Method and apparatus for fabricating cellular structural panels

• US 20040103980A1
• Filed: 12/03/2002
• Published: 06/03/2004
• Est. Priority Date: 12/03/2002
• Status: Active Grant

• Current Assignee: Hunter Douglas Incorporated (Hunter Douglas N.V.)
• Original Assignee: Hunter Douglas Incorporated (Hunter Douglas N.V.)
• Inventors: Swiszcz, Paul G., Kuperus, Ko, Ballard, Eugene, Cook, Stephen, Jeske, Tim
• Granted Patent: US 7,303,641 B2
• Time in Patent Office: Days
• US Class Current: 156/201
• CPC Class Codes: B31D 3/002 Methods for making cellular structures; Cellular structures B31D3/005 takes precedence
• CPC Class Codes: Y10T 156/101 Prior to or during assembly with additional lamina
• CPC Class Codes: Y10T 156/1015 Folding
• CPC Class Codes: Y10T 156/1051 by folding
• CPC Class Codes: Y10T 156/1095 Opposed laminae are running length webs
• CPC Class Codes: Y10T 156/1097 Lamina is running length web
• CPC Class Codes: Y10T 29/39 Venetian blind assembling

Abstract

An apparatus for manufacturing cellular laminate structural panels includes one or more supply stations of a flexible strip material including folding rollers for sequentially folding the strip material into cellular structures and feeding the cellular structures into a conveyor where the cellular structures are held in compression. The apparatus further includes a laminating station where the folded cellular structures are laminated to an upper and/or lower sheet material to which lines of a bonding medium have been applied prior to engagement with the cellular structures. The folded cellular structures are heated before engaging the sheet material so as to enhance the bonding of the sheet material to the cellular structures and subsequent to bonding, the laminate is passed through a cooling station to set the bonding medium. Downstream from the laminating station, the laminate passes through a side edge folding station where edges of the sheet material are folded over side edges of the laminate to finish the side edges of the laminate and subsequently the laminate is passed into a cutter for cutting the continuous laminate into predetermined lengths. Ends of the cut panels then receive rigid edge strips to fully finish the panel. The method of the invention includes the steps performed by the components of the apparatus.

Claims

1. A method of making a cellular laminate comprising the steps of:

providing a plurality of strips of flexible material positioned in side-by-side parallel relationship for downstream movement along a path of travel;

providing at least one supply of sheet material adjacent to said path of travel,

advancing said plurality of strips of material in a downstream direction,

providing a folding system for engagement with each strip of material, said folding system progressively folding each of said strips into an expandable cellular structure,

feeding said sheet material into engagement with said side-by-side expandable cellular structures at a laminating station and securing said sheet material to said structures at said laminating station to form a laminate having elongated side-by-side cellular structures secured to said sheet material.

2. The method of claim 1 wherein said folding system comprises folding rollers which fold said strips into a compressed but expandable cellular structure.

3. The method of claim 2 wherein said strips of material are provided in a roll form.

4. The method of claim 2 or 3 wherein said sheet material is provided in roll form.

5. The method of claim 1 or 2 further including the step of applying a bonding medium to said sheet material prior to engaging said sheet material with said cellular structures so that said structures become bonded to said sheet material at said laminating station.

6. The method of claim 5 wherein said bonding agent is not reactivated.

7. The method of claim 1 or 2 wherein said folded cellular structures open in a first direction.

8. The method of claim 7 wherein said cellular structures are heated from said first direction prior to entering said laminating station.

9. The method of claim 8 wherein said folded cellular structures are closed in a second direction opposite to said first direction and wherein said cellular structures are heated from said second direction subsequent to being heated from said first direction and prior to entering said laminating station.

10. The method of claim 1 wherein two supplies of sheet material are provided and further including the steps of feeding a first supply of the sheet material to one side of said cellular structures and feeding a second supply of the sheet material to an opposite side of said cellular structures.

11. The method of claim 10 wherein said path of travel is horizontal and said first supply of sheet material is fed onto a top surface of said cellular structures and said second supply of sheet material is fed to an underside of said cellular structures.

12. The method of claim 10 wherein said first supply and said second supply of sheet material are provided in roll form.

13. The method of claim 10 or 12 wherein said strip materials are provided in roll form.

14. The method of claim 1 or 10 further including the step of securing said sheet material to said cellular structures with resin.

