US20120180931A1 - Thermoforming Web Accumulator and Method - Google Patents
Thermoforming Web Accumulator and Method Download PDFInfo
- Publication number
- US20120180931A1 US20120180931A1 US13/430,574 US201213430574A US2012180931A1 US 20120180931 A1 US20120180931 A1 US 20120180931A1 US 201213430574 A US201213430574 A US 201213430574A US 2012180931 A1 US2012180931 A1 US 2012180931A1
- Authority
- US
- United States
- Prior art keywords
- web
- thermoforming
- accumulator
- frame
- guide element
- 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
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- 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
- B29C65/1432—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 direct heating of the surfaces to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
- B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
- B29C65/2007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror
- B29C65/2038—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror being a wire
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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- B29C65/2046—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" using a welding mirror which also cuts the parts to be joined, e.g. for sterile welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29C65/2053—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by special ways of bringing the welding mirrors into position
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29C65/7433—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a wire
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/78—Means 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
- B29C65/7841—Holding or clamping means for handling purposes
- B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/114—Single butt joints
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/1317—Means feeding plural workpieces to be joined
- Y10T156/1322—Severing before bonding or assembling of parts
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- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/1317—Means feeding plural workpieces to be joined
- Y10T156/1322—Severing before bonding or assembling of parts
- Y10T156/1326—Severing means or member secured thereto also bonds
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- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/1317—Means feeding plural workpieces to be joined
- Y10T156/1322—Severing before bonding or assembling of parts
- Y10T156/133—Delivering cut part to indefinite or running length web
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- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/14—Surface bonding means and/or assembly means with shaping, scarifying, or cleaning joining surface only
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- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
- Y10T156/1702—For plural parts or plural areas of single part
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
- Electromagnetism (AREA)
- Toxicology (AREA)
- Fluid Mechanics (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Replacement Of Web Rolls (AREA)
Abstract
A thermoforming web accumulator is provided having a frame, a web guide element, an arm, and an actuator. The frame is configured to be provided within a thermoforming line. The web guide element is configured to be provided beneath a web of thermoformable material being delivered along the thermoforming line. The arm is carried by the frame and is configured to articulate the web guide element between raised and lowered positions. The actuator is operatively coupled with the arm to articulate the arm to controllably move the web guide element between raised and lowered positions to accumulate an extra length of web and discharge the extra length of web during a web splicing operation. A method is also provided.
Description
- This application is a continuation of U.S. patent application Ser. No. 12/692,377 which was filed Jan. 22, 2010, entitled “Thermoformable Web Splicer and Method”, which claims priority to U.S. Provisional Patent Application Ser. No. 61/218,979 which was filed Jun. 21, 2009, entitled “Hot Wire Splicer”, the entirety of each of which is incorporated by reference herein.
- This invention pertains to apparatus and methods for splicing together films or sheets of thermoplastic material. More particularly, the present invention relates to butt welding of thermoplastic sheet stock material with a splice to continuously deliver sheet material to a thermoforming process.
- Apparatus and methods are known for joining together sheets of thermoplastic film being used to feed a thermoforming apparatus. Taping splicing apparatus are known. Attempts have been made to butt weld thermoplastic sheets and films in an effort to continuously supply sheet to a thermoforming apparatus. However, no one has been successful in perfecting a process that is continuous and does not interrupt operation of the thermoforming apparatus. For example, U.S. Pat. Nos. 3,769,124; 3,834,971; 3,956,047; and 4,001,067 illustrate one attempt to splice sheets of thermoplastic film, but a lack of commercial success resulted due to shortcomings.
- A splicing apparatus and method are provided for butt welding or splicing together a trailing end of a thermoplastic sheet of stock material with a leading end of a thermoplastic sheet of stock material to impart a continuous supply of sheet. A pair of clamps are used to manipulate and position the overlapped sheets while a hot wire is manipulated to sever the sheets and weld together the heated ends of the sheets, thereby joining them together into a continuous sheet. An accumulator is provided to facilitate splicing of thermoformable webs during a continuous thermoforming operation without necessitating stopping of the operation.
- According to one aspect, a thermoforming web accumulator is provided having a frame, a web guide element, an arm, and an actuator. The frame is configured to be provided within a thermoforming line. The web guide element is configured to be provided beneath a web of thermoformable material being delivered along the thermoforming line. The arm is carried by the frame and is configured to articulate the web guide element between raised and lowered positions. The actuator is operatively coupled with the arm to articulate the arm to controllably move the web guide element between raised and lowered positions to accumulate an extra length of web and discharge the extra length of web during a web splicing operation.
- According to another aspect, a thermoforming web accumulator is provided for a web splicing operation having a frame, a web support element, and kinematic linkage. The web support element is carried for movement relative to the frame. The kinematic linkage is carried by the frame and is configured to support the web support element for articulation between raised and lowered positions corresponding with accumulation and dispersal of an extra length of web prior to and during a web splicing operation.
- According to yet another aspect, a method is provided for accumulating a surplus length of thermoformable web material usable during a web splicing operation. The method includes: providing a web splicer within a thermoforming line and a web accumulator downstream of the web splicer having a web guide element configured to support a thermoformable web and movable between raised and lowered positions; determining a minimum length of surplus web needed by a thermoforming line; detecting an end condition for an old web being supplied to the thermoforming line; raising the web guide element to accumulate at least the minimum length of surplus web usable during a next web splice operation; and lowering the web guide element to disperse the accumulated length of surplus web while splicing the old web to a new web.
- According to even another aspect, a method is provided for joining together thermoformable sheets. The method includes: providing a first thermoformable sheet overlapped with a second thermoformable sheet; moving a heating element through the first sheet and the second sheet to form a trailing terminal edge and a leading terminal edge, respectively; aligning in proximate, spaced-apart relation the trailing terminal edge and the leading terminal edge; inserting the heating element between and spaced from the trailing terminal edge and the leading terminal edge; while holding the heating element between the trailing terminal edge and the leading terminal edge, heating the trailing terminal edge and the leading terminal edge with the heating element sufficiently to impart melt-back of each edge away from the heating element at a melt-back rate; while heating the leading terminal edge and the trailing terminal edge, moving the leading terminal edge and the trailing terminal edge each towards the heating element at a rate no greater than the melt-back rate so as to prevent contact of each edge with the heating element while maintaining proximity with the heating element to deliver heat to each edge; removing the heating element from between the trailing terminal edge and the leading terminal edge; and after removing, fusing together the leading terminal edge and the trailing terminal edge by moving together the leading terminal edge and the trailing terminal edge until respective melted portions on each edge engage.
