Note: Descriptions are shown in the official language in which they were submitted.
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Background of the Invention
(1) Field of the Invention
This invention relates to deposition machinery
useful for applying reinforcement/stiffening or de-
corative powder to a substrate, and more particularlyto a method and machine for producing reinforcement/
stiffening or decorative means for shoe uppers prior
to their assembly on a shoe last.
(2) Prior Art
The shoe and apparel industry have for many
years provided reinforcement/stiffening means to their
products. Manufacturers of pajamas, blue jeans,
sports clothing, including sports equipment such as
gloves, caps with visors and the like, as well as
shoe manufacturers have stitched, glued or otherwise
; applied layers of reinforcing material to their pro-
ducts for a variety of reasons. It has been standard
for the industry, particularly shoe manufacturers,
to appiy the reinforcement/stiffening means as a
layer of molten thermoplastic material adherable
to a shoe upper. Early attempts at reinforcing or
stiffening a shoe upper have included providing pre-
formed stiffener elements or counters, cut from
sheets of material of uniform thickness,
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which are inserted into a shoe upper, prior to lasting. Separate
moldable sheet materials softenable by heating or by solvent have been
inserted in the shoe uppers prior to lasting and are shaped in the
course of lasting to a desired configuration which configuration they
retain by being allowed to harden before removal of the shoe upper from
the last. Shoe uppers have also been stiffened by impregnating a shoe
component with a solution or dispersion in a volatile liquid vehicle of
hardenable stiffener materials prior to lasting of the shoe upper, the
shoe upper being stiffened by hardening of the impregnating material
after the shoe is lasted.
One such way of stiffening shoe uppers is shown in U.S. patent
3,316,573 to Chaplick et al, wherein a shoe upper has a selected area in
which a resiliently flexible stiffener element is fluidly deposited, and
heated to a moldable point, and brought to a three-dimensional
configuration which it will retain on cooling.
Another arrangement for coating shoe parts is shown in U.S. patent
3,342,62~ to Kamborian, wherein a stencil plate rests upon a shoe upper,
a concave support surface holds the combination, whereupon a doctor
blade wipes across the plate to deposit a fluid stiffener into the
depression in the shoe upper.
A more recent arrangement for stiffening shoe components, is shown
in U.S. patent 3,973,285 to Babson et al, comprising an arrangement for
depositing a molten charge of thermoplastic on a shoe upper held in a
margin clamping means.
The prior art arrangements may occasionally work well, but they
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have difficulty producing a stiffener of uniform
thickness over seams and overlaid patterns. The
adhesion of the stiffener at its edges is often poor.
Rough edges, and strings or "spider webs" character-
istic of the process may all be present. The machinesmay leak their molten material out of the connecting
joints, nozzles may drool and patterns may require
time and patience to change.
The materials usable in these prior art machines
are limited to certain viscous flow and heat stability
characteristics which necessitate careful tailoring
- often comprising the performance of the final pro-
duct. These specialty materials are also more costly.
Thus it is an object of the present invention
to provide a method and an apparatus which will over-
come the shortcomings of the prior art.
It is a further object of the present invention
to provide a reinforcement/stiffening or decorative
means in a desired configuration to a flexible sub-
strate such as a shoe upper or piece of cloth-type
material, which configuration may be readily changed
to facilitate various shoe upper patterns or styles
or reinforcement/stiffening or decorative require-
ments o~ the garment with conveniently made low cost
stencil tooling.
It is yet a further object of the present in-
- 3a -
tion to provide an apparatus which will manufacture
a smooth stiffened/reinforced or decorative shoe
upper, or article of cloth or the like, without the
inconveniences of the prior art.
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Brief Summary of the Invention
The present invention comprises an apparatus for
reinforcing/stiffening/and/or decorating substrates such as clothing,
sports equipment, or the underside portions of shoe uppers, by the
application thereon of a fused powdered material. The apparatus
comprises a generally cylindrically shaped frame having a circular
receiving surface horizontally rotatable about a plurality of arcuately
spaced work stations arranged about the frame. The first station
comprises a deposition station. The second station comprises an arcuate
array of heating elements and the third station comprises a join and
cool and/or press station. The deposition station is synchronously
arranged for slight up and down movement over the horizontally rotatable
receiving surface, in timed relation to a support plate arranged for
slight up and down movement beneath the receiving surface. The
deposition station includes a stencil means which receives a supply of
powder through a conduit attached to a supply hopper above the frame.
The stencil means comprises a reciprocably movable dispenser-carriage
arranged in a housing structure, the bottom surface of which comprises a
stencil assembly. The stencil is the replacable lower surface of the
housing, having a smooth impermeable upper surface, a foil-like lower
surface and a screen "sandwiched" therebetween, a ~ut-out being arranged
in and aligned between the upper and lower surfaces.
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1 The dispenser-carriage may be reciprocably moved
across the stencil assembly by a cable cylinder arrangement or by a
motor arranged with a rack and pinion gearing setup between the
dispenser-carriage and the housing structure. The carriage r.as a pair
of wiper blades movably disposed one on each side thereof. Each blade
is reciprocably arranged to move downwardly as the other blade is moved
upwardly, by being pivotally linked to one another and to a
pneumatically powered bell crank system actuated by switches operable
when the dispenser-carriage gets transported to its particular end of
the housing structure, which dispenser-carriage contains the powder to
be applied to the circular receiving belt through the cut-out in the
stencil assembly. The lower surface of the stencil may have a partial
peripheral stand-off gasket which may keep one side of the cut-out
raised from and thus "skewed" with respect to the rotatable horizontal
receiving surface, more than the other side of the cut-out, thus
producing a configuration of powder of varying thickness thereon. The
gasket may be of tapered thickness towards its ends, or it may be of
uniform thickness depending upon the desired product, and it may be
arranged around the entire periphery of the cut-out. ~he support plate
is disposed beneath the receiving surface and is movable up and down by
a pressurizable piston and cylinder unit arranged between the support
plate and the frame portion. A shim or strip of gasket-like material
may be disposed on the support plate in a predetermined relation to the
gasket on the screen thereabove to provide a scarf or taper to certain
patterns of powder deposited on the receiv;ng surface.
