Note: Descriptions are shown in the official language in which they were submitted.
CA 02193830 1999-09-23
Machine For Making Honeycomb Material
This invention relates generally to a machine for
making honeycomb material and, more particularly, to a
machine which allows for the continuous and uninterrupted
production of a continuous web of honeycomb material.
Honeycomb material has been conventionally produced
with either a "Pad" machine or an intermittent-feed CHS
(Continuous Hobe Splicing) machine.
Two types of "Pad" machines have been used, i.e., a
"Padder" machine and a "Booth" machine. With the "Booth"
machine, the honeycomb material is formed by feeding a
single sheet of paper, unwound from a single roll of paper,
horizontally towards a knife which cuts the sheet of paper
longitudinally along its width into a plurality of
longitudinally and horizontally disposed strips of paper.
When a strip is cut, it is turned so as to be positioned
vertically and then glued to the immediately preceding cut
strip. The plurality of vertically positioned strips are
then glued together to form the honeycomb material which is
then cut to its desired length. A disadvantage associated
with the "Booth" machine is that it uses only a single
sheet of paper and produces core material at an extremely
inefficient production speed of approximately 200 cuts per
minute.
The "Padder" machine involves a tree step process,
performed by three separate machines, which includes the
steps of forming pads of core material, sheering off slices
from the pad of core material, turning the slices of core
material on their sides so as to be positioned vertically
and, finally, bonding the slices of core material to
produce a continuous web of
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_ ~~~~~30
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core material. A disadvantage of the "Padder" machine is
that an operator is required for each of the machines and
steps in the process. As a result of the process being
multi-stepped, core material is produced at an extremely
costly and inefficient production rate. Another
disadvantage is that, as a result of having to bond
slices of core material together to form the continuous
web of core material, the resulting web includes a
plurality of solid web lines thereby reducing the
structural integrity of the web.
Three types of intermittent-feed CHS machines
have..been used, i.e., a "rotary" intermittent-feed CHS
machine, a "cutter-stacker'~ intermittent-feed CHS
machine, and a "horizontal blade" intermittent-feed CHS
machine.
With a "rotary" intermittent-feed CHS machine,
as is disclosed in United States Patent No. 3,218,217,
honeycomb core material is formed by feeding forward a
single sheet of paper, longitudinally scoring the sheet,
forming transverse lines of intermittent slits across the
sheet, applying longitudinal strips of glue to the sheet,
and then folding and pleating the slitted sheet with a
pair of meshing star wheels. The pleated sheet is then
compressed between a pair of spaced guides to insure that
the pleats are bonded to one another along the various
glue lines to form a compressed honeycomb core. A
disadvantage associated with the "rotary" CHS machine is
that the slitting rolls, star wheels, and the drive ratio
of the machine must be changed to produce honeycomb
.0 material of different thicknesses. The reuuired
changeover of parts reduces the efficiency and speed with
which honeycomb core material may be produced. Yet
another disadvantage is that the rotary CHS machine can
only produce honeycomb core material of a limited width,
.5 i.e., 13-3/4" maximum. Yet a further disadvantage is
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that it uses only one roll of sheet material and is able
to produce only a limited amount of core material.
With a "cutter stacker° intermitten-t=feed CHS
machine, as is disclosed in United States Patent No.
4,113,712, a plurality of superimposed sheets of paper
are glued together to form a composite web. Stripes of
adhesive are then applied on an outside face of one of
the sheets constituting one outside face of the composite
web. A web feed is intermittently operable in cycles to
iG feed forward horizontally an increment of the composite
web and an intermittently operable drive drives the feed
through a cycle with a dwell between successive cycles.
A vertically disposed "guillotine" type knife is operable
during each dwell for cutting the composite web into
strips and for stacking the resulting strips in a
vertical stack with the adhesive strips on the outside
face of each strip adapted to engage the other outside
face of an adjacent strip in the vertical stack. The
stack is then compressed to bond the strips together so
as to form the honeycomb material. A disadvantage of the
"cutter-stacker" intermittent-feed CHS machine is the
inefficient production speed, of approximately 400 cuts
per minute, resulting from the use of a web feed which
must start, accelerate, decelerate and stop during each
~5 cycle and the use of a "guillotine" knife which must come
forward, cut, stop, come back and stop during each
cutting cycle. The use of a "guillotine" knife also
contributes to the production of honeycomb material of
uneven thickness since the "guillotine" knife has a
..0 tendency to chop rather than cut the paper. Yet another
disadvantage is that it can only produce honeycomb
material of a limited width.
With a "horizontal blade" intermittent-feed CHS
machine, as is disclosed in United States Patent No.