- According to yet even another aspect, a method is provided for joining together thermoformable sheets. The method includes providing a first thermoformable sheet with a trailing terminal edge and a second thermoformable sheet with a leading terminal edge; aligning in proximate, spaced-apart relation the trailing terminal edge and the leading terminal edge; inserting a heating element between and spaced from the trailing terminal edge and the leading terminal edge; while holding the heating element between the trailing terminal edge and the leading terminal edge, heating the trailing terminal edge and the leading terminal edge with the heating element sufficiently to impart melt-back of each edge away from the heating element at a melt-back rate; while heating the leading terminal edge and the trailing terminal edge, moving the leading terminal edge and the trailing terminal edge each towards the heating element at a rate no greater than the melt-back rate so as to prevent contact of each edge with the heating element while maintaining proximity with the heating element to deliver heat to each edge; removing the heating element from between the trailing terminal edge and the leading terminal edge; and after removing, moving the leading terminal edge and the trailing terminal edge together until respective melted portions on each edge engage.
- According to a further aspect, an apparatus is provided for joining together thermoformable sheets. The apparatus includes a frame, an entrance vacuum clamping bar assembly, an exit vacuum clamping bar assembly, a sheet severing mechanism, and at least one sheet actuator. The entrance vacuum clamping bar assembly is supported by the frame and has a vacuum clamping member supported for movement toward and away for a vacuum servo member generally perpendicular to a sheet travel path. The vacuum clamping member is further supported for retraction and extension parallel to the sheet travel path. The exit vacuum clamping bar assembly is supported by the frame downstream of the entrance vacuum clamping bar assembly and has a clamping member supported for movement toward and away from a vacuum servo member generally perpendicular to a sheet travel path. The vacuum clamping member is further supported for retraction and extension parallel to the sheet travel path. The sheet severing mechanism is provided for severing an overlapped old sheet and new sheet. The at least one actuator is carried by the frame and is configured to move each of the vacuum clamping members toward and away from a splice to retract scrap sheet away from a splice line between the entrance vacuum clamping bar assembly and the exit vacuum clamping bar assembly. One of the entrance and exit vacuum clamping member is provided above the respective vacuum servo member and another of the entrance and exit vacuum clamping member is provided below the respective vacuum servo member.
- These and other aspects will be described in greater detail hereinafter.
- Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
-
FIG. 1 is a perspective view from above of a web splicing apparatus including a downstream web accumulator shown in a lowered position. -
FIG. 2 is a perspective view of the web splicing apparatus ofclaim 1 and showing the web accumulator shown in raised position. -
FIG. 3 is a simplified elevational view of the web splicing apparatus ofFIGS. 1-2 showing the web accumulator in a lowered and raised position, including a block diagram of control system and drive components along with a simplified perspective view of a web payout. -
FIG. 4 is a simplified plan view of a web splicing apparatus. -
FIG. 5 is a simplified right elevational view of the web splicing apparatus ofFIG. 1 from the downstream end. -
FIG. 6 is a simplified vertical sectional view taken along line 6-6 ofFIG. 4 . -
FIG. 7 is a simplified partial and vertical sectional view taken in an opposite direction of the view inFIG. 6 of the pre-feed section for the web splicing apparatus ofFIGS. 1-6 . -
FIG. 8 is a simplified partial and vertical side view of the splice section assembly for the web splicing apparatus ofFIGS. 1-6 . -
FIG. 9 is a simplified component view of the servo bars and clamp bars of the splice section ofFIG. 8 . -
FIG. 10 is a vertical sectional view of selected splicer section components corresponding with a sheet payout mode. -
FIG. 11 is an enlarged view taken from theencircled region 11 ofFIG. 10 . -
FIG. 12 is a vertical sectional view of selected splicer section components corresponding with a new sheet delivery mode. -
FIG. 13 is an enlarged view taken from theencircled region 13 ofFIG. 12 . -
FIG. 14 is a vertical sectional view of selected splicer section components corresponding with a vacuum clamp mode. -
FIG. 15 is an enlarged view taken from theencircled region 15 ofFIG. 14 . -
FIG. 16 is a vertical sectional view of selected splicer section components corresponding with a sheet apart mode. -
FIG. 17 is an enlarged view taken from theencircled region 17 ofFIG. 16 . -
FIG. 18 is a vertical sectional view of selected splicer section components corresponding with a wire cut sheets mode. -
FIG. 19 is an enlarged view taken from theencircled region 19 ofFIG. 18 . -
FIG. 20 is a vertical sectional view of selected splicer section components corresponding with a scrap retract mode. -
FIG. 21 is an enlarged view taken from theencircled region 21 ofFIG. 20 . -
FIG. 22 is a vertical sectional view of selected splicer section components corresponding with an alignment mode. -
FIG. 23 is an enlarged view taken from the encircledregion 23 ofFIG. 22 . -
FIG. 23A is a further enlarged view taken from the encircledregion 23A ofFIG. 23 . -
FIG. 24 is a vertical sectional view of selected splicer section components corresponding with a sheet approach mode. -
FIG. 25 is an enlarged view taken from the encircledregion 25 ofFIG. 24 . -
FIG. 25A is a further enlarged view taken from the encircledregion 25A ofFIG. 25 . -
FIG. 25B is further enlarged view taken from the encircledregion 25 ofFIG. 25 , but taken later in time thanFIG. 25A . -
FIG. 26 is a vertical sectional view of selected splicer section components corresponding with a wire withdraw and sheet load mode. -
FIG. 27 is an enlarged view taken from the encircledregion 27 ofFIG. 26 . -
FIG. 27A is a further enlarged view taken from the encircled region 27A ofFIG. 27 . -
FIG. 27B is a further enlarged view taken from the encircled region 27A ofFIG. 27 , but taken later in time thanFIG. 27A . -
FIG. 28 is a vertical sectional view of selected splicer section components corresponding with a sheet apart and scrap withdrawal mode. -
FIG. 29 is an enlarged view taken from the encircledregion 29 ofFIG. 28 . -
FIG. 30 is an enlarged component perspective view of an entrance vacuum bar assembly ofFIGS. 6 and 9 . -
FIG. 31 is an enlarged component perspective view of an exit vacuum bar assembly ofFIGS. 6 and 9 . -
FIG. 32 is a component perspective view of the splice section assembly ofFIG. 8 taken from the same end of the machine, but omitting the hot wire web cutting mechanism to simplify the drawing. -
FIG. 33 is a component perspective view of the splice section assembly ofFIGS. 8 and 30 taken from an opposite end of the machine. -
FIG. 34 is a component perspective view of the splice alignment assembly mechanism taken from the same end asFIG. 33 . -
FIG. 35 is a component perspective view of the splice tilt mechanism taken from the same end asFIG. 33 . -
FIG. 36 is a component perspective view of an assembly for the hot wire web cutting mechanism. -
FIG. 37 is a process flow diagram assembled together fromFIGS. 37A and 37B and showing the logic processing for accumulating surplus web needed by a thermoforming machine during a web splicing operation. - This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (
Article 1, Section 8). - Reference will now be made to one embodiment of Applicants' invention for a thermoforming sheet splicing apparatus and method for joining together old and new thermoformable plastic sheets of material for continuously feeding a thermoforming press when molding articles. While the invention is described by way of one embodiment, it is understood that the description is not intended to limit the invention to such embodiment, but is intended to cover alternatives, equivalents, and modifications which may be broader than the embodiment, but which are included within the scope of the appended claims.