The deposited three dimensional powder configuration on the
circular receiving surface gets transported an angular amount to the
first heating element, about one-eighth of a revolution, by action of a
motor adapted to rotate the circular receiving belt. As the circular
receiving belt is rotated in a step-wise manner, successive deposits of
three-dimensional powder is serially applied by the stencil to
successive locations on the circular receiving belt as they appear under
the deposition station in its low portion of its cycle.
The frame of the apparatus comprises a generally horizontally
disposed upper portion and a horizontally disposed middle portion, above
which the circular receiving belt is arranged. A pair of support rods
are journalled through tubular bearings secured to the upper frame
portion, and extend vertically downwardly therefrom, and are attached,
one at each end, to the frame of the deposition station. The support
rods have upper ends which are connected by a horizontal bar member. A
follower wheel is spaced inwardly from each support rod, on the lower
end of an arm and directed downwardly from the horizontal bar member. A
rotatable shaft is journalled at each end thereof in a housing secured
to the top end of the tubular bearings containing the support rods. A
cam member is fixed to the rotatable shaft near each end thereof, in
rolling contact with the follower wheels supported from the horizontal
bar member. A pneumatically operated piston and cylinder unit is
attached to the upper portion of the frame, and has a piston rod
7-
id
extending therefrom, in pivotal contact with an arm extending off of the
rotatable shaft. The piston and cylinder unit is in fluid communication
with a properly activatable synchronizable pressure source.
The heating stations comprise a plurality of arcuate segments
consecutively arranged on top of the middle portion of the frame. The
arcuate segments comprise about 240 degrees of lower, circumferentially
spaced heating elements. Each segment has a plurality of orifficii
therethrough which are in fluid communication with a vacuum system in
addition to their heating elements therewithin. A plurality of radiant
heating units are suspended, each from a hanger, from the upper portion
of the frame, in an arcuate array, above the receiving belt and above
the array of heaters arcuately arranged on the lower frame member. The
heating units are electrically activated by interconnection with
conduits supplying electrical energy from a proper source.
The circular receiving belt comprises an inner hub and an outer
annular ring in a planar relationship, between which, a web of glass
fibers or metal cloth, coated with polytetrafloroethylene is tensioned.
The inner periphery of the receiving belt fits into a collar arrangement
comprising the inner hub. The outer periphery of the receiving belt
comprises a plurality of links, pivotally connected to one another at
their ends, which ends are secured by radially directed fingers to the
outer annular ring. The links have the outer periphery of the receiving
belt overlapped and secured thereafter to form chord-like segments of a
polygon. The inner hub comprises a fitting having an internal spline
tooth configuration at its center. The spline toothed fitting mates
3i~,t
with a shaft secured at its lower encl, to a motor, mounted at the base
of the frame.
A splined shaft extends upwardly in a reciprocably matable
relationship from the spl;ne toothed fitting into a reciprocably movable
(upwardly and downwardly) gear housing with the frame system. The gear
housing provides the means for allowing rotational input into a
substrate transfer cube comprising the pressing station which pressing
station has a horizontal beam supported above the upper frame portion by
a pair of reciprocable shafts vertically journalled in the upper frame
lo portion. The shafts have lower portions which are affixed to opposed
shoulders on each side of the gear housing. A pressurizable piston and
cylinder unit is vertically arranged within the upper frame portion
between the reciprocable shafts to provide the power for the
reciprocating up-and-down motion thereof. The piston has a piston rod
which extends downwardly therefrom and is attached to an inverted "U"
shaped bracket, the distal ends of which are attached to the top of the
gear housing. The "U" shaped bracket has a pair of tabs which extend
off of its forward end. A shaft is arranged horizontally between the
tabs of the bracket. A leg is swingably disposed in the horizontal
shaft between the tabs. The distal end of the leg has a foot portion
which protrudes forwardly therefrom. A pressurizable piston and
cylinder unit which is in fluid communication with a proper synchronized
pressure source, is secured to the top of the gear housing and is
disposed within the walls of the inverted "U" shaped bracket. A piston
rod extends from the cylinder and is pivotally connected to a mid-point
vP~
of the leg. The gear housing encloses a forwardly directed (towards the
front of the machine) output shaft in rotational communication with the
splined shaft which reciprocably extends into the internally splined hub
within the receiving belt hub, which hub is in rotative communication
with the motor. A support hub extends from the front side of the gear
housing, around the forward shaft, which support hub rotatively receives
the transfer cube thereon, by mating with an annular socket arranged in
the backside of the cube. The cube has four planar faces which are
parallel to its axis of rotation. Each face has a partition extending
off its backside edge, perpendicular to the face, and a pair of parallel
partitions, perpendicular to the face and the edges adjacent the
backside edge. A slot is cut-into each partition, near its distal edge.
A holding bracket is slidably received into the slots in the partitions
extending fro~ each of the four planar faces parallel to the axis of
rotation of the cube. A biased plate is held against each planar face,
and behind (beneath) each bracket, within the partitions o-F the cube by
a biased camming means ~hrough each face oF the cube. The biased
camming means comprises a first lever, one end of which is pivotally
attached to the inwardly directed side of each biased plate. The other
end of the first lever is bifurcated and has a pin therethrough, which
end of the lever mates with a block arranged within the cube. The pin
extends beyond the sides of the first lever, and into a slot in the
sides of the block for guidance therein. A second lever is pivotally
arranged on the pin between the bifurcations of the first lever, and is
attached to the inward end of a rod which extends through the back end
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of the cube just outside of the annular socket. The other end of the
rod which extends rearwardly from the cube, is spaced so as to be
contactable with a rub-ring of 270 degree configuration about the
support hub on the front side of the gear housing.