..5 3,257,253, a plurality of superimposed sheets of paper
CA 02193830 1999-09-23
are initially bonded together to form a composite web.
Strips of adhesive are then applied on the outside face of
the web. The composite web is then fed vertically
downwardly through an intermittently operable web take-up
and then into a cutting station including a horizontally
positioned knife which is operable intermittently in cycles
to cut the web into strips. The strips are then stacked
horizontally and compressed to form the web of honeycomb
material. A disadvantage associated with a "horizontal
blade" intermittent-feed CHS machine is the extremely
inefficient production speed resulting from the use of an
intermittently operable web take-up and a horizontal knife
which has a straight back and forth motion. The horizontal
knife is also disadvantageous because it has a tendency to
chop rather than cut the web, thus leading to the
production of honeycomb material of uneven thickness. Yet
another disadvantage is that it can only produce honeycomb
material of a limited width.
Thus, there remains a need for a continuous, rather
than intermittent, feed CHS machine which allows for the
production of honeycomb material at efficient production
speeds in excess of 700 cuts per minute. There also
remains a need for a continuous-feed CHS machine which
produces honeycomb material of substantially uniform
thickness. Further, there remains a need for a continuous-
feed CHS machine wherein the width of the honeycomb
material is unlimited. There also remains a need for a
continuous-feed CHS machine that is capable of switching
from the production of honeycomb material of one thickness
or cell size to the production of honeycomb material of
another thickness or cell size quickly and efficiently.
The present invention is a machine.for the production
of a continuous honeycomb web which includes a
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CA 02193830 1999-09-23
cutting assembly for successively and continuously cutting
a sheet of material, to which adhesive has been applied,
into a plurality of strips, the adhesive causing the
plurality of strips to adhere to each other to form the
continuous honeycomb web. A pull roll assembly
continuously pulls the sheet of material towards the
cutting assembly, and a stationary guide means positions
the sheets for cutting by the cutting assembly. A curved
support is positioned between the pull roll assembly and
the stationary guide means over which the sheet of material
continuously passes directly into the stationary guide
means free of any moveable guide member between the curved
support and the stationary guide means. The sheet of
material intermittently bubbles to spring the sheet of
material through the stationary guide means into the
cutting assembly.
Preferably a springing assembly urges the sheet of
material back against the curved support in response to
bubbling of the sheet of material away from the curved
support.
The springing assembly includes a plurality of line
assemblies positioned adjacent the curved support, the
sheet of material contacting and exerting an outward force
to the line assemblies during bubbling of the sheet of
material causing the line assemblies to move outwardly, the
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CA 02193830 1999-09-23
line assemblies then contracting and exerting an inward
force to the sheet of material to urge the sheet of
material back against the curved support.
In a preferred embodiment, the cutting assembly
includes a knife assembly disposed transversely to the
sheet of material for cutting the sheet of material
horizontally along its width into a plurality of strips,
the knife assembly including a reciprocating knife and a
stationary knife, a frame for mounting the reciprocating
knife, and a camshaft assembly operatively associated with
the knife assembly for providing a horizontal reciprocating
scissors action to the reciprocating knife.
The machine can further include a packing table for
packing the strips of material and a packing bar for
pushing the strips of material on the packing table away
from the cutting assembly into abutting relation with
previously cut strips on the table, the adhesive previously
applied to sheet of material causing the strips to adhere
to each other thereby forming a continuous honeycomb web.
In the accompanying drawings which form a portion of
this disclosure:
FIGURES lA and 1B are side views, with some parts
simplified, of a continuous-feed CHS machine constructed in
accordance with the present invention;
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CA 02193830 1999-09-23
FIGURE 2 is an enlarged broken perspective view of the
first station of the continuous-feed CHS machine depicted
in FIGURE 1B and, more particularly, the manifold
assemblies thereof;
FIGURE 3 is an enlarged broken perspective view of the
third station of the continuous-feed CHS machine depicted
in FIGURE 1B and, more particularly, the pull roll
assembly, the curved support, the cutting assembly, the
packing assembly and the run-off table thereof;
FIGURE 4A is a broken vertical cross-section of the
third station of the continuous-feed CHS machine, taken
along the line 4A-4A of FIGURE 3, depicting the web
positioned against the surface of the curved support at the
beginning of a cutting cycle;
FIGURE 4B is a broken vertical cross-section of the
third station of the continuous-feed CHS machine, similar
to FIGURE 4A, depicting the web bubbled away from the
surface of the curved support during the cutting cycle
FIGURE 5 is a broken perspective view of the cutting
assembly of the continuous-feed CHS machine; and
FIGURES 6A-6D are simplified plan views depicting the
reciprocating double scissors action of the cutting
assembly depicted in FIGURE 5.