- In an effort to prevent obscuring the invention at hand, only details germane to implementing the invention will be described in great detail, with presently understood peripheral details being omitted, as needed, as being presently understood in the art.
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FIGS. 1-3 show a sheet orweb splicing apparatus 10 according to the present invention. As shown inFIGS. 1-3 ,apparatus 10 includes aweb accumulator 11 that is mounted atop asplicer frame 12.Web splicing apparatus 10 operates to splice a leading edge of a new web onto a trailing edge of an old web, each typically stored as a roll, in a manner that does not interrupt feeding of a thermoformable web into a continuously operating thermoforming line.Web accumulator 11 has been omitted fromFIGS. 4-6 in order to simplify the drawings, but it is understood thataccumulator 11 is normally provided atopapparatus 10 inFIGS. 4-6 , according to one implementation. Optionally,accumulator 11 can be omitted and another form of accumulation device can be used in conjunction with the remaining portion ofapparatus 10. Alternatively,accumulator 11 can be omitted fromapparatus 10 or can be provided as a separate stand-along machine.Web accumulator 10 is raised in order to store an extra length of thermoformable web sheet material during a web splicing operation so that delivery of the web to a downstream thermoforming machine does not interrupt operation of the thermoforming machine during a web splicing operation. The accumulated length is paid out during a splicing operation. - As shown in
FIG. 1 ,web accumulator 11 provides acylindrical support roller 25 that is raised and lowered in order to temporarily store an extra length of thermoformable web to supply the web while a splicing operation is being performed withapparatus 10, such that a downstream thermoforming operation does not need to be slowed down or stopped during a splicing operation. A typical thermoforming operation is continuous, with a thermoformable web being delivered in a continuously fed, intermittent motion matching the motion of platens opening and closing on a heated web such that the web is stopped during a forming step and moved after the thermoforming step to prepare for a subsequent thermoforming step. -
Web accumulator 11 includes a pair ofsupport arms frame 12 ofapparatus 10 with a plurality of threaded fasteners (not shown). A pair of curvedtubular lift arms support arm lift arm cylindrical roller 25 for rotation. A web of thermoformable material that leavesexit assembly 18 passes overroller 25. By raisingroller 25, an extra length of web can be stored atoproller 25 for later use while the web is being shuttled back and forth withinsplicing apparatus 10 when splicing together a nearly depleted, or old web and a new web. - More particularly,
roller 25 is raised and lowered by extending and retracting a pair ofpneumatic cylinders support arms arms pneumatic cylinders lower roller 25. -
FIG. 2 showsroller 25 in a raised configuration, whereasFIG. 1 showsroller 25 in a lowered configuration. A pair of cross bars 39 and 41, each of rectangular cross section, are connected betweensupport arms arms lift arms clamp brackets Bars - According to one construction,
roller 25 is formed from a cylindrical piece of aluminum machined with a central bore and cylindrical end grooves that each receive a standard deep grooveroller ball bearing central bolt shaft 75 extends throughroller 25, as well as inner races ofbearings end mounting brackets arms - Proximal ends of
lift arms support arms ball bearing assemblies shaft arm assembly shaft lift arm arm assembly -
FIG. 2 illustratesaccumulator 11 articulated to a position withroller 25 raised in order to accumulate a web of thermoformable material exitingexit assembly 18 ofsplicer 10. A web of thermoformable material leavessplicer 10 viaexit assembly 18 and passes overroller 25.Roller 25 is raised and the web is fed at an increased rate prior to a splicing operation in order to accumulate an extra length of web material overroller 25, which is later used to feed a thermoforming machine downstream ofsplicer 10 during a splicing operation. During the splicing operation, the accumulated web is used to feed a downstream thermoforming machine.Roller 25 is lowered at a controlled rate in order to supply the accumulated web during a splicing operation to the thermoforming machine, while preventing the web from collecting on a factory floor. - As shown in
FIG. 3 , acomputer 73 having auser interface 19 enables setup and operator control of a control system 13 (seeFIG. 3 ) that configures the height, timing and speed with whichroller 25 is raised prior to and during a web splicingoperation using splicer 10. -
FIG. 3 illustratescontrol system 13 in a simplified block diagram form for controlling operation ofsplicer 10, including controlled articulation ofaccumulator 11.Control system 13 is implemented oncomputer 73.Control system 13 includesprocessing circuitry 15,memory 17,user interface 19 and acontrol algorithm 21. -
Control algorithm 21 enablescontrol system 13 to control delivery of pneumatic fluid from apneumatic source 77 via apneumatic control valve 23 and to control operation ofservomotors control algorithm 21 includes a recipe comprising control settings that can be set and retrieved to raiseroller 25 to a sufficient height and at an appropriate rate based upon operating characteristics of a specific thermoforming line. For example, a specific thermoformable web material on a specific thermoforming line will operate with a specific shot length and with a specific cycle time. This information is combined with a period of time needed to perform a web splice, thereby enabling determination of how much web needs to be accumulated in order to prevent any need to slow down or stop the thermoforming line. - In order to enable automatic operation of