A chill plate is disposed beneath the transfer cube, on the middle
portion of the frame. The chill plate has a refigeration means therein,
in the form of cooling coils connected to a refrigeration unit.
An arcuate stationary plate is secured to the middle portion of the
frame, on the other side of the chill plate from the heating segments.
Thus, a complete annular base, is attached to the middle portion of theframe, one portion of which comprises the deposition base, the major
portion comprising the arcuate heating segments, one arcuate portion
comprising the chill plate, and an arcuate stationary plate which thus
comprises the locus of (and support for) travel of the receiving belt,
which rotates thereon.
In the method of operating the reinforcing and stiffening
apparatus, a powdered polymer material such as ionomer, polyethylene,
ethylene vinyl acetate, polyvinylchloride or nylon at about a 35 to 100
mesh size, suitable for being heated, fusing, and being adherable to a
relatively flexible substrate such as a shoe upper or a piece of cloth
or the like, is deposited in the hopper, supported above the upper
portion of the frame of the apparatus. More explicit examples of the
material are recited below. The powder drops down from the hopper,
through the conduit secured beneath the hopper and into the
dispenser-carriage on the deposition means. The circular receiving belt
I
arranged beneath the deposition means is supported therebeneath to move
it into touching contact with gasket and any spacer means on the bottom
side of the stencil, by activation of the support plate arranged
immediately therebeneath as the stencil and deposition means is lowered
by its support rods which are in cammed relation to their bearings and
upper frame portion.
The completion of a radially outwardly and a radially inwardly
directed synchronized sweep by the dispenser-carriage in the housing
thus transfers the powder in the dispenser-carriage across the stencil
and through the cut-out in the stencil, causing a three-dimensional
array of powder to be configured onto the receiving belt. The sweep of
the dispenser-carriage by empowerment means such as a stepping motor
arranged with a rack and pinion gear system or by the cable cylinder,
causes a cam mounted on the frame o~ the holding unit
unit to actuate a switch; dropping the support
plate beneath the receiving belt. A cam on one of
the rods guiding the support plate is caused to strike a switch,
signalling its withdrawal to an out-of-the-way position to permit a
signal to first raise the deposition means by rotating the cammed shaft
connected to its support rods, and also a signal to be sent ~o the
motor, through appropriate circuitry, to rotatively advance the
receiving belt and its three-dimensional configuration of powder thereon
45 degrees to the first of a series of heating localities to enable the
powder to melt and fuse into a sticky mass. The holding unit of the
deposition station is thus again signalled to be lowered into contact
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with the receiving belt with the support plate rising therebeneath, the
deposition station effectuated to a sweep of thereof by the wiper
blades mounted on the dispenser-carriage, thus depositing a successive
three-dimensional array of configured powder on the receiving belt, the
cycle continuing, each heating station heating the configured
three-dimensional arrays oF successive masses of powder radiantly from
above at about 500-700~C and beneath the stepwise rotating belt at a
temperature of about 375-500F, depending on the particular powder, as
discussed in the examples following, each configuration losing the
discreteness of its powder and becoming a fused shaped entity on the
belt as the latter rotates in a stepwise manner through the heating
cycle, which cycle comprises about 270 degrees of its circumference and
takes about 25 seconds to fuse.
An unreinforced (flexible) article, to be reinforced, such as a
shoe upper or a piece of cloth for a cap visor, a shirt collar, a knee
patch, a sports glove or the like is placed between the biased plate and
the holding bracket held by the partitions on three sides thereof. The
holding brac~et may have any configured opening therethrough sufficient
to expose that portion of the article to receive the fused mass of
heated powder. The unfinished or bottom (inner) side of the article, a
shoe upper in the preferred embodiment, faces away from the axis of
rotation of the cube, as it is gripped therewithin. The cube is rotated
in timed sequence with the rotation of the rotatable receiving belt.
That is, the cube rotates 90 degrees about its axis for every 45 degree
rotation of the rotary belt. This is to allow an unreinforced article
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such as a shoe upper or the like to be presented in a spaced
relationship immediately above a viscous three-dimensional configuration
of melted powder on the rotary receiving belt therebelow prior to its
being pressed thereagainst. The motor beneath the splined hub
effectuates rotation of the rotary receiving belt also effectuates
rotation of the cube, through the splined shaft comprising the
interlinkage between the splined hub and the gear housing includiny the
linkage through the collar, to the cube. The pressurizable piston and
cylinder unit vertically arranged within the upper frame, for raising
and lowering the transfer cube and gear housing, is periodically
advanced and retracted, through proper actuation means, in timed
relationship with the rotation of the transfer cube and presentation of
an unreinforced article thereby. That is, the configuration of fused
powder on the rotary belt is presented in timed relation at the press
station and above the chill plate to the unreinforced substrates as they
are supplied thereabove by the transfer cube as fed to the same by the
machine operator.
Upon retracting of the piston within the cylinder in the upper
frame, the cube is withdrawn from a pressed relationship against the
rotary receiving belt. After the three-dimensional configuration of
viscous (sticky) matter has thus been cooled to about 30F to 100F and
caused to adhere to the bottom side of the article, (here a shoe upper),
the cube is then caused to rotate 90 degrees to present a successive
unreinforced article on its successive lowermost face to a successive
viscous mass rotated thereunder on the rotary receiving belt~ to be
3(~
lowered and pressed against the fused configuration of
powder on the receiving belt and similarly joined as
were the previous entities.
The now cooled and reinforced article on the side
of the cube is ready fox removal therefrom, by an opera-
tor, because the biasing plate is caused to be retracted
inwardly towards the axis of rotation of the cube,
because the bias camming means has rotated out of con-
tact with the rub-ring thus permitting the newly re-
inforced article to be removed from between the biasedplate and the holding bracket to await a subsequent
r~ceipt of an unreinforced article, such as a shoe upper
or other article (substrate) once the transfer cube has
rotated to the next 90 degree point of rotation (the
"12 olclock" position~ to present to the operator an un-
loaded face of the transer cube.