Referring to the drawings and, more particularly,
FIGURES lA and 1B, there is depicted
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7 ~ ~' a .~~~:
~ - 193830
therein a continuous-feed machine 20 for the production
of a continuous honeycomb web.
Referring to FIGURE lA, machine 20 includes a
roll stand 22 including a frame 24 defined by horizontal
tube members 25 and upstanding supports 2G. A plurality
of rolls of sheet material 27 such as paper or the like
which are mounted on a plurality of shafts 28, are
mounted and spaced along the length of the frame 24.
a. The sheet material is unwound from each of the
l0 rolls 27 to form a plurality of continuous sheets of
material 30-35 having a first face 42 and a second face
44.
Each of the roll shafts 28 has a pneumatic
brake 4G operatively connected thereto which allows for
the variance and control of the speed, and thus the
tension, at which the sheets of material unwind from
rolls 27.
According to the invention, the tube members 25
are hollow to allow the flow of pressurized air from an
air source (not shown) through the tube members 25 and
into the brakes 4G by means of air lines 50 between
members 25 and brakes 4G. The pressurization of the tube
members 25 eliminates the need to run lengthy external
air lines from an air source to each of the brakes 46 and
thus eliminates the inherent risks associated therewith
such as puncture of the air lines with tools, etc.
Referring to FIGURE 1B, the machine 20 further
includes a first station 52 into which the sheets of
material 30-35 are fed. The first station 52 includes a
frame 54 with a base 5G and an upper frame member 58.
The base 5G includes an elevated deck GO with a_plurality
of panels G2. Each of the panels G2 are spaced from each
other to define slits G3 therebetween which extend
substantially the width of panel G2.
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293830
A plurality of brake roller assemblies G~~-G8
are disposed beneath the deck G0. The brake roller
assemblies G4-G8 are spaced in parallel relation along
the length of base 5G. Each of the brake roller
assemblies G4-G8 is comprised of three elongate and
rotatable shafts G9, 70 and 72. The shafts G9,_7-0 and 72
are parallel to each other and extend the width of the
base 56. The shafts G9 and 70 are geared and coupled to
each other at one end for rotation. The shaft 72 is also
rotatable but independently of shafts G9 and 70. Each of
the brake roller assemblies G~~-G8 further comprises a
brake assembly 71 'including a brake caliper 71a
operatively associated with a brake rotor 71b mounted to
the shaft 70 (FIGURE 2). According to the invention, the
panels 62 are hingedly connected to the deck GO so that
panels G2 may be opened to allow access to and
maintenance of the brake roller assemblies G~~-G8 therein.
Referring to FIGURES 1B and 2, the first
station 52 further includes a plurality of adhesive
manifold assemblies 73-77 which are positioned and spaced
along the length of the upper frame member 58. Referring
to FIGURE 2, each of the adhesive manifold assemblies 73-
77 is positioned transversely to the upper frame member
58 and extends the width thereof. Further, each of the
adhesive manifold assemblies 73-77 is aligned
approximately co-planarly with each of the brake roller
assemblies G4-G8, respectively.
Each of the adhesive manifold assemblies 73-77
includes a pair of parallel and co-planar bars 78 and 79,
which extend the width of, and are bracketed to, the
upper frame member 58. Each of the adhesive manifold
assemblies 73-77 further includes an elongate adhesive
manifold 82 which, similarly to bars 78 and 79, also
extends the width of the upper frame member 58. The
manifold 82 is positioned between and spaced from bars 78
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and 79. Manifold 82 is secured to bar 78 by clamps 84.
Manifold 82, preferably made of copper, is hollow and
includes a plurality of holes (not shown) which,
preferably, are drilled therethrough and spaced along the
length thereof. Adhesive is fed from an adhesive source
(not shown) through a plurality of adhesive filt-er
assemblies 88, then through adhesive supply lines 94,
into respective hollow.manifolds 82 and finally through
the holes therein onto the sheets of material 30-34.
According to the invention, the holes in manifold 82 of
manifold assemblies 73, 75 and 77 are aligned and co-
planar to each other while the holes in manifold 82 of
manifold assemblies 74 and 7G are aligned and co-planar
to each other but offset from the holes in manifold 82 of
manifold assemblies 73, 75 and 77.
As shown in FIGURE 1B, the first station 52
further includes a brake roller assembly 92 secured to
the top of upper frame member 58. The brake roller
assembly 92 is comprised of rotatable, elongate and
parallel shafts 94 and 9G which extend the width of the
upper frame member 58.