splicer 10 to perform a splice between a terminal portion of an old web roll and a leading portion of a new web roll, a sensing apparatus is implemented on aweb roll payout 5. The sensing apparatus comprises anoptical sensor 6 having an emitter and detector that combines with an alignedmirror 8 to provided an optical line ofsight 9 that generates a signal when an old web roll is nearly depleted. Such signal is received bycontrol system 13.Sensor 6 andmirror 8 generate a feedback signal to controlsystem 13 when an old roll reduces in diameter sufficient thatsensor 6 detects a reflected back signal frommirror 8, corresponding with a diameter of the old web roll falling below a specific size. A time delay is then implemented bycontrol system 13, after which a splice is implemented automatically corresponding with a terminal end portion of the old web roll beingproximate splicer 10, ensuring a splice before the old web passes throughsplicer 10. -
FIGS. 4-6 further illustrate construction ofweb splicing apparatus 10. In order to simplify the drawings,accumulator 11 has been omitted but is understood to be mounted atopapparatus 10 as depicted inFIGS. 1-3 above. Optionally,accumulator 11 can be provided by a separate stand-along device.Apparatus 10 has aframe 12 that supports acontrol box 14, an entrancepre-feed assembly 16, anexit assembly 18 and asplice section assembly 20. Avacuum tank 22 for storing a source of vacuum air is provided atopframe 12. -
FIG. 6 illustratespre-feed assembly 16 where a new sheet of thermoformable material is received into the machine. The sheet is then advanced to thesplice section assembly 20 where it is spliced together with a trailing end of an old sheet of thermoformable material. The sheet normally exits the machine via theexit assembly 18.Tank 22 supplies an air vacuum from a vacuum source (not shown) for vacuum bars and clamp bars of thesplice section assembly 20. Thesplice section assembly 20 includes an entrancevacuum bar assembly 130 and an exitvacuum bar assembly 132. -
FIG. 7 shows an arrangement of coacting pre-feed wheels 24 (provided on both lateral edges of an incoming sheet) driven by aprefeed motor 28 to drive a new sheet towards a nip/payout rollers assembly 26.Assembly 26 is driven in coacting relation via apayout motor 30.Assembly 26 can drive new and old sheets in forward and reverse directions, under computer control.Motors FIG. 3 ). - According to one construction,
prefeed motor 28 ofFIG. 7 is a Siemens servo motor Model No. 1FK7043-7AK71-1DA3.Payout motor 30 ofFIG. 7 is a Siemens servo motor Model No. 1FK7085-7AF71-1DA3. Furthermore, tilt motor 32 (seeFIG. 32 ) is a Siemens servo motor Model No. 1FK7043-7AK71-1DA3 and splice align motor (for sheet thickness) 34 is a Siemens servo motor Model No. 1 FK7043-7AK71-1DA3. Finally, hot wire motor 36 (seeFIG. 36 ) is a Siemens servo motor Model No. 1FK7043-7AK71-1DA3. These servo motors are available commercially in the USA through Siemens Johnson City—SIAC, One Internet Plaza, Johnson City, Tenn. 37604, USA. -
FIG. 8 illustrates thesplice section assembly 20 from a side opposite to that shown inFIG. 7 . Further component details are shown inFIGS. 30 and 31 below. More particularly, atilt motor 32 drives a pair ofsplice tilt mechanisms cross bar 70 that links identical, but opposed articulating motions between the twomechanisms web cutting mechanism 38 supports an electrically resistive heated hot wire between a pair of end spools for severing and heating webs of thermoformable material that the wire is articulated through via upward and downward pivotal motion of hot wireweb cutting mechanism 38. Hot wireweb cutting mechanism 38 is driven up and down along a large arc via ahot wire motor 36. Further details of hot wireweb cutting mechanism 38 are shown below with reference toFIG. 34 . Asplice alignment motor 34 adjusts one side of thesplice section assembly 20 in elevational height as depicted below byFIG. 23 . -
FIG. 9 illustrates further details of thesplice section assembly 20. More particularly, an upstream clamp assembly is formed by aservo bar 40 and aclamp bar 42. A downstream clamp assembly is formed by aservo bar 44 and aclamp bar 46.Bars bar stiffener plates bars bars - As shown in
FIG. 9 , a pair oflateral retraction assemblies frames assemblies pneumatic cylinders 60 that retract and extendbars -
FIG. 10 is a vertical sectional view of selected splicer section components ofsplicer section assembly 20 corresponding with a sheet payout mode where a terminating end of oldthermoformable sheet 86 needs to be spliced onto a leading end of a new thermoformable sheet (not shown yet). -
FIG. 11 is an enlarged view taken from the encircledregion 11 ofFIG. 10 showing details ofsheet 86 and the clamp bars and servo bars during a sheet payout mode while thermoformingsheet 86, prior to running out ofsheet 86.Splice tilt mechanisms eccentric links respective pivot point - Hot wire
web cutting mechanism 38 includes a pair of arms that are clamped onto a pivot shaft in spaced apart relation. Each arm, at a radial end, supports a ceramic wheel with a conductive hot wire stretched between the wheels. The wire is raised and lowered to cut throughsheets Mechanism 38 is driven in reciprocation by the hot wire motor. Optionally, a cutting wheel or blade (such as a carbide blade) can be provided on a linear track (supported by the frame) in order to cut the old and new sheets, andmechanism 38 can be used solely to heat and splice together the two sheets. For example, solid plastic sheet can be cut with a rotating cutting wheel on a track, andmechanism 38 can be used to heat and splice together the two sheets. This modification would overcome the need for additional heat to quickly sever solid sheet, thereby potentially speeding up the operation. -
FIG. 12 is a vertical sectional view of selected splicer section components corresponding with a new sheet delivery mode. More particularly, a leading end of a new sheet is overlappingold sheet 86 prior to being spliced together.FIGS. 12 through 29 occur sequentially. -
FIG. 13 is an enlarged view taken from the encircledregion 13 ofFIG. 12 showing a leading end ofnew sheet 88 lying atop a trailing end ofold sheet 86. Thehot wire 84 is provided belowsheets -
FIG. 14 is a vertical sectional view of selected splicer section components corresponding with a vacuum clamp mode where both servo bars and clamp bars are driven into engagement withsheets bar FIG. 4 ). -
FIG. 15 is an enlarged view taken from the encircledregion 15 ofFIG. 14 showing thebars contacting sheets -
FIG. 16 is a vertical sectional view of selected splicer section components corresponding with a sheet apart mode. More particularly,servo motor 34 drives splicealignment mechanism 96 ofFIG. 32 so as to articulatesplice section assembly 20 and move the sheets apart vertically in order to provide a gap between thesheets sheets -