Broadly defined, the pr~sent invention provides, in
accordance with a broad aspect thereof, a machine for
operating on a fusible powder for a substrate. The machine
comprises a frame mem~er and an annular receiving surface
rotatably disposed in a horizontal manner in a journal in
the frame memberO Means is provided for intermittently
rotating the annular receiving surface. Means is also
provided for intermittently depositing a configuration of
powdered material on the annular receiving surface in-
between successive periods of rotative advancement of the
receiving surface. Means is provided for intermittently
treating the deposited powder to transform the powder into
a fused three-dimensional configuration thereof. Means is
further provided for intermittently withdrawing the fused
configuration from the annular receiving surface inbetween
successive periods of rotative advancement of the receiving
surface.
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According to a further broad aspect of the
present invention, there is provided a method of
sequentially manufacturing reinforced articles of
manufacture. The method comprises dropping a mass
of powder into a deposition means. The deposition
means including a stencil means is lowered towards
a receiving surface. The stencil means is touched
against a receiving surface. The powder is then
swept through a cut-out in the stencil means and
onto the receiving surface in a three-dimensional
configuration. The deposition means is lifted from
contact with the receiving surface. The receiving
surface with the powder thereon is then advanced
through heating means to fuse the powder. The re-
ceiving surface with the fused powder is then movedto a join and cool means.
Brief Description of the Drawings
The objects and advantages of the present invention will become
more apparent, when viewed in conjunction with the following drawings,
in which:
Figure 1 is a sectional view of a portion of the machine taken
along its center;
Figure 2 is a perspective view of the front of the machine, with
portions thereof omitted for clarity,
Figure 3 is a close-up perspective view of the middle frame portion
and work stations on the front of the machine, certain elements being
omitted for clarityj
Figure 4 is another perspective view of the machine, showing the
backside thereofi
Figure 5 is a close-up perspective view of the backside of the
machine, and
Figure 6 is a close-up perspective view of the deposition apparatus
of the machine.
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Description of the Preferred Embodiments
Referring now to the drawings in detail, and pariicularly to
figures 1 and 2, there is shown a reinforcment application machine 10.
The machine 10 comprises a generally cylindrically arranged frame 12
having a horizontally disposed upper frame portion 14, a~d a
horizontally disposed middle frame portion 16, supported on a frame base
18. The frame 12 includes a plurality of upright columns 20 securing
the upper frame portion 14 to the middle frame portion 16. A control
panel 15 is mounted on the upper frame portion 14, and d pair of start
switches 17 and a stop switch 19 are attached to the front of the upper
frame portion 14.
A circular receiving surface or rotary belt 22, having an outer
support ring 24, is horizontally rotatable about a hub 23 through which
a splined shaft 26 is arranged, the receiving surface 22 being arcuately
advancable, counter clockwise in this embodiment, in a stepped manner
through a plurality of arcuately spaced work stations, arranged beneath
the upper frame portion 14 and on elements of middle frame portion.
The first work station comprises a powder deposition station 30,
shown most clearly in figures 2, 4, 5 and 6. The second work station
comprises a heating station 32, consisting of a plurality of arcuately
arranged lower heating elements 34 and upper heating units 36, shown in
figures 3, 4 and 5. The third station may comprise a load/press station
38, shown generally in figure 1. The load station 38 may include chill
means and press/transfer means, described below.
3L~3L'~ 3 ~
The circular receiving surface 22 is preferrably made from a web of
woven glass fibers or from a thin woven stainless steel web, about .010
inches thick, covered on both sides by a smooth reinforced ~ilm of
polytetrafluroethylene or the l;ke, which permits release of any fused
powder therefrom. The thin web of either receiving surface material
permits rap;d cycling from fusion heat to cold press because of its
thermal mass. The bottom side of the receiYing surface 2Z is in sliding
contact with the arcuate array of lower heating elements 34 of the
second work station.
IO The deposition station 30 is supported by a reciprocating means 31
secured to the upper frame portion 14. The deposition station 30,
comprises a rectangular frame 40 arranged at least partially over and
parallel to the horizontal receiving surface 22. The bottom of the
deposition station 30 comprises a stencil assembly, including a
replacable template or stencil 42. The stencil 42 comprises a lower
wire mesh screen supported in a frame. The wire mesh screen has a
smooth impervious uppermost surface adhered thereon, and a lowermost
foil-like surface adhered thereunder, each surface having a cut-out
arranged thereacross and aligned with one another. The cut-out is
formed into the desired shape of the powder to be deposited onto the
receiving belt. A dispenser-carriage 44 is slidingly arranged
in the frame 40 of the deposition station 30.
, ~ -
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~L~ 3'~3
A holding tank or hopper 46 is supported in the top side of the
upper frame portion 14, to hold fus1b1e powder "P" prior to its
distribution on the receiving surface 22. A flexible conduit 48 has one
end arranged at the bottom of the holding tank 46, the other end of the
conduit 48 being attached to the dispenser-carriage 44 for distribution
of powder therethrough during operation of the deposition station 30.