15. The method of claim 1 or 10 wherein said plurality of cellular structures are provided at a plurality of locations spaced longitudinally along said path of travel.

16. The method of claim 15 wherein a plurality of supplies of said cellular structures are provided at each of said plurality of locations.

17. The method of claim 16 wherein said plurality of supplies of cellular structures at each of said locations are laterally offset from each other relative to the length of said path of travel.

18. The method of claim 17 wherein said plurality of supplies of said cellular structures at each of said locations are also laterally offset from said supplies of said cellular structures at all others of said locations such that said cellular structures at said lamination station are positioned in closely adjacent side-by-side relationship.

19. The method of claim 2 further including the step of providing a plurality of rollers extending transversely relative to said path of travel and adapted to receive and confine said folded cellular structures in a compressed state as they are moved along said path of travel.

20. The method of claim 19 wherein said cellular structures are made from glass fibers embedded in a resin binder.

21. The method of claim 20 wherein said sheet material is made from glass fibers embedded in a resin binder.

22. The method of claim 1, 2, 3, 10, 11, 12, 19, 20 or 21 wherein said method is continuous.

23. The method of claim 1 or 2 wherein said plurality of cellular structures at said laminating station are positioned in side-by-side relationship.

24. The method of claim 1 or 2 wherein said sheet material is a single unitary structure.

38. The method of claim 5 further including the step of heating said cellular structures prior to bonding to said sheet material at said laminating station.

39. The method of claim 5 further including the step of providing said cellular structures with a porous structure adapted to absorb said bonding medium.

60. The method of claim 1 or 57 further including the step of providing a cutter for cutting the sheet material with the strips of material secured thereto into predetermined lengths.

61. The method of claim 60 wherein said cutter is a rotary cutter with a cutting blade mounted on a rotating drum such that the blade engages and cuts the sheet material with the strips secured thereon on each revolution of the drum.

25. A method of making a cellular panel from flexible materials comprising the steps of;

providing a plurality of strips of flexible material,

providing at least one supply of sheet material,

forming said strips of flexible material into elongated cellular structures, and

securing said cellular structures to said sheet material.

26. The method of claim 25 wherein said cellular structures are positioned in parallel relationship.

27. The method of claim 25 wherein said cellular structures are expandable.

28. The method of claims 25 or 26 wherein said cellular structures are bonded to said sheet material.

29. The method of claim 25 or 26 further including the step of securing a second sheet material to the opposite side of said cellular structures from said first mentioned sheet material.

30. The method of claim 29 wherein said cellular structures are bonded to said first mentioned and second sheet materials.

31. The method of claim 28 wherein said cellular structures are expandable.

32. The method of claim 29 wherein said cellular structures are expandable.

33. The method of claim 25 or 26 further including the step of roll forming said cellular structures from said strips of materials.

34. The method of claim 27 further including the step of roll forming said cellular structures from said strips of materials.

35. The method of claim 27 further including the step of securing said cellular structures to said sheet material by compressing said cellular structures, applying a bonding medium to said sheet material or cellular structures positioning said compressed cellular structures adjacent to said sheet material and allowing said cellular structures to expand into engagement with said sheet material against said bonding medium.

36. The method of claim 35 wherein said bonding medium is applied to said sheet material and further including the step of heating the cellular structure prior to engagement with said sheet material.

37. The method of claim 28 further including the step of heating said cellular structures prior to bonding with said sheet material.

40. The method of claim 35 or 36 further including the step of providing said cellular structures with a porous structure adapted to absorb said bonding medium.

41. The method of claim 25 wherein said strips of material are formed into cellular structures by folding the strips of material.

42. The method of claim 41 wherein said folding occurs along a plurality of fold lines.

43. The method of claim 25 or 42 wherein said cellular structures are expandable and further including the step of holding the cellular structures in compressed condition prior to securing the cellular structures to the sheet material.

44. The method of claim 43 wherein said strips of material are folded with rollers.

45. The method of claim 44 wherein said method is a continuous method with said cellular structures and sheet material moving continuously and said folding of the strips of material being progressive along said plurality of fold lines.

