Note: Descriptions are shown in the official language in which they were submitted.
-` ~1 3~7g~i~
This invention relates to moulding machines for producing fully
finished moulded products made from fibrous materials such as
wood pulp. In particular this invention relates to machinery for
the drying and finishing of moulded preforms in continuous motion
in one continuous production line, while maintaining complete
control of each product in a special cam-controlled transfer
mould assembly throughout their travel together to the point of
final discharge. This invention relates also to the camming
elements for the control and positioning of the transfer mould
assemblies and their contained moulded products.
Prior Art
In prior devices for producing fully finished moulded articles
from fibrous pulps, a number of different pressing stations have
been provided at spaced circumferential intervals about the axis
of rotation of a carrier, and each of the moulds mounted on the
carrier is indexed and pres~nted sequentially, together with the
contained product, to a different matching mould at each of the
pressing stations. One such device is described in U.S. Patent
No. 2,183,868, Randall et al. This intermittent action reduces
the speed of operation and the contact time of the matching mould
elements.
In the moulding machine of the present invention, each transfer
mould element, together with its contained product, is mated
sequentially with one matching finishing mould element mounted on
a continuously moving carrier, and the moulded product remains
within the same matching pair of moulds in the drying and
-- 1 --
. ~
,'
~31~7~9
finishing process throughout their travel around on the finishing
carrier and until the transfer mould assembly and its contained
product are transferred therefrom.
The transfer system comprises a multiplicity oE transfer mould
assemblies each having a ser:ies of cam followers mounted
circumferentially about the supporting shaft thereof at
intervals, and a series of cam tracks by means of which the
transfer mould assemblies are controlled and oriented throughout
their travel path between an input carrier and a finishing
carrier, the number and spacing of the cam followers being
adapted to provide for complete rotation through lBO degrees in
either direction in relation to the main shaft of the rotary
carrier, as required for the transfer of the moulded products
from the input carrier to the finishing carrier and thence to the
point of final discharge. According to one aspect of the present
invention ,there is provided a moulding machine for moulding
fibrous material such as wood pulp to form moulded items
comprising an input carrier and a finishing carrier each mounted
for continuous synchronized rotation about parallel axes, input
moulds mounted on said input carrier, each input mould having an
input mould face, finishing moulds mounted on said finishing
carrier, each finishing mould having a finishing mould face,
transfer moulds which are mounted in a releaseable transfer mould
assembly for transfer to a chain conveyor, each transfer mould
having a transfer mould face adapted to cooperate with the input
mould face of the input moulds and also with the finishing mould
2 --
~. ~i,
~3~
face of the finishing moulds to form mould cavities therebetween
in use, each transfer moul~ assembly having an axis of rotation
about which it is rotatable to reorient its transfer mould face
with respect to the input and finishing mould faces as required
in use, transporting means for transporting said transfer moulds
along an endless path which for~ls an enclosure within which the
finishing carrier is located, said transporting means comprising
a first transfer and mould reorienting means serially arranged
between the input carrier and the finishing carrier to cause each
transfer mould to rotate about its axis of rotation through 180
degrees from a first orientation in which the transfer mould face
is directed outwardly of said enclosure when in engagement with
said input mould carrier to a second orientation in which the
transfer mould face is directed inwardly of said enclosure when
in engagement with said finishing mould carrier when transferring
a moulded .item from the input carrier to the finishing carrier, a
second transfer and mould reorienting means serially arranged
between the finishing carrier and said input carrier to cause
each transfer mould to rotate about its axis of rotation through
:180 degrees from said second orientation to a third orientation
in which the transfer mould face is directed outwardly of said
enclosure so as to be correctly oriented for re-engagement with
said input moulds of said input carrier.
The invention will be more clearly understood after reference to
the following detailed specification read in conjunction with the
drawings wherein ;
: - 3 -
~,
Figure 1 is a side elevation of a moulding machine constructed in
accordance with an embodiment o~ the present invention.