The dispenser carriage 44 has a pair of wiper blades 50, one arranged on
each side of the carriage 44, only one being shown in figure 6. The
wiper blades 50 are linked together to operate reciprocably about a
common axis. The wiper blades 50 are each regulated by a pressurizable
piston and cylinder unit 54, having a piston rod 56 which is
articulated with a pivotable bell crank lever 58. Each bell crank lever
58 has an arm which is pushable against a tab 60 on each respective
wiper blade 50. When one wiper blade 50 is pressed downwardly against
the smooth impervious upper surface of the stencil 42, the other wiper
blade 50 is brought to its raised orientation. An arrangement of
cammable valves 62 and 64 are spaced along one side of the reciangular
frame 40 of the deposition station 30 to control the pressurization of
the piston and cylinder units 54 moving the wiper blades 50. A
pressurizable cable cylinder 66 is arranged along one side of the
rectangular frame 40 articulated with the carriage 44 to provide the
motivation for the dispenser-carriage 44 to sweep across the stencil
means. A support rod 70 is attached at its lower end, to each end of
the rectangular frame 40 of the deposition sta$ion 30. Each support rod
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70 extends through a tubular beariny 72. Each tubular bearing 72 is
fixed near its upper end, to a plate 7~ attached to the upper frame
portion 14 as shown in figure 4. Each support rod 70 extends out of
from the top of its respective tubular bearing 72, and is attached to a
horizontal bar member 76. A follower wheel 78, is attached to the lower
end of a short arm 80, which is attached to the bar member 76, spaced
inwardly from each tubular bearing 72. A housing 82 is arranged near
the top end of each tubular bearing 72, journalling a rotatable shaft 84
therebetween, as shown in figures 2 and ~. A cam member 86 is secured
to each end of the rotatable shaft 84, each being in rolling contact
with its respective follower wheel 78 attached to the short arms 80,
only one shown, disposed from the horizontal bar member 76. A
pressurizable piston and cylinder unit 90 is secured to the upper frame
portion 14, and has a piston rod 92 extending therefrom, which is in
swingable contact with a lever 94 extending radially from the rotatable
shaft 84. The pressurizable piston and cylinder unit 90, like the other
piston and cylinder units, is connected to proper pressurizable sources,
which is synchronized to efFectuate their reciprocable articulation.
A lower support plate 100, shown in figure 5, mounted on the middle
frame portion 16 is movable upwardly and downwardly (toward and away
from) the bottom side of the circular receiving surface 22 which for
clarity, is omitted from the figure. The lower support plate 100 is
motivatable by a pressurizable piston and cylinder unit 102, mounted
beneath the plate 100, pressurized from a proper synchronized pressure
source, not shown. The lower support plate 100 has a plurality of
-20-
vertically arranged gu;de shafts 104, one of which has a cam 106, to
enable it to activate a sequencing switch 107, thus providiny a link in
the synchronizing of the machine 10. A shim "S" may be disposed on the
bias plate 100 for certain applications to provide pressure so as to
distort the receiving surface 22 at particular locations to provide a
scarf on the configuration of powder "C" on the receiving surface 22 as
recited in the aforementioned incorporated applications.
The heating station 32, which is located adjacent the deposition
station 30, comprises the plurality of arcuate heater segments 34
arranged in an arc of about 240 degrees, on top of the middle frame
portion 16. Each arcuate heater segment 34 has a plurality of orifficii
112 arranged therethrough, which are in fluid communication with a
vacuum system, not shown, which vacuum system is in addition to the
heating elements therewithin. The heating station 32 also comprises a
plurality of square shaped heating units 36 which are each hingedly
supported on a hanger 116 suspended from the bottom side of the upper
frame portion 14, throughout the arcuate contour of the lower arcuate
heater segments 34. The square shaped heating units 36 are electrically
activated by interconnection with conduits supplying electrical energy
from a proper source, not shown. When it is desired to clean or repair
the machine 10 or the circular receiving surface 22, the square shaped
upper heating units 36 may be tilted upwardly on their hinges, to permit
easier access to the elements therebeneath, as shown in figures 3 and 5.
It is to be noted that the rotary receiving surface 22 and its hub are
omitted from figures 3 and 5, in order to more fully show the elements
21
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thereunder.
The third work stat;on 3~ comprises chilling means and
press/transfer means at the front of the machine, as shown in figures 1,
2 and 4. An arcuate chill plate 120 is disposed over an insulator 122,
on top of the middle frame portion 16, as shown in figure 3. The chill
plate 120 has a cooling arrangement, 121 built therein, in communication
with a proper refrigeration means, also not shown.
The press/transfer portion of the machine 10, may be adaptable for
uses such as stamping parts out of a material, or pressing portions of
two substrates together, as recited herein.The pressing and transfer
portion of the third work station 38 comprises a gear housing 130, shown
most clParly in figure 1, wherein the splined shaft 26 extends
downwardly from the gear housing 130, and reciprocably mates with the
internally splined hub 23 of the receiving surface 22 above and arranged
with the motor "M". The gear housing 130, through a gear arrangement
131 therein, directs rotary motion in a counter-clockwise direction from
the splined shaft 26, to a horizontal shaft 134 extending through the
middle of the front hub 136, as shown in figure 2, on which a transfer
cube 140, shown in figure 1 is journalled. The gear housing 130 and the
front hub 136 are made from a casting having a pair of shoulders 142
shown in figure 2, on each side thereof. Each shoulder 142 has a
vertical shaft 144 shown in figure 3, extending upwardly therefrom,
journalled through the upper frame portion 14, and are each secured at
their upper end to a respective end of a horizontal beam 150, arranged
above the upper frame portion 14. A compression spring 152 with an
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~ L'~ 33 ~
adjustable damper 154 is set in the middle of the horizontal beam 150,
aimed downwardly. A pressurizable piston and cylinder unit 160 is
vertically arranged within the upper frame portion 14, between the
vertical shafts 144 journalled within the upper frame portion 14, which
is pressurizable from a properly sequenceable pressurizable source, not
shown. The piston has a piston rod, 161 which extends downwardly
therefrom, shown in figure 1, and is attached at its lower end, to an
inverted "U" shaped bracket 162, the distal ends of the "U"shaped
bracket 162 being pivotally attached to the top side of the gear housing
130. The "U" shaped bracket 162 has a pair of tabs 164 which extend off
of its forward end. A shaft 166 is horizontally arranged between the
tabs 164 of the bracket 162. A driver leg 168 is swingably disposed by
one end thereof, on the horizontal shaft 166 extending between the tabs
164. The distal end of the driver leg 168 has a foot portion 170 which
protrudes forwardly therefrom. A pressurizable piston and cylinder unit
172, in synchronized fluid communication with a proper pressure source,
not shown, is secured to the top of the gear housing 130 and within the
confine of the walls of the inverted bracket 162, as shown in figures 1
and 3. A piston rod 174 extends forwardly from the piston and cylinder
unit 172, and is pivotally connected at its distal end, to a mid-point
of the driver leg 168. The front hub 136 rotatively receives the
transfer cube 140, as shown in figure 1, by mating with an annular
socket 167. The transfer cube 140 has four planar faces which are
parallel to its axis of rotation "R". Each face has a partition 180
extending off of its backside edge, perpendicular to its face, as shown
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3~;~
in figure 1, and each face also has a pair of parallel partitions 182,
perpendicular to the face and the edges adjacent its backside edye. A
slot 184 is disposed in each partition 180 and 1~2 on each face, each
slot 184 being arranged parallel to its respective face and near the
distal end of each partition 180 and 182. A bracket 186 is slidably
receivable in the slots 184 in the partitions 180 and 182 extending from
each of the four planar faces parallel to the axis of rotation of the
cube 140. A biased plate 187 is reciprocably arranged on the outside of
each planar face of the cube 140, within the confines of the partitions
180 and 182 thereon, by a biased camming means 190, shown in figure 1.