46. The method of claim 41 or 42 wherein said strips of material are made of a fiberglass material.

47. The method of claim 44 wherein said strips of material are made of a fiberglass material.

48. The method of claim 45 wherein said strips of material are made of a fiberglass material.

49. The method of claim 41 wherein said cellular structures are secured to the sheet material by bonding, said cellular structures have an open side and a closed side, and further including the step of directing hot air toward the open and closed sides of the cellular structures prior to bonding the sheet material to the cellular structures.

50. The method of claim 49 wherein said cellular structures are bonded to two sheets of material with one bonded to the open side and one to the closed side of the cellular structures.

51. A method of making an expandable structural panel comprising the steps of:

providing a plurality of elongated strips of material comprising glass fibers embedded in a thermoset and/or thermoplastic binder with the material being inherently biased toward a flat condition,

providing at least one sheet of material,

folding said strips of material along at least one longitudinally extending fold line,

compressing the folded strips of material,

applying a bonding medium to one of said sheet of material or strips of material, and

engaging said folded strips of material with said sheet material to bond the materials together.

52. The method of claim 51 further including the step of heating said folded strips of material prior to engaging the folded strips of material with said sheet material.

53. The method of claim 52 wherein said folded strips of material and sheet material are provided in rolls and the steps of folding, compressing, applying and engaging are continuous.

54. The method of claim 53 wherein said strips of material are folded along a plurality of longitudinally extending fold lines.

55. The method of claim 54 further including the step of providing rollers for progressively folding said strips of material.

56. The method of claim 54 further comprising the step of providing rollers for compressing the folded strips of material.

57. The method of claim 53 wherein said strips of material are continuously moved along a path of travel and wherein said strips of material are laterally offset from each other.

58. The method of claim 57 further including the step of providing a plurality of locations for said strips of material and said locations are disposed along said path of travel.

59. The method of claim 58 wherein the strips at each said location are offset laterally from strips at other locations.

62. An apparatus for fabricating a structural panel having at least one planar sheet of material secured to a plurality of individual cellular members comprising in combination,

at least one supply station having a support for a roll of elongated flexible strips of material,

a folding station having folding members for providing at least one longitudinal fold in said strips of material to form a cellular structure,

a supply of sheet material,

at least one bonding medium applicator for applying a bonding medium to one of said sheet material or cellular structures,

laminating members for receiving said sheet material and cellular structures and causing said sheet material and cellular structures to become engaged so as to form said structural panel.

63. The apparatus of claim 62 further including drive means for advancing said cellular structures and sheet material through the apparatus.

64. The apparatus of claim 63 wherein said cellular structures and sheet material are advanced continuously through the apparatus by said drive means.

65. The apparatus of claim 62, 63, or 64 wherein said laminating station includes supports for two sheet materials.

66. The apparatus of claim 63 or 64 wherein said support for at least one sheet material is adapted to rotatably support a roll of said sheet material.

67. The apparatus of claim 65 wherein said supports for said two planar sheet materials are adapted to rotatably support rolls of said sheet materials.

68. The apparatus of claim 63 wherein said folding members include rollers.

69. The apparatus of claim 68 wherein said rollers function to provide a plurality of folds in said strip material.

70. The apparatus of claim 69 wherein said folds are continuous.

71. The apparatus of claim 70 wherein said apparatus has a length and further including drive means for advancing said sheet material and cellular structures longitudinally through said apparatus.

72. The apparatus of claim 71 wherein said strips of material are progressively folded into a cellular structure as it is advanced through said apparatus.

73. The apparatus of claim 72 wherein there are a plurality of supply stations for said strips of material spaced longitudinally of said apparatus.

74. The apparatus of claim 73 wherein there are a plurality of supports for said strips of material at each supply station.

75. The apparatus of claim 74 wherein said supports support said strips of material at positions transverse to the length of said apparatus such that said cellular structures are positioned in side-by-side relationship.

76. A method of finishing a side edge of a cellular laminate having a plurality of side-by-side cellular structures and a sheet material secured to said cellular structures along one surface thereof so as to overhang said cellular structures along at least one side of said laminate, an outermost cellular structure along said at least one side of said laminate having a longitudinally extending recess formed therein and opening laterally of said laminate when said laminate is at least partially compressed, comprising the steps of:

providing a folder block having a contoured surface adapted for engagement with said overhang,

moving said laminate along said folder block so that said folder block engages said overhang and causes said overhang to be folded into said recess and around an opposite surface of said outermost cellular structure from said surface that is secured to said sheet material, and

securing said overhang to said opposite surface.