Figure 2 is an end view of a transfer mould assembly.
Figure 3 is a side view of the transfer mould assembly of Fig.2
Figure 4 is an end view of a transfer mould assembly mated with a
finishing mould assembly.
Figure 5 is a longitudinal vertical section of a portion of the
machine of Figure 1 showing the input carrier, first, second and
third transfer carriers and the finishing carrier in more detail.
Figure 6 is a transverse vertical section of the moulding machine
of Figure 1.
Figure 7 is a diagram which illustrates the gear train which
synchronizes the rotary motion of the rotary carriers, and which
also illustrates the path of travel of an endless conveyor
according to one aspect of the invention.
Figure 7x is a diagram similar to Figure 6a showing the path of
travel of the endless conveyor according to a second aspect of
the present invention.
Figure 8 is a diagram which illustrates the various cam tracks
used for guiding the cam followers through the transfer stations
and it also illustrates the position of the various cam followers
in relation to the cam tracks.
Figure 8x is a diagram similar to Figure 8 which illustrates the
various cam tracks used for guiding the cam followers between and
through the transfer stations according to the said second aspect
4 --
`':' ;',
~. ,
.: .
,:
: :
.
of the present invention, and it also illustrates the position
of the various cam followers in relation to the cam tracks.
Figure 9 is a side view of a portion of an endless conveyor chain
showing the releaseable connection with the cam followers of the
transfer mould assembly.
Figure 10 is a plan view of a portion of the chain of Figure 9
showing the position of the shaft of the shoe of the transfer
carrier in relation to the chain.
With reference to Figure 1 of the drawings, the reference numeral
8 refers generally to a moulding machine constructed in
accordance with an embodiment of the present invention. The
moulding machine 8 comprises an input carrier 10, a finishing
carrier 13, a first rotary transfer carrier 11, a second rotary
transfer carrier 12, a third rotary carrier 14, and a
transporting chain conveyor 16. The input carrier 10 rotates
through the forming vat 9, and acts as a vacuum former on which
the preform moulded items are formed in a well known manner.
Referring to Figure 5 the first rotary transfer carrier transfers
the transfer mould assemblies 40 and their contained moulded
items to the second rotary transfer carrier which in turn
transfers the transfer mould assemblies 40 and their contained
moulded items to the finishing carrier. The third rotary
transfer carrier transfers the transfer mould assemblies 40 and
the contained finished items from the finishing carrier to the
chain conveyor 16 which in turn conveys the transfer mould
assemblies 40 through the discharge point and thence onward to
- 5 -
'~
.; .
.
~. ,
75~9
the first transfer carrier 11 and into cooperation with the
input moulds 41 on input carrier 10. The input carrier 10,
finishing carrier 13 and the transfer carriers 11, 12 and 14 and
the sprocket 63 of the chain conveyor 16 each have parallel axes
about which the transfer mould assemblies 40 are caused to
rotate as they are being reoriented. A first transfer station
100 is located between the input carrier 10 and the first rotary
transfer carrier 11. ~ second transfer station 200 is located
between the second transfer carrier 12 and the finishing carrier
13. A third transfer station 300 is located between the
finishing carrier 13 and the third transfer carrier 14. The
chain conveyor travels through a fourth transfer station 400
where moulded items are discharged from the transfer moulds.
The finishing process performed between the transfer moulds and
the finishing moulds when mated on the finishing carrier 13 may
optionally comprise pressing a previously dried preform with one
or both moulds heated to achieve permanent densification and a
smoother surface, or pressing a wet moulded preform with unheated
moulds, to achieve partial densification, partial dewatering and
a smoother surface, or pressing a wet moulded preform with one or
both moulds heated to achieve improved densification, with
partial dewatering by pressing and further drying by evaporation.