Each biased camming means 190, comprises a first lever 192, one end of
which is pivotally secured to a stud 189 attached to the middle of the
inwardly directed side of each biased plate 187, disposed through an
opening in its respective face of the cube 140. The other end of each
first lever 192 is bifurcated, having a pin 194 extending through the
tines thereof, which end of each first lever 192 mates with a block 196
supported within the cube 140. The pin 194 extends beyond the edges of
the tines, and into slots 195 cut into the inner sidewalls of the block
196, in which they (the ends of the pin 194) may slide. A second lever
198, one end of which is pivotally arranged on the pin 194 between the
tines of each first lever 192, is hingedly attached at its other end, to
a central mount 199 anchored within the transfer cube 140. A biased rod
200, which is journalled rearwardly through the backside of the cube
140, as shown in figure 1, is located just radially outwardly of the
annular socket 167 is in abutable contact with the rearward surface of
-2~-
33'i.~
the block 196. A spring biased rod 201 is disposed against the frontsurface of the block 196, having a spring 203 arranged between its
forward end, and the front of the transfer cube 140~ The rearward end
of the rod 200, extending from the backside of the cube 140, is arranged
so as to be contactable with a rub-ring 202, shown in figures 1 and 3,
disposed about the front hub 136 on the front side of the gear housing
130. The rub-ring 202 is in radial alignment with respect to the radial
displacement of the rods 200 extending rearwardly from the cube 140
about its axis of rotation "R". The foot portion 170 protruding
O forwardly from the distal end of the driver leg 168 is also in radial
alignment with the rub-ring 202 and the circular locus of travel of the
rods 200 which extend rearwardly from the transfer cube 140.
A stand-off 20R, of resilient material such as rubber, or the like,
is glued to the outer face of each biased plate 187. The configuration
of each stand-off 208, for the particular use recited in this example,
is of the outline of a vamp of a shoe upper.
The chill plate 120, disposed beneath the transfer cube 140 upon
the middle frame portion 14 has refrigeration means, 121 arranged
therewith, in the form of cooling cools connected to a refrigeration
unit, not shown to chill ~he plate 120 to about 32-100F.
An arcuate stationary plate 212, shown in figure 3 is secured to
the middle frame portion 10, contiguous to the chill plate 210 and the
deposition station 30, thus completing the annular array of work
stations arranged on the middle frame portion 16, and adjacent the locus
of travel of the annular receiving surface 22 or belt, which rotates
-~5-
3 ~
thereabove.
In the method of operating the reinforcing and stiffening
apparatus, powdered material, preferably a polymer powder, such as an
ionomer, polyethylene, ethylene vinyl acetate powder, polyvinyl
choloride or nylon in combination with colors, fillers or other
additives, preferably in a size of 35 mesh, or as fine as 50 mesh to 100
mesh for intricate, thin, reinforcement or decorative work, suitable for
being spread through a template, heated, fusing, and being adhereable to
a substrate, such as a shoe upper or a portion of cloth for a shirt
collar, pajama knees or feet, sports clothing or an athletic garment, or
the like, is deposited in the hopper 46, supported above the upper frame
portion 14 of the apparatus. The powder is permitted to drop down from
the hopper 46, through the conduit 48 secured between the hopper 46 and
the deposition carriage 44 on the deposition means 30. The powder then
lands on top of the stencil assembly, comprising the template or stencil
15 42, the deposition means 30 having been lowered into contiguous contact
with the upper side of the receiving belt or surface 22, because of
rotation of the rotatable shaft 84 due to proper synchronized
pressurization of the pressurizable piston and cylinder unit 90 secured
to the upper frame portion 14. The cam member 86 is therefore caused to
rotate, causing the follower wheel 78, rotatable thereagainst, to roll
in contiguous relationship therewith, permitting the horizontal bar
member 76, to which the follower wheel 78 is attached, to drop slightly.
The support rods 70 on each end of the horizontal bar member 76 are
thereby permitted to drop slightly, thus lowering the deposition means
-26-
3L~ 3~
30 with whatever spacer means is utilized against the receiving belt 22.