Still referring to FIGURE 1B, the machine 20
further includes a second station 98 comprising a
plurality of rollers 100-104 which are secured to the top
of the upper frame member 58. The rollers 100-104 are
positioned transversely along the length of the upper
frame member 58 and are spaced from each other in
parallel relation. Each of the rollers 100-104 extends
the width of the upper frame member 58. The rollers 100-
104 are aligned generally co-planarly with the manifold
assemblies 73-77, respectively.
As shown in FIGURES 1B and 4A, the machine 20
further includes a compression roller assembly 105
comprised of roller 100 and. an elongate and rotatable
roller lOG disposed adjacent to and directly above roller
100. The roller 10G, like the roller 100, extends the
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width of machine 20. The roller lOG is mounted on a
roller support IOGa which biases the roller 10G against
the roller 100. Although not shown, the rollers 100 and
106 are geared.and coupled to each other for rotation.
Preferably, each of the rollers 100 and 10G is made of
rubber or other suitable material.
As shown in FIGURES 1B and 4A, the machine 20
includes a slitter assembly 107, located in front of the
compression roller assembly 105, which comprises a pair
of spaced, elongate and parallel shafts lO8a and 108b
which extend the width of and are secured to the machine
by brackets 109: A circular slitter blade 110 is
secured to and surrounds the shaft 108a. A circular roll
guide 111 is secured to and surrounds the shaft 108b.
15 The slitter blade 110 and the roll guide 111 may be moved
to any desired position along the length of the shafts
108a and 108b, respectively. A chain 112 connects the
shafts 108a and 108b for coupled and simultaneous
rotation. A motor 112a, via chain 112b connected to the
20 shaft 108b, supplies the rotary slitter motion to the
shafts 108a and 108b and thus to the slitter blade 110
and roll guide 111, respectively.
Referring to FIGURES 1B and 4A, the machine 20
further includes a hollow web adhesive manifold 112 which
is located on top of the machine 20 in front of the
compression roller assembly lOG and is similar in
structure to adhesive manifolds 82. The web manifold 112
extends the width of the machine 20.
As shown in FIGURES 1B, 3 and 4A, the machine
20 further includes a third station 114. The third
station 114 is comprised initially of a pull roll
assembly 11G which is located near the top of third
station 114 and adjacent web adhesive manifold 112. The
pull roll assembly 11G includes a pair of elongate,
parallel and adjacent rotatable rollers 118 and 120 which
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extend the width of third station 124. Each of the
rollers 118 and 120 includes a plurality of ribs 1~2 (not
shown for roller 120) positioned and spaced along the
length thereof. The ribs 122 extend around the
circumference of each of the rollers 118 and 120.
Although not shown, the rollers llFi and 120 are_geared
and coupled to each other for rotation. The roller 118
is mounted on a roller support 121 which biases the
roller 118 against the roller 120. A pull roll assembly ,
gear motor (not shown), operatively associated and
connected to a machine drive motor (not shown), provides
the power to rotate rolls 118 and 120. Referring to
FIGURE 4A, a chain 123 connects the roller 120 of pull
roll assembly 11G to the roller 100 of compression roller
assembly 105 thereby connecting the pull roll assembly
116 and the compression roller assembly 105 for coupled
rotation.
Referring to FIGURES 3, 4A and 4B, the third
station 114 also includes a curved support or accumulator
2o bed 124 which extends generally downwardly from the pull
roll assembly 116 to the edge of a blade header 163.
According to the invention, the support 124 is composed
of expanded metal. Alternatively, the support 124 may be
composed of a solid sheet of metal with a plurality of
holes punched therein. Although a metal~sheet is
preferred, the curved support 124 may be composed of any
other suitable material.
Associated with the curved support 124 is a
springing assembly 125 (FIGURE 4A). The springing
assembly 125 includes an upper or first line bar 126,
positioned in front of the adhesive manifold 112 and
behind pull roll assembly 116 which e~ctends the width of
the machine 20 and is secured to and positioned away from
the surface of curved support 124 by brackets 127. The
springing assembly 125 additionally includes a second
line bar 128, positioned below the pull roll assembly 116
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12 ~? 193830
and generally adjacent to an intermediate portion of
curved support 124, which extends the width of sheet 124
and is secured to and positioned away from the surface of
support 124 by brackets 129.
The springing assembly 125 also includes a
spring bar 130, positioned below the line bar 128-, which
extends the width of the support 124 and is secured to
and positioned away from the surface of curved support
124 by upstanding brackets 131 which are secured to the
top of the blade header 163 and extend transversely to
the spring bar 130. Each of the brackets 131 includes a
fixed outer member~.131a and an inner member 131b which is
hingedly connected to the outer member 131a. The ends of
the spring bar 130 are connected to the upper end portion
l5 of the inner members 131b, respectively.