Removal of moisture pressed or evaporated from the moulded
product is effected by the application of vacuum internally of
the moulds in a manner well know to the industry.
he input carrier lO consists of a carrier wheel 124 which has a
-- 6 --
~;
~3~ 9
support shaft 20 mounted for rotation in bearings 128. The
lower segment of the carrier wheel 124 extends into a pulp vat 9.
A plurality of forming moulds 41 are located at circumferentially
spaced intervals about the carrier wheel 124 and are arranged to
pass sequentially through the vat 9. A gear wheel 30 is mounted
on the shaft 26 and serves to drive the carrier wheel 124 in a
synchronized rotation with respect to the finishing carrier 13 as
will be described hereinafter.
The first transfer carrier 11 has a support shaft 21 mounted for
rotation in bearings 136 which are mounted on the frame 18. In
the embodiment illustrated in Figure 5/ the second transfer
carrier 12 has a shaft 22 mounted for rotation in bearings 138
which are supported by the frame. The finishing carrier 13 has a
shaft 23 mounted for rotation in bearings 140 which are mounted
on the frame 18. The third transfer carrier 14 has a support
shaft 24 mounted for rotation in bearings 142 which are mounted
on khe frame 18 and the sprocket 63 of the chain conveyor has a
support shaft 25 which is mounted for rotation in bearings 144
also supported on the frame 18.
The input carrier and the finishing carrier 13 are each supplied
with facilities for the controlled application of compressed air
and vacuum to each of the moulds which they support, the means o~
supply comprising connecting piping leading from a rotary valve
mounted on each of their principal shafts in a manner which is
well know to the industry and will not therefore be described in
detail, and also to the transfer moulds as they and their related
- 7 -
~3~17~
valve connectors enter together into cyclical engagement withthe corresponding moulds and valve connectors mounted on said
input carrier 10 and said finishing carrier 13.
The sprocket 63 has ~acilities for the controlled supply of
compressed air to the trans:fer moulds by means of valve
connectors individually mounted on their respective transfer
mould assemblies and on said sprocket 63. The finishing carrier
also has facilities for the controlled application of compressed
air at a higher pressure level to a plurality of air mounts.
Referring to Figure 6 of the drawings, a rotary valve 163 is
comprised of a rotary element 161 mounted on the shaft 23 and
connected to the wheel 70 and cooperating with a stationary
element 160, the element 161 being preferably made of stainless
steel with a smooth wearing face with ports connected to all of
the piping 164, 165 and 166, and the element 160 being preferably
made of a resilient material such as urethane and pressed tightly
by springs or other means against the rotary element 161 to
prevent leakage in operation of the vacuum and compressed air
between the said elements 160 and 161. The stationary element
160 has ports leading from the vacuum plenum chamber 163 and the
compressed air ring through the rotary element 161 to the piping
connections 165 and 166 respectively. Separate external piping
(not shown) is connected to separate ports on the stationary
element 161 for the application of compressed air to the
finishing moulds at alternate times through the connecting
piping 165, 166. Compressed air to the airmounts 168 is
- 8 -
- ~L3~ 69
connected from the outer ring 162 through an outer ring of
separate ports. A drive train which may be used to drive various
carriers and the conveyor chain 61 rotatably is illustrated in
Figure 7 of the drawings to which reference is now made. As
shown in Figure 7, the gear wheel 30 of the input carrier 10 is
meshed with the gear wheel 31 of the first transfer carrier 11.
The gear wheel 31 is in turn meshed with the gear wheel 32 of the
second transfer carrier 12. The gear wheel 32 is meshed with the
gear wheel 33 of the finishing carrier 13. The gear wheel 33 is
meshed with the gear wheel 34 of the third transfer carrier 14.