FIG. 17 is an enlarged view taken from the encircledregion 17 ofFIG. 16 .Sheets hot wire 84 up through the sheets, during the following step. -
FIG. 18 is a vertical sectional view of selected splicer section components corresponding with a wire cut sheets mode.Hot wire 84 has been heated (by electrical resistance) and raised throughsheets -
FIG. 19 is an enlarged view taken from the encircledregion 19 ofFIG. 18 . A trailingscrap sheet 90 is severed fromold sheet 86 and aleading scrap sheet 92 is severed from anew sheet 88.Hot wire 84 has been moved to a raised position, abovesheets sheets -
FIG. 20 is a vertical sectional view of selected splicer section components corresponding with a scrap retract mode. The clamp bars and servo bars are holding each respective sheet via an applied vacuum while the respective pairs of servo bar and clamp bar are retracted laterally away from the other pair of servo bar and clamp bar. -
FIG. 21 is an enlarged view taken from the encircledregion 21 ofFIG. 20 . The movement of clamp bars 42 and 46 moves thescrap sheets sheets -
FIG. 22 is a vertical sectional view of selected splicer section components corresponding with a sheet alignment mode. -
FIG. 23 is an enlarged view taken from the encircledregion 23 ofFIG. 22 . Servo bars 40 and 44 are driven down and up, respectively, to bringsheets Bars bars Hot wire 84 is now centered between the severed ends ofsheets -
FIG. 23A shows alignment ofsheets wire 84. Splice alignment occurs using the mechanism ofFIG. 33 .Wire 84 is held here for a time (dwell delay that can be adjusted, depending on the sheet. Computer control via processing circuitry, memory and a program enables tailoring of the dwell time where motion is held still during the heating process. -
FIG. 24 is a vertical sectional view of selected splicer section components corresponding with a sheet approach mode. During this stage, the heated wire dwell ends and thesheets FIG. 32 ). -
FIGS. 25 and 25A provide enlarged views taken from the encircledregion 25 ofFIG. 24 and the encircledregion 25A ofFIG. 25 , respectively. Sheets are brought closer together during heating bywire 84 as each clamp assembly is tilted so as to push the edges ofsheets wire 84 “dwells” between the edges ofsheets FIG. 25B is taken later in time than the view ofFIGS. 25 and 25A and depicts the further advancement together of the edges of sheet, building a melted bead or pool on each edge. During a “mashing” operation, it is presently believed (although not certain) that the melted beads on each edge intermix and join together to form a stronger splice because of the presence of the beads and the increased rate with which the “mash” operation ofFIG. 27B is implemented. It is presently believed that the creation of these melted beads is somewhat analogous to formation of a welding bead when welding steel. The building of this bead in the steps ofFIGS. 25A and 25B has been found through preliminary testing to generate a stronger and less brittle splice. The trailing terminal edge and the leading terminal edge are both heated with the heating element, or wire, sufficiently to impart melt-back of each edge away from the heating element at a melt-back rate. While heating the leading terminal edge and the trailing terminal edge, the leading terminal edge and the trailing terminal edge are each moved towards the heating element at a rate no greater than the melt-back rate so as to prevent contact of each edge with the heating element while maintaining proximity with the heating element to deliver heat to each edge. Additionally, the process that forms the bead edge on each sheet also straightens out the edge, eliminating any “mouth-shaped edge” caused during severing and resulting from sheet stresses. -
FIG. 26 is a vertical sectional view of selected splicer section components corresponding with a wire withdraw and sheet load mode. During this mode, the wire is moved down and thesheets FIG. 29 ). -
FIG. 27 is an enlarged view taken from the encircledregion 27 ofFIG. 26 .Sheets FIG. 27A shows the ends ofsheets -
FIG. 27B occurs later in time thanFIG. 27A and depicts a “mash” step where the heated ends of sheet are pushed together edge-wise at a higher rate (than inFIG. 25B ), imparting greater fusing and increased strength and resilience to the resulting joining splice. As shown inFIGS. 25A and 25B , while heating the leading terminal edge and the trailing terminal edge, the leading terminal edge and the trailing terminal edge each move towards the heating element at a rate no greater than the melt-back rate so as to prevent contact of each edge with the heating element while maintaining proximity with the heating element to deliver heat to each edge. In the step ofFIG. 27B , the rate with which the leading terminal edge and the trailing terminal edge are moved together is increased in order to fuse together the leading terminal edge and the trailing terminal edge as they cool to form a connection seam. -
FIG. 28 is a vertical sectional view of selected splicer section components corresponding with a sheet apart and scrap withdrawal mode. During this mode, the fused togethersheets Scrap 90 is ejected and dropped while a vacuum still holdsscrap 92 for later removal by a machine operator or technician. -
FIG. 29 is an enlarged view taken from the encircledregion 29 ofFIG. 28 . Fused togethersheets splice 85. This splice operation occurs quick enough that acontinuous sheet 86/88 can be spliced together to feed a continuously operating thermoforming operation without having to stop and start the thermoforming machine. - In one exemplary implementation, tests were run using polystyrene foam sheet with 8.5 pound density and 0.1″ (one hundred thousandth inch) thickness. A one (1) millimeter diameter Inconel® X750 hot wire was heated to 800 degrees Farenheit (a range of 700 to about 1200 degrees Farenheit has been found to work for various materials). A melt-back distance (see
