力可以穿过第一物体12的气孔被提供到第二物体14且使得第一物体12和第二物体14可以被同时保持。还应理解,抽吸构件20或其他抽吸装置可以以除了本文所图示和描述的这些方式之外的任何合适的方式同时抓住、保持、夹持和运输第一物体12和第二物体14。
一旦第一物体12和第二物体14被夹持,致动器24就可使框架47朝着操作装置26的真空架27a、27b致动,如如图4所示。例如,真空架27a、27b可以被配置为邻接但在热成形机器外部(图5),且框架47可以在真空架27a、27b之间移动且通过减小或消除来自于抽吸构件20的吸力而将物体12、14存放在真空架27b上。然后,框架47可以从真空架27a、27b之间移出。
此外,如图5和图6所示,真空架27a可以朝着物体12、14和真空架27b移动。一旦真空架27a接触第一物体12且将吸力提供到第一物体12,真空架27a就可以移动远离真空架27b,从而将第一物体12和第二物体14分开。此时,第一物体12可以通过吸力被保持在真空架27a上,且第二物体14可以通过吸力被保持在真空架27b上。
随后,如图6所示,真空架27a、27b和所附接的物体12、14可以向热成形机器30的加热装置32移动且被加热。第一物体12和第二物体14可以以任何合适的温度被加热任何合适的时长(例如,约30秒和3分钟之间),直到其柔韧。在一些实施方案中,第一物体12和第二物体14可以被加热直到其开始在真空架27a、27b的相应开口49(图4)内略微下垂或离开真空架27a、27b的相应开口49。
当物体12、14正被加热时,抽吸构件20可以背对装载构件22致动以抓住插入件17并从支撑表面36抬升。此外,抽吸构件20和插入件17可以向热成形机器30移动。
一旦第一物体12和第二物体14被充分加热,真空架27a、27b就可以从热成形机器30移除,且插入件17可以使用如图7所示的真空装置18存放在第一物体12和第二物体14之间。插入件17可以定位在第二物体14上,使得每个插入件17随后被接纳在模具28a、28b的相应的腔52中。在一些实施方案中,模具28b被向上致动且被部分地接纳在真空架27b中的开口49内,以在插入件17被放置在其上时支撑第二物体14的中心部分。
此外,如图8所示,真空装置18可以从模具28a、28b移除,且模具28a、28b可以被移动到一起。在一些实施方案中,模具28a、28b可以被接纳在真空架27a、27b的开口49内。随后,如图9所示,真空架27a、27b、模具28a、28b及物体12、14可以被运输到热成形机器30,且热量可以被进一步施加。模具28a、28b也可以将压力施加到物体12、14,从而附接、粘附并熔合物体12、14的邻接表面。同时,插入件17的第一部分42可以附接到第一物体12,而物体的第二部分44可以附接到第二物体14。另外,由于物体12、14保持在模具28a、28b的相应的腔52内,因此连接构件46可以在长度上延伸且保持被连接到第一部分42和第二部分44。
在一些实施方案中,通过模具28a、28b提供的吸力足以将物体12、14保持在模具28a、28b的相应的腔52内。而且,在一些实施方案中,充气装置34也可以将加压气体提供(例如,充气)到如图8所示的物体12、14之间的密封空间中,从而根据腔52的三维弯曲内表面形成物体12、14。在还有的另外的实施方案中,代替提供吸力的模具28a、28b且代替用充气装置34将物体12、14之间的空间充气,重力或其他力促使物体12、14在模具28a、28b的相应腔52内移动以在其中形成。
