Apparatus and Method for Manufacturing Foam Parts

• US 20090061153A1
• Filed: 08/28/2007
• Published: 03/05/2009
• Est. Priority Date: 08/28/2007
• Status: Active Grant

• Current Assignee: Sealed Air Corporation US (Sealed Air)
• Original Assignee: Sealed Air Corporation US (Sealed Air)
• Inventors: De Luca, Nicholas P., Perkins, Andrew B.
• Granted Patent: US 7,963,020 B2
• Time in Patent Office: Days
• US Class Current: 428/131
• CPC Class Codes: B26D 3/006 specially adapted for cutting blocs of plastic material
• CPC Class Codes: Y10T 156/12 Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means
• CPC Class Codes: Y10T 156/1744 Means bringing discrete articles into assembled relationship
• CPC Class Codes: Y10T 29/49796 Coacting pieces
• CPC Class Codes: Y10T 29/49861 Sizing mating parts during final positional association
• CPC Class Codes: Y10T 29/49902 by manipulating aligning means
• CPC Class Codes: Y10T 29/5138 and means to machine work part to fit cooperating work part
• CPC Class Codes: Y10T 29/5142 and means to sever work from supply
• CPC Class Codes: Y10T 29/5197 Multiple stations working strip material
• CPC Class Codes: Y10T 29/53961 with work-holder for assembly
• CPC Class Codes: Y10T 428/24273 including aperture

Abstract

A method and machine for manufacturing foam parts are provided. The method generally includes cutting a plurality of sections across the width of the base sheet, engaging and reorienting at least one portion of each section, and joining the portions of each section in a desired configuration to thereby form a plurality of parts. The portions can be engaged by actuator assemblies operating in successively adjacent work spaces across the width of the base sheet to simultaneously produce a plurality of similar parts. In some cases, each part includes at least one portion that is reoriented relative to another portion, such as by rotating one of the portions or adjusting one of the portions to a position that is offset from the plane of the section.

Claims

1. A method for manufacturing a plurality of similar foam parts, the method comprising:

providing a base sheet of foam, the base sheet extending in a longitudinal direction and defining a width in a transverse direction perpendicular to the longitudinal direction;

cutting the base sheet to define a plurality of sections across the width of the base sheet, each section including at least first and second portions for manufacturing a respective one of the foam parts, the first and second portions of each section being cut in a first configuration;

engaging the second portions in the first configuration with engagement tools such that the second portion of each section is engaged by a respective one of the engagement tools;

with the second portion of each section engaged by the respective engagement tool, automatically actuating the engagement tools and thereby reorienting the second portion of each section relative to the first portion such that the portions of each section are supported in a desired configuration different from the first configuration; and

joining the first and second portions of each section in the desired configuration to thereby form the plurality of parts.

2. A method according to claim 1 wherein actuating the engagement tools comprises actuating the engagement tools at the same time such that each second portion is reoriented during the reorienting of the second portions of the other sections.

3. A method according to claim 1 wherein actuating the engagement tools comprises actuating each of the engagement tools to move through a similar motion.

4. A method according to claim 1 wherein actuating the engagement tools comprises maintaining the second portions substantially parallel.

5. A method according to claim 1 wherein actuating the engagement tools comprises rotating each of the second portions relative to the first portion of the respective section to a nonparallel configuration relative to the first portion and wherein joining the portions comprises joining the portions of each section in the nonparallel configuration.

6. A method according to claim 1 wherein actuating the engagement tools comprises extending each tool through one of the sections with the tool engaged to one of the second portions.

7. A method according to claim 1 wherein cutting the base sheet comprises cutting the sheet to define at least a third portion in each section and repeating the engaging, actuating, and joining steps to engage the third portion of each respective section, reorient the third portion relative to the first portion of the respective section, and join the third portion to at least one of the first and second portions in the desired configuration.

8. A method according to claim 1 wherein cutting the base sheet comprises cutting each section to define the second portion in an aperture of the first portion, and wherein actuating the engagement tools comprises removing the second portion of each section from the first portion to thereby open the aperture in the first portion.

9. A method according to claim 1 wherein actuating the engagement tools comprises reorienting the second portion to the second configuration in which the second portion is substantially parallel to the first portion and offset from a plane defined by the first portion.