FIGS. 25A and 25B ) on each sheet of 0.115″ inches was achieved and a 0.025″ “mash” distance was achieved on each sheet. It was found through preliminary testing that any delays greater than 200 milliseconds from the time heat was removed from the sheet edges and the time that “mash” initiated resulted in a non-desirable weakening in strength and resilience of the resulting splice. It is presently believed that air quickly cools a surface along each melted bead on each sheet edge, and the “mash” step ofFIG. 27B (occurring at a higher speed) better intermixes the internal melted regions of each melted bead, thereby resulting in a stronger splice. -
FIG. 30 is a component perspective view of the entrancevacuum bar assembly 130 shown inFIGS. 6 and 9 .Assembly 130 is formed by an upper vacuumbar stiffener plate 48 that is mounted for reciprocation in parallel relation relative to a lower vacuumbar stiffener plate 50 via a pair of paralleldie post assemblies tilt linkages FIG. 34 ) attach via pivotally supported and threadedattachment bolts plate 48 in order to adjust vertical positioning ofplate 48 during a splicing operation. A pair oftoggle brackets FIG. 34 ) attach via pivotally supported and threadedattachment bolts plate 50 in order to adjust vertical positioning ofplate 50 during a splicing operation. Furthermore, a pair ofeccentric cam linkages FIG. 35 ) attach via pivotally supported and threadedattachment bolts plate 50 in order to tilt the assembly ofplates plates FIGS. 25-27 ). Eachbolt cylindrical cam spacer respective mount -
Plate 48 is supported for up and down reciprocation atopplate 50 viadie post assemblies FIG. 30 .Assemblies pneumatic cylinder mount base bracket suitable cylinder 138, 139 is an SMC Model No. NCDGWBA50, High Speed/Precision Cylinder, Double Acting, Single Rod, pneumatic cylinder sold by SMC Corp of America, US Headquarters, 10100 SMC Blvd., Noblesville, Ind. 46060. No pneumatic fluid is delivered to each cylinder. Instead, pneumatic supply fittings at opposed ends of each cylinder are joined together with a pneumatic tube in order to prevent contaminants from entering each cylinder. A central body of eachcylinder plate 48 via acylindrical clamp assembly clamp 120, secures each end ofvacuum bar 40 onto the central body of eachcylinder Die post assemblies post assemblies FIG. 31 . -
Servo bar 40 andclamp bar 42 ofFIG. 30 each receive a vacuum via a plurality offlexible vacuum tubes Tubes common vacuum manifolds main vacuum lines -
Clamp bar 42 is supported by a plurality of double acting, double rodpneumatic cylinders 60, as shown inFIG. 30 . Eachcylinder 60 is mounted at each rod end to plate 50 and acylinder attachment bar 159 that is secured ontoplate 50 via acylinder mounting bar 158. A body of each cylinder is secured with threaded fasteners onto a bottom surface ofclamp bar 42. Onesuitable cylinder 60 is an SMC Model No. SMC MUWB 50-25D, plate cylinder, double acting, double rod, pneumatic cylinder sold by SMC Corp of America, US Headquarters, 10100 SMC Blvd., Noblesville, Ind. 46060. A cylindricalplastic bumper 160 is provided on one rod of eachcylinder 60 away frombar 42 to limit lateral movement to a predetermined amount. Apneumatic manifold 122 supplies pressurized air, or pneumatic fluid via fluid lines to eachactuator 60. -
FIG. 31 is a component perspective view of the exitvacuum bar assembly 132 shown inFIGS. 6 and 9 .Assembly 132 is formed by an upper vacuumbar stiffener plate 48 that is mounted for reciprocation in parallel relation relative to a lower vacuumbar stiffener plate 50 via a pair of paralleldie post assemblies tilt linkages FIG. 34 ) attach via pivotally supported and threadedattachment bolts plate 52 in order to adjust vertical positioning ofplate 52 during a splicing operation. Atilt spacer bushing 180 is provided in eachmount 176 and 177 (seeFIG. 6 ). A pair oftoggle brackets FIG. 34 ) attach via pivotally supported and threadedattachment bolts plate 54 in order to adjust vertical positioning ofplate 54 during a splicing operation. Furthermore, a pair ofeccentric cam linkages FIG. 35 ) attach via pivotally supported and threadedattachment bolts plate 54 in order to tilt the assembly ofplates plates FIGS. 25-27 ). Eachbolt cam spacer bushing respective mount -
Plate 52 is supported for up and down reciprocation beneathplate 54 viadie post assemblies FIG. 31 .Assemblies pneumatic cylinder mount base bracket suitable cylinder cylinder plate 44 via acylindrical clamp assembly clamp 152, secures each end ofvacuum bar 40 onto the central body of eachcylinder Die post assemblies post assemblies FIG. 30 . -
Servo bar 44 andclamp bar 46 ofFIG. 31 each receive a vacuum via a plurality offlexible vacuum tubes Tubes common vacuum manifolds main vacuum lines -
Clamp bar 46 is supported by a plurality of double acting, double rodpneumatic cylinders 60, as shown inFIG. 31 . Eachcylinder 60 is mounted at each rod end to plate 54 and acylinder attachment bar 159 that is secured ontoplate 54 via acylinder mounting bar 158. A body of each cylinder is secured with threaded fasteners onto a top surface ofclamp bar 46. Onesuitable cylinder 60 is an SMC Model No. SMC MUWB 50-25D, plate cylinder, double acting, double rod, pneumatic cylinder sold by SMC Corp of America, US Headquarters, 10100 SMC Blvd., Noblesville, Ind. 46060. A cylindricalplastic bumper 160 is provided on one rod of eachcylinder 60 away frombar 46 to limit lateral movement to a predetermined amount. Apneumatic manifold 168 supplies pressurized air, or pneumatic fluid via fluid lines to eachactuator 60. -
FIG. 32 is a component perspective view of thesplice section assembly 20 ofFIG. 8 taken from the same end of the machine. A lateralscrap retraction assembly 56 is shown with a plurality of spaced-apart pneumatic cylinders 60 (seeFIG. 9 ) used to laterally retractclamp bar 42, as shown inFIG. 21 .Splice section assembly 20 includes entrancevacuum bar assembly 130 and exitvacuum bar assembly 132 which are articulated to desirable positions using the kinematic mechanisms described below with reference toFIGS. 34 and 35 . -
FIG. 33 is a component perspective view of the splice section assembly ofFIGS. 8 and 32 taken from an opposite end of the machine and showing lateralscrap retraction assembly 58 used to laterally retractclamp bar 46, as shown inFIG. 21 . Interconnectingcross members vacuum bar assembly 130 and exitvacuum bar assembly 132. -