The pressurizable piston and cylinder unit 90 on top of the upper frame
portion 14, is double acting, so upon synchronized reversal thereof, the
depostion means 30 may be lifted slowly from the receiving belt 22 upon
proper timing, to permit the three-diMensional configuration of powder
"C" placed thereon, to be advanced stepwise in its arcuate path of
travel. The lower support plate 100, is moved upwardly into supportive
contact with the bottom of the receiving belt 22, time-wise, just before
the deposition means 30 is brought into contact downwardly,
thereagainst, by proper synchroni~ed actuation of its pressurizable
double acting piston and cylinder unit 102, arranged on the middle frame
portion 16, therebeneath. The lower support plate 100 is oriented in
its proper position by the guide shafts 104, which also has the
appropriate cam actuated switches to permit the lower support plate 100
to be moved downwardly at a time just prior to the synchronized upward
1S movement of the deposition means 30, after of course, the three
dimensional array of configured powder "O" has been deposited upon the
upper surface of the receiving belt 22.
Once the lower support plate 100, has been brought into the
aforementioned supportive contact (and distortive contact by the shims
"S") with the arcuately advanced receiving belt 22 and the deposi-
tion means 30 has been lower~d into contact with the receiv-
ing belt 22 (more specifically, the spacing elements and the
peripheral spacer member of the cut-out on the kottom
-27-
~ L~33 ~
side of the lower surface of the template 42 into touching contact with
the receiving belt 22), the dispenser carriage 44 is caused to sweep
across the frame 40 of the deposition station 30 by interaction with the
double acting pressurizable cable cylinder 66, which receives the proper
signal to effectuate the sweep of the dispenser-carriage 44, by signal
means received when the lower support plate 100 and the deposition means
30 were properly in place. The wiper blades 50, arranged one on each
side of the dispenser-carriage 44, are caused to bear down on the upper
surface of the template or stencil 42, so that as the dispenser-carriage
44 moves, the wiper blade SO on the trailing edge of the
dispenser-carriage 44 being pressurized by its respective pressurizable
piston and cylinder unit 54 efFectuate the bearing down pressure, to
sweep the powder into the cut-out in the template 42. The wiper blades
50 move reciprocably, about their common pivot axis, so that when the
dispenser-carriage 44 reverses direction for a return sweep across the
template or stencil 42, the return sweep trips a switch to effectuate
the dropping of the lower support plate 100, the raising of the
deposition means 30, and the arcuate stepwise advancement of the
receiving belt 22 with its cargo of configured powder "C" in a three
dimensional array thereon, to the heating station 32~ where successive
arcuate advancement causes the powder on the receiving belt 22 to heat
at each 45 degree spaced apart heating unit, to fuse the powder into a
molten mass, permitting it to retain however, its three-dimensional
thick, skived, or tapered configuration.
The configuration of fused powder advances to the chill and release
~2~-
station 38, whereupon it is held for about 1-2 seconds and caused to be
chilled, from its bottom side upwardly, by the chill plate 120, to a
temperature of about 32-100F, from beneath the receiving belt 22, the
top side of the three-dimensional configuration of fused powder being
tacky, for adhesion (if desired), to a substrate such as a shoe upper, a
piece of shirt/pajama clo~h, sports equipment or the like, or for
subsequent lifting (peeling) from the receiving surface as it advances,
for adhesion to a substrate at some further point in its manufacturing
cycle.
The configuration of three-dimensional powder "C" preferably
receives the substrate, be it the upper of a shoe or a piece of cloth in
need of reinforcement or stiffening, from the transfer cube 140. As the
receiving belt is advanced in 45 degree increments, the transfer cube
140 is rotated 90 degree increments through the interrelationship of the
two components via the mating gears 131 in the gear housing 130, to
present the substrate "U" held by the transfer cube 140 just over a
configuration of powder "C" upon the chilled plate 120, similar to the
orientation shown in figure 1, for the subsequent synchronized pressing
of the components together. The transfer cube 140 is caused to move
downwardly in timed response to the arrival of the fused configuration
of powder "C" on the chill plate 120 by synchronized pressurization of
the double acting pressurizable piston and cylinder unit 160 arranged
within the upper frame portion 14. The operator of the machine 10 loads
a fresh (unreinforced-unstiffened) substrate into the to space outwardly
of (above when loading) the biased plate 187 and resilient shaped
-~9-
33~
stand-off 208 and the cut-out plate 186 secured in the grooves 184 in
the partitions 180 and 182, on the transfer cube 140, in the "12
o'clock" position. When the biased plate 187 is retracted toward the
axis of rotation "R" of the transfer cube 140, by the depression of a
foot treadle, not shown, by the operator's foot, which depression will
actuate (pressurize) the pressurizable piston and cylinder unit 172
whose piston rod 174 is in pivotable conjuncture with the driver leg 168
behind the transfer cube 140. The foot 170 on the distal end of the
driver leg 168 thus pushes forwardly (towards the front of the transfer
cube 140) pushing against the particular biased rod 200 currently at the
"12 o'clock" position, which rod 200 extends rearwardly from the back of
the transfer cube 140, and which is in radial alignment with the
rub-ring 202, one rod for each biased plate 186 on the faces of the
transfer cube 140. The foot 170 thus pushes the biased rod 200
forwardly to hingedly push on the pin 194 which holds the first and
lS second levers 192 and 198, together, the pin 194 being held at both ends
thereof, by the slots 195 in the block 196, the effect of which is to
cause axial displacement of the block 196 and the biased rod 201,
compressing the spring 203, and effectuating radial displacement of the
biased plate 187. Actuation of the start switches 17 by the operator is
effective to cause rotation of the transfer cube 140 about the axis "R",
the biased rod 200 then coming into rubbing contact with the rub-ring
202 as the rod 200 is caused to traverse counter clockwise out of the
"12 o'clock" position, the levers 192 and 198 as well as the bias plate
187 assuming the orientation shown in figure 1 in its' "6 o'clock"
30-
3~
position, just prior to actuation/pressurization of the piston and
cylinder unit 160, to press the transfer cube 140 downwardly, with
whatever substrate is held therewith, a shoe upper "U", being shown in
figure 1, against a configuration of powder "C" on the receiving belt 22
supported by the chill plate 120. The three dimensional configuration
of fused powder "C", as described in the aforementioned incorporated
reference may then be pressed by the resilient stand-off 208 and issued
as a product by itself, or be pressed by and attached to a flexible
substrate being held between the resilient stand-off 208, and the cut
out in the bracket 186. Subsequent advancement of the transfer cube 140
counter clockwise around its axis of rotation 270 degrees from the "12
o'clock position to the "3 o'clock position", will release the biased
rod 200 from contact with the rub-ring 202. Thus withdrawing the biased
plates 187, in succession, from their loaded configuration, withdrawing
the resilient shaped pad 208 from behind the flexible substrate and from
the cut-out in the cut-out plate 186, permits the operator to remove the
newly reinforced or stiffened substrate cloth, leather or whatever, as
tne case may be. Subsequent turning of the transfer cube 140 through 90
degrees, will present an unloaded, unbiased biased plate 187 to the top
(12 o'clock) location for loading of a subsequent substrate and biasing
thereof between the resilient pad 208 and the cut-out in the cut-out
plate 186.