10. A method according to claim 9 wherein cutting the base sheet comprises cutting each section to define the second portion in an aperture of the first portion, and wherein joining the portions comprises joining the second portion in a telescopic configuration relative to the first portion.

11. A method according to claim 10 wherein cutting the base sheet comprises cutting the sheet to define at least a third portion in an aperture of the second portion, and repeating the engaging, actuating, and joining steps to engage the third portion of each respective section, reorient the third portion relative to the first and second portions of the respective section such that the third portion is substantially parallel to the second portion and offset from a plane defined by the second portion, and join the third portion to the second portion in a telescopic configuration relative to the second portion.

12. A method according to claim 1 wherein said engaging step comprises energizing an actuator and thereby rotating a helical pin in a first direction such that the rotating helical pin is advanced into the second portion to engage the second portion, and further comprising subsequently rotating the helical pin in a second opposite direction such that the rotating helical pin is retracted from the second portion.

13. A method according to claim 1 wherein said engaging step comprises energizing an actuator and thereby advancing at least two pins in nonparallel directions such that the pins are advanced into the second portion to engage the second portion, and further comprising subsequently retracting the pins from the second portion.

14. A method according to claim 1, further comprising, subsequent to joining the first and second portions of each section:

dispensing the plurality of parts;

adjusting the base sheet in the longitudinal direction; and

repeating the cutting, engaging, actuating, and joining steps to form a second plurality of parts from the base sheet.

15. A method according to claim 1, further comprising:

providing a plurality of slits in at least one of the portions;

subsequent to joining the portions, expanding the portion defining the slits and thereby opening the slits to define apertures.

16. A machine for manufacturing a plurality of similar foam parts, the machine comprising:

a support member configured to support a base sheet of foam, the base sheet extending in a longitudinal direction and defining a width in a transverse direction perpendicular to the longitudinal direction;

a cutting device configured to cut the base sheet on the support member into a plurality of sections defined across the width of the base sheet and cut each section into at least first and second portions for manufacturing a respective one of the foam parts, the cutting device configured to cut the first and second portions of each section while the portions are disposed in a first configuration;

a plurality of engagement tools disposed across the width of the base sheet, each tool configured to engage the second portion of a respective one of the sections in the first configuration;

a plurality of actuator mechanisms, each actuator mechanism configured to adjust a respective one of the engagement tools with the second portion of each section engaged by the respective engagement tool to thereby reorienting the second portion of each section relative to the first portion such that the portions of each section are supported in a desired configuration different from the first configuration; and

a joining device configured to join the first and second portions of each section in the desired configuration to thereby form the plurality of parts.

17. A machine according to claim 16 wherein the actuator mechanisms are configured to adjust the engagement tools at the same time such that each second portion is reoriented during the reorienting of the second portions of the other sections.

18. A machine according to claim 16 wherein the actuator mechanisms are configured to adjust the engagement tools to move through similar motions.

19. A machine according to claim 16 wherein the actuator mechanisms are configured to adjust the engagement tools to maintain the second portions substantially parallel while reorienting the second portions to the desired configuration of each section.

20. A machine according to claim 16 wherein each actuator mechanism comprises:

a first member defining an end extending from a frame of the machine;

a second member adjustably connected to the end of the first member and configured to be adjusted along a longitudinal direction defined by the first and second members; and

a head member connected to the second member by two links, each link being rotatably connected to the second member and the head member such that the head member is configured to be rotated relative to the second member about an axis perpendicular to the longitudinal direction of the members,

wherein the engagement tool is adjustably mounted to the head member.

21. A machine according to claim 20 wherein at least one of the first and second members defines a rotary joint such that the head member is configured to rotate about a longitudinal axis of the members.

22. A machine according to claim 20 wherein the axis perpendicular to the longitudinal direction of the members about which the head member is configured to rotate is offset from a longitudinal axis defined by the members such that the engagement tool is configured to be disposed substantially along the longitudinal axis when the head member is rotated about the axis perpendicular to the longitudinal direction to each of two perpendicular positions of the head member.