FIG. 34 is a component perspective view of thesplice alignment mechanism 96 taken from the same end asFIG. 33 .Splice alignment mechanism 96 articulates entrance vacuum bar assembly 130 (seeFIG. 30 ) and exit vacuum bar assembly 132 (seeFIG. 32 ) so as to perform the vertical alignment betweensheets FIGS. 22 and 23 . More particularly,servo motor 34 drives splicealignment mechanism 96 back and forth via primary crankarm 248 and asecondary crank arm 249, as shown inFIGS. 34 and 35 . Crankarm 249 pivotsshaft 205 back and forth so as to pivottilt linkages fasteners - As shown in
FIG. 34 , a compound crankarm 250 is affixed onto an end ofshaft 205 in order to drive remaining shafts 202-204 in corresponding pivotal motion. Shafts 202-205 are each mounted at each end to opposed walls onframe 12 with rotary bearing assemblies. Adrive linkage 246 is pivotally affixed via a bearing mount onto crankarm 250 and via a second bearing mount onto a drivencrank arm 255. Crankarm 255 is affixed onto an end ofshaft 202 to drivetilt linkages toggle brackets tilt linkages Fasteners respective toggle bracket linkage 246 includes apneumatic cylinder 243 that is pressurized during use so as to provide a spring withinlinkage 246. One suitablepneumatic cylinder 243 is an SMC Model No. NCG50-ICN004-0100,SMC NCG CYLINDER 50MM BORE 1″ STROKE W/AIR CUSHION & 5/8-11 THREAD, pneumatic cylinder sold by SMC Corp of America, US Headquarters, 10100 SMC Blvd., Noblesville, Ind. 46060. Likewise, anotherdrive linkage 244 is pivotally affixed via a bearing mount onto crankarm 250 and via a second bearing mount onto a drivencrank arm 252. Crankarm 252 is affixed onto an end ofshaft 204 to drivetilt linkages toggle brackets tilt linkages Fasteners respective toggle bracket Drive linkage 244 includes apneumatic cylinder 242 that is pressurized during use so as to provide a spring withinlinkage 244. One suitablepneumatic cylinder 242 is an SMC Model No. NCG50-ICNO04-0100,SMC NCG CYLINDER 50MM BORE 1″ STROKE W/AIR CUSHION & 5/8-11 THREAD, pneumatic cylinder sold by SMC Corp of America, US Headquarters, 10100 SMC Blvd., Noblesville, Ind. 46060. Finally, adrive linkage 71 is pivotally affixed via a bearing mount onto crankarm 250 and via a second bearing mount onto a drivencrank arm 254. Crankarm 254 is affixed onto an end ofshaft 203 to drivetilt linkages Tilt linkages drive fasteners -
FIG. 35 is a component perspective view of thesplice tilt mechanism 94 taken from the same end asFIG. 32 . Thismechanism 94 tilts or pivots the bars in order to drive togethersheets FIGS. 23-27B .Splice tilt mechanism 94 articulates entrance vacuum bar assembly 130 (seeFIG. 30 ) and exit vacuum bar assembly 132 (seeFIG. 32 ) so as to move together ends ofsheets FIGS. 24-26 , as well as during the “mash” operation of Figures 26-27. More particularly,shaft 207 supports a pair of eccentriccam bearing assemblies 260 provided ineccentric cam linkages shaft 206 supports a pair of eccentriccam bearing assemblies 260 provided ineccentric cam linkages cam bearing assembly 260. Alternatively, a cylindrical end segment of eachshaft FIG. 30) and 174 , 175 (seeFIG. 31 ) so that splice tilt mechanism drives entrance vacuum bar assembly 130 (seeFIG. 30 ) and exit vacuum bar assembly 132 (seeFIG. 31 ).Tilt motor 32 drives eccentric cam linkages 256-259 substantially horizontally to and fro by rotatingshafts crossbar 70 and coupled crankarms Tilt motor 32drives shaft 206 in back and forth rotation via primary crankarm 270 andsecondary crank arm 271. -
FIG. 36 illustrates one implementation for a web cutting apparatus comprising a hot wireweb cutting mechanism 38. Optionally, a blade or scissor cutting mechanism can be used to cut a terminal end of an old web and a leading end of a new web prior to splicing them together. More particularly,web cutting mechanism 38 comprises ahot wire 84 carried under tension between a pair ofwheels Wheels wire 84 is a circumferential outer groove.Wheel 82 is pivotally supported by an arm 262 (with a bearing) and includes an integral arm rotateswheel 82 so as totension wire 84 as a result of a tensionedcoil spring 267.Wheel 79 is rigidly mounted onarm 263.Arms cylindrical shaft 208. Adrive arm 264 secures ontoshaft 208 and drivesshaft 208 into rotation in order to raise andlower wire 84.Shaft 208 is supported at each end with a rotational bearing supported by end plates of theframe 12 for apparatus 10 (seeFIG. 1 ). Acrank arm 264 drivesarm 264 andshaft 208 in response to activation of a hot wireservo drive motor 36. Aelectromagnetic sensor 268 detects position ofmotor 36 base upon movement of a base plate onmotor 36. -
FIG. 37 is a logic flow diagram illustrating the steps implemented by the control system when setting up and performing a splice between a trailing end of an old, or first web and a leading end of a new, or second web. - In Step “S1”, a thermoforming machine, web splicer and web accumulator are provided along with a source of thermoformable web comprising an old web and a new web to be spliced onto the old web. The web accumulator has an articulating frame and a height adjustable roller provided along a downstream end of the splicer. A control system is also provided along with an actuator that is controlled to articulate the frame so as to raise and lower the roller when accumulating extra web and releasing the accumulated web when splicing the new web onto the old web so that a downstream thermoforming machine can run at a consistent cyclical rate, even during a splicing operation. After performing Step “S1”, the process proceeds to Step “S2”.
- In Step “S2”, an operator determines a cycle time for the operating thermoforming machine for a specific thermoformable web and a specific die set. After performing Step “S2”, the process proceeds to Step “S3”.
- In Step “S3”, an operator determines a shot length for the operating thermoforming machine for a specific thermoformable web and a specific die set. After performing Step “S3”, the process proceeds to Step “S4”.
- In Step “S4”, an operator sets a splice cycle time for the web splicer. After performing Step “S4”, the process proceeds to Step “S5”.
- In Step “S5”, an operator determines a minimum length of surplus web needed by the thermoforming machine during a splice cycle time. After performing Step “S5” the process proceeds to Step “S6”.
- In Step “S6”, a control system drives the splicer to deliver the old web through the splicer and to an operating thermoforming machine to accumulate at least the minimum length of web, or sheet. Concurrent with or after performing Step “S6”, the process proceeds to Step “S7”.