此外,如图9所示,成形的囊16a、16b可以被冷却,且模具28a、28b和真空架27a、27b可以移动远离彼此。然后,抽吸构件20可以在模具28a、28b之间移动,以便抓住囊16a、16b并将囊16a、16b从模具28a、28b移除。随后,如图10所示,附接的囊16a、16b可以被切割或者以其它方式彼此分开,且多余的材料(例如,外围边缘)可以被修整、切割或者以其它方式从每个囊移除,如通过图10中的虚线所示的。这些切割/分开工艺可以自动或手动地完成。
此外,尽管没有阐述,但囊16a、16b可以每个被成形为包括可以用于另外的将囊16a、16b充气的口部、阀或其他特征部。因此,囊16a、16b的制造可以包括队囊16a、16b的进一步充气直到预定压力。此外,囊16a、16b可以随后被加工并安装到鞋类物品、运动器械、背包或任何其他物件中。
因此,上面所描述的系统10及其使用方法可以提供制造囊16a、16b或许多其他物品的高效率方式。例如,物体12、14可以被快速且容易地在支撑表面36上被分层堆积在彼此上面,且然后被同时从支撑表面36自动地抬升以便于另外的加工。与相关的现有技术方法相比,这可以显著地减少准备时间和精力。而且,物体12、14可以随后同时被以自动的方式保持、模制并附接。因此,囊16a、16b可以被相对快速地制造且在高公差内。
为了说明和描述的目的,提供了对实施方案的前述描述。其不意在是穷尽的或者限制本发明。特定实施方案的个别元件或特征通常不限于该特定实施方式,但在适用的情况下,是可互换的且可以用在所选择的实施方案中,虽然没有特别地示出或描述。这些个别元件或特征也可以以许多方式改变。这样的变化不被认为是偏离本发明,且所有这样的修改意在被包括在本发明的范围内。

Claims (23)

1.一种制造物品的方法,所述方法包括:
用真空装置同时保持彼此重叠且邻接的第一物体和第二物体;
相对于机器同时运输所述第一物体和所述第二物体;以及
用所述机器将所述第一物体和所述第二物体附接在一起。
2.根据权利要求1所述的方法,其中所述真空装置包括抽吸构件,且其中同时保持所述第一物体和所述第二物体包括用所述抽吸构件直接接触所述第一物体和所述第二物体中的仅仅一个。
3.根据权利要求2所述的方法,其中同时保持所述第一物体和所述第二物体包括通过所述第一物体和所述第二物体之间的静电保持所述第一物体与所述第二物体。
4.根据权利要求2所述的方法,其中同时保持所述第一物体和所述第二物体包括增加所述第一物体和所述第二物体之间的大体密封的腔的容积。
5.根据权利要求2所述的方法,其中同时保持所述第一物体和所述第二物体包括从所述第一物体和所述第二物体中的一个悬置所述第一物体和所述第二物体中的另一个。
6.根据权利要求1所述的方法,其中所述第一物体和所述第二物体各自是大体平坦的聚合材料片材。
7.根据权利要求1所述的方法,还包括将插入件设置在所述第一物体和所述第二物体之间。
8.根据权利要求7所述的方法,还包括将所述插入件附接到所述第一物体和所述第二物体两者。
9.根据权利要求8所述的方法,其中将所述插入件附接到所述第一物体和所述第二物体两者包括将所述插入件的第一部分附接到所述第一物体且将所述插入件的第二部分附接到所述第二物体,且还包括延伸所述插入件的连接到所述第一部分和所述第二部分两者的连接构件。
10.根据权利要求7所述的方法,还包括在用所述真空装置同时保持所述第一物体和所述第二物体之前将所述第一物体、所述第二物体及所述插入件布置在支撑表面上的堆栈中。
11.根据权利要求10所述的方法,还包括用所述真空装置从所述堆栈同时抓住所述第一物体和所述第二物体,其中相对于所述机器同时运输所述第一物体和所述第二物体包括用所述真空装置将所述第一物体和所述第二物体同时运输远离所述支撑表面,且将所述第一物体和所述第二物体邻近热成形机器存放,且还包括使用所述真空装置从所述支撑表面抓住所述插入件并使用所述真空装置朝着所述热成形机器运输所述插入件。