The transporting chain conveyor 16 extends along guide tracks 64
and 65 and around sprockets 62 and 63 which are mounted for
rotation with the shafts 21 and 25 respectivel~. The notches 178
in the links 58 of the chain conveyor 16 (Figure 9) face the cam
track 151a (Fig.8) so that the chain rollers 59 and shaft mounted
rollers 50 of the transfer mould assemblies 40 travel together
along said track 151a which acts as chain roller and cam roller
control and serves to guide said mould assemblies 40 as they are
returned from the discharge station to the first transfer station
100, and to retain the cam roller 51 in the notch 178 to propel
the transfer mould assemblies 40 along with the chains 61 in
their continuing travel together.
Referring again to Figure 5 of the drawings, it will be seen that
a discharge conveyor 17 is arranged to cooperate with the
sprocket 63 to receive moulded items 36 and to transport the
moulded items 36 away from the moulding machine.
_ g
-" ~L3~3~
As shown in Figures 1 and 2 of the drawings, the finishing
carrier 13 is mounted for rotation in a fixed housing 73 which
forms an enclosure surrounding a major portion of the finishing
carrier 13, the transfer carriers 11, 12 and 14, and ths sprocket
63.
Transfer Carriers
The transfer carriers 11, 12 and 14 which are illustrated in
Figure 5 of the drawings are designed to transport the transfer
mould assemblies 40 as they are driven through the transfer
stations. The transfer carrier 11 includes a central body
portion 79 on which four heads 76 are mounted for radial movement
with respect to the axis of the shaft 21.
Each of the heads 76 has a notch 75 which receives a roller 52
(Fig.3) of the transfer mould assembly 40 about which the
transfer mould assemblies 40 may be caused to pivot as they are
being reoriented by the reorienting cam tracks as will be
described hereinafter.
Compression springs 77 are mounted in the main body 79 and serve
to bear against each head 76 to urge it radially outwardly along
guide rods 78 and in cooperation with the roller 52 to maintain
the companion roller 50 in continuous serial contact with guide
tracks 151a, 151b, 151c and 151d in their travel path around the
three transfer carriers and along the chain conveyor 16.
In the embodiment illustrated in Figure 5, the second and third
transfer carriers are constructed in the same manner as the first
-- 10 ~
~' - . ' .. ~, ~
.
" ~3~7~9
transfer carrier 11 and will not therefore be described in
detail.
Transfer Moulds
The transfer moulds 42 on the transfer mould assemblies 40 are
used to transfer the moulded
items from the forming moulds 41 to the finishing moulds 43 and
between the finishing moulds 43 and the discharge conveyor 17.
With reference to Figure ~ of the drawings, a transfer mould
assembly constructed in accordance with one embodiment of the
invention is generally identified by the reference number 40.
This assembly includes a plurality of transfer moulds 42 which
are mounted on a shoe 45. The shoe 45 has supporting pivot
shafts 53 projecting from opposite ends thereof. Lever arms 46
are mounted at opposite ends of the shafts 53. Heavy duty
pressure rollers 55 are mounted on the reverse side of the shoe
45 for use in the pressing action between the transfer moulds 42
and the finishing moulds ~3 as will be explained later. The
lever arms 46 have follower rollers 47, 48 and 49 mounted for
rotation thereon. Rollers 50, 51 and 52 are mounted on the
shafts 53. This entire transfer mould assembly 40 is transferred
back and forth between the carriers and the chain conveyor and
around on the finishing carrier. The shoe 45 of the transfer
mould assembly 40 has a plenum chamber 156 formed therein and
spring mounted valve connectors 157 and 158 mounted thereon for
the application of vacuum or compressed air. As said moulds 42
are cyclically mated at transfer point 100 with their cooperating
~ 11 --
,
~3~
input moulds 41 mounted on input carrier 10 said valve
connectors 157 are simultaneously mated with corresponding valve
connectors mounted on said input carrier lo and the porting of
the rotary valve mounted on said input carrier 10 is arranged to
supply vacuum at the same time through the valve connector 157
for application internally of the moulds 42 to attract and assist
in the transfer of the moulded preform from said input moulds 41
to said transfer moulds 42. Thereafter as the transfer moulds 42
are cyclically mated with their corresponding finishing moulds 43
mounted on the finishing carrier 13 said valve connectors 157 are
simultaneously mated with corresponding valve connectors mounted
on the shoe of said moulds 43 but connected separately to the
porting of the rotary valve 160 of said carrier 13 to supply
vacuum through said valve connectors internally of the moulds 42
to remove moisture pressed or evaporated from the moulded
products during the finishing operation as they travel around on
said carrier 13, and finally to attract and retain the finished
moulded products on the transfer moulds 42 as they separate from
the finishing moulds ~3 at the transfer point 300, and continue
on their path towards transfer point 400. As the transfer mould
assemblies pass through the discharge position at transfer point
400 the valve connector 158 is mated with a corresponding
connector mounted on the sprocket 63 and connected to the
porting of the rotary valve thereof for the application of
compressed air internally of the moulds 42 to blow off and thus
discharge the finished moulded products on to the conveyor 17.