Examples of powders usable here, as well as operating parimeters of
the apparatus, are recited herein, by the following:
A) A preferred utilization of the present invention
g,-~
comprises the reinforcement of stiffening of a shoe upper. A
35 - 50 mesh ionomer powder of the sodium cation type having:
a melt index of 2.5, d flexural modulus of 51,000 psi, a heat
softening temperature (Vicat) 63C, with no additives. A
pattern template is prepared to the particular shape desired
and placed on an 8 mesh screen woven from .015 inch stainless
steel wire. The choice of an 8 mesh screen represents a
balance of opposing factors:
a - fine mesh produces a smooth action
to the wiper blades;
b too thick a screen wire size makes
the scarf or taper edge too thick;
c - coarse, small diameter wire mesh
presents less surface for residual
powder particles to cling to or
bridge across.
Spacer means on the bottom of the stencil are utilized
for an approximately .040 inch thick fused product.
Considering the bulk density and flow behavior of the powder,
a .100 inch thick peripheral gasket is used on the bottom side
of the stencil means. The scarf shim "S", on the lower
support surface is adjusted thereon so as to distort the
"no-spacer means" portion of the receiving belt into contact
with the bottom surface of the stencil means as to provide a
proper (desired) taper on the powder applied on the receiving
r~ 3
belt and within the confines of the peripheral ~asket.
In the heating station, the lower heating units are set
for about 490F. Each radiant heater above the receiv;ng belt
is set for about a 600F surface temperature thereof.
The deposition mechanism is actuated to allow an overall
time of about 25 seconds for fusing the powder on the
receiving belt, at which time, the product is transferred to
the final station for application to the substrate, here the
bottom of a shoe upper, then chilled to about 30F to 100F
lo for about 1-2 seconds by the chill plate as it is pressed
thereagainst.
The final product for a box toe shoe upper is tapered
from .012 inches thick at its scarf edge, to .035 inches thick
along its full edge.
1~ B) A further example includes the preferred utilization
above-described, having as additions in the powder 0.3%
polyalkoxy tertiary amine as an antistatic agent, and 0.3%
fine silica as a dryer and flow promoter, resulting in less
residual powder on the screen and less electrostatic motion of
the powder particles during the deposition process, as well as
having the printed pattern of a higher quality. The product
here may be .040 inches thick at its full edge.
C) A still further example includes ~he earlier described
-33
~ 2 ~ 3~.~
preferred configuration (A) haviny as its additives: .05%
conductive furnace black. The deposition behavior, flow
behavior and product pattern are similar to example (B). The
time for fusion at the hea-ting station may be reduced here, to
about 20 seconds, having a product thickness of about .040
inches.
(D) For a flexible box toe for mens' or womens' shoes, a 35
mesh low density polyethylene powder may be used, having a
melt index of 229 a flexural modulus of 19,000 psi, a heat
softening temperature (Vicat) of 83C with no additives. The
lower heating block is raised to a temperature of about 400F,
the upper radiant heater at about 500F for a tapered product
from about .012 to .035 inches and a heating (fusion) time of
about 18 seconds.
E) For a soft box toe for slippers, womens' and some
childrens' shoes, a 35 mesh ethylene vinyl acetate copolymer,
having a melt index of 9, a flexural modulus of about 13,500
psi and a heat softening temp. of about 59C. The machine
conditions are the same as those for example (D), in a heating
(fusing) time of 12 seconds producing a tapered product of
from about .012 to .035 inches thick.
F) If the apparatus is to be used for throat reinforcement,
-34-
B~3V
eyelet stay or topline reinforcement for a shoe upper, then
the preferred powder is 100 mesh nylon 12 and 0.3 ~ polyalkoxy
tertiaryamine. The stencil screen would be of about 30 mesh
size. This particular product is not tapered, therefore the
gasket is arranged about the entire periphery of the cut-out,
and is of uniform thickness, of the type of "dot" spacers .040
inches thick, utilizing machine conditions as in example A,
with a heating time of 12 seconds and a print pattern
thickness of .017 inches.
G) A thin film reinforcement similar to example F wherein a
100 mesh vinyl powder and 0.3% polyalkoxy tertiary amine
powder is used, with a heat stabilizer if desired, having the
same deposition means, conditions and results as in the
previous example.
Typical colorment pigments useful for coloring plastics may be
pre-mixed with the powder in the hopper, to provide the decorating
characteristics, pigments being carbon black for one example.
-35-
~23L%~
Thus, there has been shown and described an arrangement for
producing reinforcing andtor stiffening and/or decorating means for
footwear or articles of clothing, from a fusible powder, which powder
can be configured in a three-dimensional array, to a desired taper and
thickness, depending on the thickness of the template cut-out peripheral
member, for same operation application (if desired) of that
three-dimensional configuration of powder after proper heating and
fusing thereof, eliminating costly and messy operations and procedures
common with the prior art.
It is submitted, that the appended claims are to be interpreted as
exemplary only, and not in a limiting sense.