23. A machine according to claim 16, further comprising a mandrel defining first and second surfaces corresponding to the first and second portions of each section in the second configuration, the first and second surfaces being parallel and offset in different planes.

24. A machine according to claim 16 wherein the actuator mechanisms are spaced transversely along the width of the base sheet and the support member in successive work areas along the width of the base sheet and the support member such that each actuator mechanism is configured to rotate the respective engagement tool within a respective one of the work area.

25. A machine according to claim 16 wherein each engagement tool comprises a helical pin, and each actuator mechanism comprises an actuator configured to rotate the pin in a first direction and thereby advance the pin into a respective second portion to engage the second portion and to rotate the pin in a second opposite direction and thereby retract the pin from the respective second portion.

26. A machine according to claim 16 wherein each engagement tool comprises at least two pins, and each actuator mechanism comprises an actuator configured to advance the pins in nonparallel directions such that the pins are advanced into a respective second portion to engage the second portion and to retract the pins from the second portion.

27. A machine according to claim 16, further comprising a feed mechanism configured to adjust the base sheet in the longitudinal direction toward the engagement tools.

28. A mechanism for engaging and reorienting a foam portion, the mechanism comprising:

a first member extending along a longitudinal direction;

a second member adjustably connected to an end of the first member and configured to be adjusted relative to the first member in the longitudinal direction;

first and second links rotatably connected to the second member;

a head member rotatably connected to each of the first and second links such that the head member is configured to be rotated relative to the second member about an axis perpendicular to the longitudinal direction; and

an engagement tool adjustably mounted to the head member, the engagement tool configured to be advanced into the foam portion to engage the foam portion and retracted from the foam portion to disengage the foam portion.

29. A mechanism according to claim 28 wherein at least one of the first and second members defines a rotary joint such that the head member is configured to rotate about a longitudinal axis of the members.

30. A mechanism according to claim 28 wherein the axis perpendicular to the longitudinal direction of the members about which the head member is configured to rotate is offset from a longitudinal axis defined by the members such that the engagement tool is configured to be disposed substantially along the longitudinal axis when the head member is rotated about the axis perpendicular to the longitudinal direction to each of two perpendicular positions of the head member.

31. A mechanism according to claim 28 wherein the engagement tool comprises a helical pin, and the mechanism further comprises an actuator configured to rotate the pin in a first direction and thereby advance the pin into the foam portion and to rotate the pin in a second opposite direction and thereby retract the pin from the foam portion.

32. A mechanism according to claim 28 wherein the engagement tool comprises at least two pins, and mechanism further comprises an actuator configured to advance the pins in nonparallel directions such that the pins are advanced into the foam portion and to retract the pins from the foam portion.

33. A method of engaging and reorienting a foam portion, the method comprising:

disposing a head member proximate to the foam portion, the head member extending from at least a first member, and at least one pin being adjustably mounted to the head;

advancing the at least one pin into the foam portion to engage the foam portion to the head;

rotating the head member relative to the first member to adjust the foam member to a desired position; and

retracting the pin from the foam portion to thereby disengage the foam portion.

34. A method according to claim 33, further comprising adjusting the position of the head member by adjusting a second member relative to the first member along a longitudinal direction of the first member, the head member being connected to the first member via the second member.

35. A method according to claim 34, further comprising rotating the head member about an axis parallel to the longitudinal direction of the first member by adjusting a rotary joint defined by at least one of the members.

36. A method according to claim 33, wherein rotating the head member comprises rotating first and second links, each link rotatably connected to the head member and the at least first member, such that the head member is rotated about an axis perpendicular to a longitudinal direction of the first member.

37. A method according to claim 36 wherein rotating the head member comprises rotating the head member about an axis perpendicular to the longitudinal direction of the at least first member and offset from a longitudinal axis defined by the at least first member such that the engagement tool is configured to be disposed substantially along the longitudinal axis when the head is rotated about the axis perpendicular to the longitudinal direction to each of two perpendicular positions of the head member.

38. A method according to claim 33 wherein advancing the at least one pin comprises rotating a helical pin in a first direction and thereby advancing the pin into the foam portion, and wherein retracting the pin comprises rotating the pin in a second opposite direction and thereby retracting the pin from the foam portion.