77. The method of claim 76 wherein said contoured surface is continuous.

78. The method of claim 76 or 77 wherein said laminate has an overhang on both sides, and further including the steps of providing a folder block with a contoured surface on both sides of said laminate and folding the overhang on both sides just as it was folded on said at least one side.

79. The method of claim 76 or 77 wherein said overhang is secured to said opposite surface with a bonding medium.

80. The method of claim 78 wherein said overhang is secured to said opposite surface with a bonding medium.

81. A method of finishing a side edge of a cellular laminate having a plurality of side-by-side cellular structures and a sheet material secured to said cellular structures along at least one side of said cellular structures, an outermost cellular structure along said at least one side of said laminate having a longitudinally extending recess formed therein and opening laterally of said laminate when said laminate is at least partially compressed, comprising the steps of:

providing a plurality of folding rollers aligned along said at least one side of said laminate, said rollers being positioned to successively engage said overhang,

moving said laminate along said aligned folding rollers so that said overhang successively engages said rollers whereby said overhang is folded into said recess and around an opposite surface of said outermost cellular structure from said surface that is secured to said sheet material, and

securing said overhang to said opposite surface.

82. The method of claim 81 wherein at least some of said rollers are of a different configuration from others of said rollers.

83. The method of claim 81 or 82 wherein said laminate has an overhang on both sides, and further including the steps of providing a plurality of aligned folding rollers on both sides of said laminate.

84. The method of claim 81 or 82 wherein said overhang is secured to said opposite surface with a bonding medium.

85. The method of claim 83 wherein said overhang is secured to said opposite surface with a bonding medium.

86. A method of finishing an end of a cellular panel having a plurality of side-by-side compressible cellular structures and a sheet material secured to said cellular structures along one surface thereof, said cellular structures being substantially perpendicular to said end of the panel and having open ends at said end of the panel when the cellular structures are not fully compressed, comprising the steps of

compressing said panel,

applying a clip over said end of said panel to retain said end of said panel in a compressed condition, and

forming a notch in said panel adjacent to said clip and transversely of said compressed cellular structures.

87. The method of claim 86 further including the steps of

expanding said panel except where it remains compressed in said clip, and

folding said clip along said notch into confronting relationship with the open ends of said cellular structures at said end of the panel.

88. The method of claim 86 wherein said notch is formed in said panel by making two spaced cuts in said panel and cleaning the material between said cuts out of said panel.

89. The method of claim 88 wherein said steps of making cuts and cleaning material out are performed simultaneously.

90. The method of claim 88 wherein said step of cleaning material out is performed after the step of making the cuts.

91. The method of claim 87 further including the step of providing on said clip an element for connecting said clip to a support structure in a drop ceiling system.

92. The method of claim 91 wherein said element on said clip is a releasable hook.

93. The method of claim 86 or 87 further including the step of providing a magazine for storing a plurality of said clips and a mechanism for receiving a single clip from said magazine and applying it over the end of said panel.

94. The method of claim 93 further including the step of using said mechanism to tilt said clip while applying it to the end of the panel and tilting the clip again to set it in position on said end of said panel.

95. The method of claim 94 further including the step of moving said panel, magazine and mechanism along a path of travel while applying said clip to said end of the panel.

96. A system for removing the lowermost panel from a vertical stack of panels comprising in combination:

a support plate for supporting the stack of panels,

a pusher plate disposed adjacent to the lowermost panel,

a mechanism for reciprocally moving said pusher plate across said support plate so as to push said lowermost panel out from beneath the remainder of the panels in the stack in one direction of movement and to retract to a beginning position in a second opposite direction of movement, and

an expanse of material secured to said pusher plate so as to extend beneath and support said remainder of the stack as said pusher plate moves in said one direction.

97. The system of claim 96 wherein said expanse of material is flexible.

98. The system of claim 97 wherein said flexible material is stored on a spring biased roller and unrolled therefrom as said pusher plate moves in said one direction.

99. The system of claim 96 wherein said expanse of material supports said remainder of the stack at an elevation that allows the pusher plate to move in said opposite direction without engaging said remainder of the stack.

100. The system of claim 97 wherein said expanse of material is a fabric material.