Apparatus and method for manufacturing foam parts
First Claim
1. A machine for manufacturing a plurality of similar foam parts from a supply of foam sheet material, the machine comprising:
- a support member configured to support a base sheet of the foam sheet material, with 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 reorient 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.
2 Assignments
0 Petitions
Accused Products
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.
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Citations
13 Claims
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1. A machine for manufacturing a plurality of similar foam parts from a supply of foam sheet material, the machine comprising:
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a support member configured to support a base sheet of the foam sheet material, with 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 reorient 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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A machine for manufacturing a plurality of similar foam parts, the machine comprising:
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a supply of foam sheet material; a support member configured to support a base sheet of the foam sheet material, with 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 reorient 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.
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Specification