12.根据权利要求1所述的方法,将所述第一物体和所述第二物体之间的大体密封的区域充气。
13.根据权利要求1所述的方法,还包括将所述第一物体和所述第二物体从所述真空装置转移到操作装置并用所述操作装置将所述第一物体和所述第二物体分开。
14.根据权利要求13所述的方法,其中所述操作装置包括第一抽吸构件和第二抽吸构件,所述第一物体通过吸力结合到所述第一抽吸构件,且所述第二物体通过吸力结合到所述第二抽吸构件。
15.根据权利要求1所述的方法,其中所述机器是热成形机器,且所述方法还包括用所述热成形机器的模具模制所述第一物体和所述第二物体中的至少一个。
16.一种热成形系统,包括:
真空装置,其可操作成同时保持彼此重叠且邻接的第一物体和第二物体;以及
热成形机器,其加热所述第一物体和所述第二物体,所述热成形机器将所述第一物体和所述第二物体附接在一起并将所述第一物体和所述第二物体成形为热成形物品。
17.根据权利要求16所述的热成形系统,其中所述真空装置包括抽吸构件,所述抽吸构件可操作成通过直接接触所述第一物体和所述第二物体中的仅仅一个而同时保持所述第一物体和所述第二物体。
18.根据权利要求17所述的热成形系统,其中所述抽吸构件可操作成同时保持所述第一物体和所述第二物体,其中从所述第一物体和所述第二物体中的一个悬置所述第一物体和所述第二物体中的另一个。
19.根据权利要求16所述的热成形系统,还包括操作装置,所述真空装置可操作成使所述第一物体和所述第二物体受控于所述操作装置,所述操作装置可操作成分开所述第一物体和所述第二物体。
20.根据权利要求19所述的热成形系统,其中所述真空装置还可操作成保持插入件且在所述热成形机器将所述第一物体和所述第二物体附接在一起之前将所述插入件放置在所述第一物体和所述第二物体之间。
21.根据权利要求20所述的热成形系统,还包括堆栈被存放在其上的支撑表面,所述堆栈包括所述第一物体和所述第二物体及所述插入件。
22.根据权利要求16所述的热成形系统,还包括将所述第一物体和所述第二物体之间的大体密封的区域充气的充气装置。
23.一种制造热成形囊的方法,所述方法包括:
提供具有吸头的真空装置、具有第一真空架和第二真空架的操作装置,以及具有加热装置和模具的热成形机器;
将第一片材、第二片材及插入件设置在支撑表面上的堆栈中,所述第一片材和所述第二片材由聚合物制成,其中所述第一片材和所述第二片材在所述堆栈中邻接地分层堆放在彼此之上,且其中所述第一片材和所述第二片材在所述堆栈中堆叠在所述插入件之上;
用所述真空装置通过用吸头接触所述第一片材和所述第二片材中的仅仅一个而从所述堆栈同时抓住所述第一片材和所述第二片材,且从所述第一片材和所述第二片材中的一个悬置所述第一片材和所述第二片材中的另一个;
将所述第一片材和所述第二片材同时从所述支撑表面运输到所述操作装置;
通过吸力将所述第一片材结合到所述第一真空架且通过吸力将所述第二片材结合到所述第二真空架;
将所述第一片材和所述第一真空架远离所述第二片材和所述第二真空架移动;
用所述真空装置抓住所述插入件且用所述真空装置将所述插入件放置在所述第一片材和所述第二片材之间;
用所述加热装置加热所述第一片材和所述第二片材;
将所述插入件的第一部分附接到所述第一片材,将所述插入件的第二部分附接到所述第二片材,且延伸连接到所述插入件的所述第一部分和所述第二部分的所述插入件的连接构件;以及
将所述第一片材和所述第二片材附接在一起且使用所述模具将所述第一片材和所述第二片材成形为包括所述囊的三维弯曲表面。
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