39. A method according to claim 33 wherein advancing the at least one pin comprises advancing at least two pins from the head member in nonparallel directions such that the pins are advanced into the foam portion.

40. A method according to claim 33, further comprising:

providing a section of a foam base sheet, the foam portion being cut from the sheet; and

with the head member engaged to the foam portion, extending the head member through the sheet,

wherein the rotating of the head member is performed with the head member extended through the sheet.

41. A method for manufacturing a foam part, the method comprising:

cutting a base sheet to define at least first and second portions in a first configuration, the second portion in the first configuration being defined in an aperture of the first portion such that the first portion at least partially defines a perimeter of the second portion;

reorienting the second portion relative to the first portion to a second configuration such that the second portion is offset from a plane defined by the first portion; and

joining the first and second portions in the second configuration.

42. A method according to claim 41 wherein joining the portions comprises joining the portions with the second portion disposed parallel to the first portion.

43. A method according to claim 41 wherein joining the portions comprises joining the portions with the second portion disposed at least partially in the aperture of the first portion in the second configuration.

44. A method according to claim 41 wherein reorienting the second portion comprises adjusting the second portion only in a direction perpendicular to the plane defined by the first portion.

45. A method according to claim 41 wherein cutting the base sheet comprises cutting the sheet to define a third portion, the third portion in the first configuration being defined in an aperture of the second portion such that the second portion at least partially defines a perimeter of the third portion, and further comprising:

reorienting the third portion relative to the second portion such that the third portion is substantially parallel to the second portion and offset from a plane defined by the second portion in the second configuration; and

joining the second and third portions in the second configuration.

46. A method according to claim 41 wherein reorienting the second portion comprises disposing the portions of the base sheet in the first configuration against a mandrel, the mandrel first and second surfaces corresponding to the first and second portions, the first and second surfaces being parallel and offset in different planes.

47. A method according to claim 41 wherein joining the portions in the second configuration comprises joining the portions in a telescopic shape such that the part is nestable with another identical part.

48. A method according to claim 41 wherein cutting the base sheet comprises cutting a polygonal shape defining the perimeter of the second portion such that the first portion defines the entire perimeter of the second portion.

49. A method according to claim 41 wherein cutting the base sheet comprises cutting a plurality of second portions in the base sheet, each second portion being defined in a respective aperture of the first portion such that the first portion at least partially defines a perimeter of each second portion, wherein reorienting the second portion comprises reorienting each of the second portions relative to the first portion to the second configuration such that the second portions are substantially parallel to the first portion and each second portion is coplanar with the other second portions, and wherein joining the portions comprises joining each of the second portions to the first portion in the second configuration.

50. A method according to claim 41, further comprising determining an area of the second portion according to a desired shock absorption characteristic of the part.

51. A method according to claim 41, further comprising:

providing a plurality of slits in at least one of the portions;

subsequent to joining the portions, expanding the portion defining the slits and thereby opening the slits to define apertures.

52. A foam part comprising:

a first portion defining a first plane and defining an aperture; and

at least one second portion joined to the first portion, the second portion having an outer perimeter corresponding in size and position to the aperture of the first portion, and the second portion being offset from a plane defined by the first portion.

53. A foam part according to claim 52 wherein the first and second portions are parallel.

54. A foam part according to claim 52 wherein the second portion is disposed at least partially in the aperture of the first portion.

55. A foam part according to claim 52, further comprising a third portion joined to the second portion, the third portion having an outer perimeter corresponding in size and position to an aperture of the second portion, and the third portion being offset from a plane defined by the second portion.

56. A foam part according to claim 52 wherein the part defines a contour on a first side that corresponds to a contour on an opposite second side such that the part is nestable with another identical part.

57. A foam part according to claim 52 wherein the first portion defines the entire perimeter of the second portion.

58. A foam part according to claim 52 wherein the part defines a plurality of the second portions, each second portion joined to the first portion, having an outer perimeter corresponding in size and position to a respective aperture of the first portion, and being offset from the plane defined by the first portion.

59. A foam part according to claim 52 wherein at least one of the portions defines a plurality of slits such that the portion defining the slits is structured to be expanded.