- 12 -
'Jl~
07~3~9
The two transporting chains 61 of the chain conveyor 16 which
are shown on Figure 5 and Figure 7 each consist of links 58
which are interconnected by coupling links 57 (Figure 9).
Rollers 59 are mounted for rotation in the links 58. A notch
178 is formed on each of the links 58 facing outwardly of the
tracks 64 and 65 and the sprockets 62 and 63 to accommodate the
roller 51 in a releaseable connection to the chain for transport
of the related mould assemblies 40 batween transfer stations 300
and lOO. The rollers 50 and 51 are both mounted on shaft 53 of
said transfer mould assembly, the roller 50 being sufficiently
larger in diameter than the roller 51 to contact the track 151c
to support said roller 51 securely in its position in the notch
178 and free of said track 151c as the roller 50 rolls along the
tracks 63 and 64 of the chain conveyor.
In the embodiment illustrated in Figure 7x of the drawings the
transporting chains 61x extend around the sprocket 62 and the
guide tracks 66, 67, 68 and 64xb, with the notches 178 facing
inwardly of the finishing carrier. As the links of the
supporting chain commence their travel on the sprocket 62 the
rollers 52 of the transfer mould assemblies are supported in the
notches 75 of the spring mounted heads 76, the track 64 is
discontinued and the rollers 50 are urged into contact with the
track 151d for continuing control of the travel path of the
related transfer mould assembly 40 through the transfer point 100
and around on the first transfer carrier 11 to reach the chain
track 66. At t~is point the rollers 50 are transferred to the
- 13 -
., .
. .
notches 178 of the links 58 of the conveyor chains 61x, the
track 151a begins shortly before the track 151d ends, and
thereafter the travel path of the rollers 50 are urged into
continuous contact with track 151a for control of the travel path
of shafts 53 of the transfer mould assemblies 40 as they travel
around on conveyor track 66 to the transfer point 200 where the
transfer moulds 42 are mated with the finishing moulds 43 mounted
on the finishing carrier 13 and the travel path of the mated
pairs of moulds together around the finishing carrier is
controlled by the action of the airmounts 168 urging the wheels
55 of the transfer mould assemblies 40 into continuing contact
with the track 155. In the same manner the travel paths of the
transfer mould assemblies around on transfer carrier 14 and
through transfer point 300 are controlled by their support in the
notches 82 of the heads 80 of the said transfer carrier and the
continuous contact of the wheels 50 with the track 151c. A
preferred configuration of the travel path of the pivot shafts 53
and schedule of orientation of the transfer moulds 42 as these
are cyclically engaged with and disengaged from their
corresponding input moulds 41 and finishing moulds 43 is
described in my Canadian patent 861385 and is well known to the
industry and will not be described further here~
In the embodiment illustrated in Figure 7x, the conveyor chains
61x extend around the sprockets 62 of the transfer carrier 11
and along chain tracks 66, 67, 68, 6~xa and 64xb, thus forming an
enclosure surrounding said transfer carrier and said finishing
- 14 -
.~
.