- In Step “S7”, an operator arms the splicer to automatically perform a splice in response to a web terminal end condition being detected for the old web. In one case, a preselected time delay is provided between detecting the condition and performing the splice. In another case, the splice occurs immediately after detecting the condition. After performing Step “S7”, the process proceeds to Step “S8”.
- In Step “S8”, the control system detects with a sensor presence of a terminal end condition for the old web. If a terminal end condition is detected, the process proceeds to Step “S9”. If not, the process returns to Step “S8”.
- In Step “S9”, the control system drives the actuator to raise the accumulator roller sufficient to accumulate a length of surplus web needed for use when splicing a leading end of a new web to a terminal end of the old web. After performing Step “S9”, the process proceeds to Step “S10”.
- In Step “S10”, the control system drives the actuator to lower the accumulator roller sufficient to supply the accumulated length of surplus web for use by the thermoforming machine while splicing the old web to the new web. After performing Step “S10”, the process proceeds to Step “S11”.
- In Step “S11”, the new web becomes an old web and a subsequent new web is provided to the splicer. After performing Step “S11”, the process proceeds to Step “S7”. If a new web is not provided, the process is terminated.
- In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
Claims (22)
1. A thermoforming web accumulator, comprising:
a frame configured to be provided within a thermoforming line;
a web guide element configured to be provided beneath a web of thermoformable material being delivered along the thermoforming line;
an arm carried by the frame and configured to articulate the web guide element between raised and lowered positions; and
an actuator operatively coupled with the arm to articulate the arm to controllably move the web guide element between raised and lowered positions to accumulate an extra length of web and discharge the extra length of web during a web splicing operation.
2. The web accumulator of claim 1 , further comprising a control system operatively coupled with the actuator and adapted to control operation of the arm to raise the web guide element in order to accumulate the extra length of web material and to lower the web guide element in order to supply the accumulated extra length of web to a downstream thermoforming machine during a splicing operation of the thermoforming line.
3. The web accumulator of claim 2 , wherein the frame comprises a splicer frame, and further comprising a web splicing apparatus operative to splice together a leading edge of a new web onto a trailing edge of an old web so as to not interrupt feeding of a thermoformable web into a continuously operating thermoforming line.
4. The web accumulator of claim 2 , wherein the web guide element comprises a roller configured to support an extra length of web of thermoformable material during accumulating and delivery of the extra length of web material during a web splicing operation.
5. The web accumulator of claim 1 , wherein the arm comprises a pair of support arms pivotally supported by the frame in spaced apart relation.
6. The web accumulator of claim 5 , wherein the roller comprises a cylindrical roller having a central bore, a pair of bearings one provided at each end about the bore, and a central support shaft extending through the bore, supporting the bearings and affixed at each end to a respective one of the pair of support arms.
7. The web accumulator of claim 1 , wherein the frame comprises a pair of spaced-apart support arms, and the arm comprises a pair of curved lift arms each pivotally supported by a respective one of the pair of support arms.
8. The web accumulator of claim 1 , wherein the actuator comprises a pneumatic cylinder extending between the arm and the frame and operative to raise and lower the web guide element by extending and retracting the pneumatic cylinder.
9. The web accumulator of claim 1 , wherein the web guide element comprises a lateral element extending from the arm and configured to support and guide the web of thermoformable material during delivery of the web through a splicing operation of a continuously operating thermoforming line, while preventing the web from collecting onto a floor.
10. A thermoforming web accumulator for a web splicing operation, comprising:
a frame;
a web support element carried for movement relative to the frame; and
a kinematic linkage carried by the frame and configured to support the web support element for articulation between raised and lowered positions corresponding with accumulation and dispersal of an extra length of web prior to and during a web splicing operation.
11. The thermoforming web accumulator of claim 10 , wherein the frame is a web splicer frame.
12. The thermoforming web accumulator of claim 10 , wherein the web support element comprises a cylindrical roller supported laterally and beneath the web of thermoformable material.
13. The thermoforming web accumulator of claim 10 , wherein the kinematic linkage comprises a pair of arms carried for pivotal movement relative to the frame, the web support element carried between the arms spaced from the frame.
14. The thermoforming web accumulator of claim 13 , further comprising a drive mechanism coupled between the frame and at least one of the arms operative to articulate the arms to raise and lower the web support element.
15. The thermoforming web accumulator of claim 14 , wherein the web support element comprises a cylindrical roller extending laterally between the arms and configured for rotation therebetween.
16. A method for accumulating a surplus length of thermoformable web material usable during a web splicing operation, comprising:
providing a web splicer within a thermoforming line and a web accumulator downstream of the web splicer having a web guide element configured to support a thermoformable web and movable between raised and lowered positions;
determining a minimum length of surplus web needed by a thermoforming line;
detecting an end condition for an old web being supplied to the thermoforming line;
raising the web guide element to accumulate at least the minimum length of surplus web usable during a next web splice operation; and
lowering the web guide element to disperse the accumulated length of surplus web while splicing the old web to a new web.
17. The method of claim 16 , wherein the web guide element comprises a cylindrical roller extending beneath and transverse to the web and configured to rotate during delivery of the web over the cylindrical roller.
18. The method of claim 17 , further comprising advancing the web over the cylindrical roller to advance the web during a thermoforming operation.
19. The method of claim 18 , wherein advancing the web occurs concurrent with raising the cylindrical roller.
20. The method of claim 18 , wherein advancing the web occurs concurrent with lowering the cylindrical roller.
21. The method of claim 16 , wherein determining a minimum length of web comprises determining cycle time and shot length for a thermoforming machine downstream of the splicer, and providing a splice cycle time.
22. The method of claim 16 , wherein the old web is provided on a roll, and detecting an end condition for an old web comprises detecting when a diameter of the old web roll falls below a specified size.
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US13/430,574 US20120180931A1 (en) | 2009-06-21 | 2012-03-26 | Thermoforming Web Accumulator and Method |
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US13/430,574 US20120180931A1 (en) | 2009-06-21 | 2012-03-26 | Thermoforming Web Accumulator and Method |
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US13/453,858 Expired - Fee Related US8770250B2 (en) | 2009-06-21 | 2012-04-23 | Thermoformable web joining apparatus |
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Also Published As
Publication number | Publication date |
---|---|
US20120205053A1 (en) | 2012-08-16 |
US8163118B2 (en) | 2012-04-24 |
US8770250B2 (en) | 2014-07-08 |
US20100319837A1 (en) | 2010-12-23 |
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