' :
~L~ [)7~
carrier. The notches 178 in the links 58 of said chain conveyor
61b face inwardly of the shaft 21 of the transfer carrier 11 as
they travel around on the sprocket 62 so that the transfer mould
assemblies are released inwardly of the chains on to the notches
82 of the spring-mounted heads 80 of said transfer carrier so
that their tra~el path and schedule of orientation can be
controlled b~ the tracks 151ax and 151bx and tracks 147ax and
148ax respectively as they pass through the transfer points 100
and 200. Said notches 178 face outward of the track 66 and
inwardly toward the shaft 23 of the finishing carrier 13 so that
the transfer moulds 42 mounted on transfer mould assemblies 40
are guided by the chain tracks 66 and the cam tracks 151d and
148d of Figure 7 into engagement with finishing moulds 43 mounted
on said finishing carrier 13, after which said chain conveyor 61x
is led into a circular path outwardly of said finishing carrier
by the tracks 67 as it travels toward and through transfer point
300 at which point the notches 178 of the links 58 are brought
into cooperation with the wheels 51 of the transfer mould
assemblies 40, the transfer moulds 42 are disengaged from the
finishing moulds 43 by the combined action of the chain conveyor
and its track 68 of Figure 7x and the cam tracks 151cx and 148bx
of Figure 8x. Thereafter said transfer mould assemblies
supported on chain conveyor 61x are transported towards transfer
point 100 along track 68 and between tracks 64ax and 64bx of
Figure 7x, guided by the action of wheels 50 serially on tracks
151ax, 151ex and 151ax of Figure 8x.
- 15 -
~3~17~ 9
Referring again to Figure 7 and Figure 8 of the drawings, as atransfer mould assembly 40 and its support rollers 50 are
transported by the chain conveyor 61 along track 64 and thence
into support and control on transfer carrier 11 toward the first
tranmsfer station 100, the cam follower 48 enters the first guide
track 148d which serves to guide and control the continuously
changing orientation of the transfer moulds 42 mounted on
transfer mould assembly 40 as they travel into cooperation with
their mating input moulds 41 (Figure 1) mounted on the input
carrier 10. Thereafter as track 148d is discontinued the moulds
42 and their transfer mould assemblies are guided and controlled
serially by the action of cam rollers 47, 49 and 48 on cam tracks
147a, 149a and 148a respectively in their changing orientation
as they travel out of cooperation with said moulds 41 and are
reoriented into cooperation with finishing moulds 43 mounted on
finishing carrier 13, and also by the action of the rollers 48,
49 ,47, 48, 47 and 48 serially on tracks 148b, 149b, 147b, 148c,
147c and 148d as they travel out of cooperation with their mated
moulds 43 and through transfer point 300 and through the
discharge point located over conveyor 17 and are reoriented for
discharge of the finished moulded products and thence onward
toward transfer point 100.
As previously indicated, it will be noted that by reason of this
series of cam tracks and the multiplicity of cam followers, it is
possible to cause the finishing moulds 40 to rotate about the
axis of the shaft on which they are mounted so as to permit the
- 16 -
,.
~3~'7~
moulds to be arranged to face inwardly and to face outwardly of
the enclosure 210 which is located within the endless path 150
along which the transfer moulds are caused to travel in a
complete cycle. It is this structure which eliminates the
need to provide a long length of chain and a large number of
additional moulds in order to return the moulds from the load
discharge station to the first transfer station as is required in
the structure described in my prior Canadian Patent Application
Serial No. 576,355 filed September l, 1988.
From the foregoing, it will be apparent that the present
invention provides a moulding machine which makes efficient use
of the transfer moulds required.
~,
. ~ :