The springing assembly i25 further includes a
line guide bar 132, positioned generally adjacent to the
lower end of the curved support 124, which extends the
width of curved support 124 and is secured to and
positioned a distance away from the surface of support
124 by the upstanding brackets 131 which are secured to
the top of blade header 1G3. The brackets 131 extend
transversely to the line guide bar 132. The ends of the
line bar 132 are secured to the lower end portion of the
inner members 131b, respectively of brackets 131. The
line guide bar 1~2 has a plurality of rotatable line
guides 134 positioned and spaced along the length
thereof. Each of the line guides 134 has a peripheral
groove 13G.
The springing assembly 125 further comprises a
plurality of spring line assemblies 13B which ar_e
positioned above and adjacent support 124 in spaced and
parallel relation along the width thereof. Each of the
spring line assemblies 13F3 includes a spring 140 which
has one end connected to the spring bar 130 and a line
142 which is connected to the other end of spring 140.
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- 13 -~ 193830
The line 142 extends from the spring 140 around a
respective line guide 134 on lower line bar 132, then
upwardly over the surface of support 124, then under line
bar 128 and roll 118 of pull roll assembly 116. The line
142 is then secured to the upper line bar 126.
Alternatively, and although not shown, each of the spring
line assemblies 138 may start from the line bar 128
instead of the line bar 130.
The springing assembly 125 further comprises a
plurality of line assemblies 143 which are positioned
above and adjacent the upper end portion of support 124
in spaced and parallel relation along the width thereof.
Each of the line assemblies 143 includes a line 143a
having one end connected to the line bar 128. The line
143a then extends upwardly over the surface of the upper
end portion of support 124, then between rolls 218 and
120 of pull roll assembly 116. The line 143a is then
secured to the upper bar 126 between two corresponding
lines 142 of spring line assemblies 138. The lines 143a
and the lines 142 are positioned so as to be
alternatingly disposed with respect to each other in the
area defining the upper end portion of support 124.
The third station 114 further includes a pair
of knobs 146 which are secured, adjacent the line guide
bar 132, to opposite ends of the blade header 163. Each
of the knobs 146 is mounted on a bracket 150 and includes
a distal end 149 which abuts the line guide bar 132.
Each of the knobs 14G may be loosened to allow the
movement of the line guide bar 132 and the spring line
assemblies 138 away from the support 124 in the direction
of arrow A thereby simplifying the adjustment or repair
of structures associated with the third station 114
without interference by the spring line assemblies 138.
Referring to FIGURES 3, 4A and 4B, the third
station 114 further includes a cutting assembly 154 below
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and downstream of the curved support 124. The cutting
assembly 154 includes a knife assembly 156, disposed
transversely to support 124, which includes a
reciprocating knife 158 and a stationary knife 1G0. The
stationary knife 1G0 is mounted to the bottom of the
blade header 153. The reciprocating knife 258 .has an
elongate blade 1G1 mounted on an elongate blade holder
1G2 (FIGURE 6D). A wear plate 1G5 is mounted to the top
surface of the blade holder 162 and is positioned behind
the blade 1G1. According to the invention, the blade
holder 162 is made of aluminum and the blade 1G1 extends
approximately 0.75~~inches (1.90 centimeters) over the
outer edge of blade holder 1G2. The blade 1G1 is
preferably approximately 0.50 inches (1.27 centimeters)
thick. A pair of spaced connecting rods 1G4 are secured
to the rear of blade holder 1G2 and extend rearwardly
therefrom. The blade holder 1G2'also includes a guide
arm 1GG (FIGURES GA-GD) secured to one end thereof.
Referring to FIGURE 5, the reciprocating knife
158 is mounted on a frame 1G8 including a horizontal base
plate 170 and vertical side plates 172 which are secured
to the ends of base plate 170. The base plate 170 has a
pair of spaced guide rollers 174 (FIGURES 6A-GD) secured
to the surface thereof. The guide arm 1G6 on blade
holder 1G2 is positioned between guide rollers 174 for
guiding the movement of the reciprocating knife 158.
Also associated with the knife assembly 15G is a blade
hold-down plate 167 (FIGURES 4A and 4B) which is mounted
to the bottom surface of the rear portion of the blade
header 1G3. The plate 1G7 contacts the wear plate 1G5
and holds the knife 158 down against the frame 168. A
packing bar 171 (FIGURES 4A and 4B) is secured to the
front of the blade holder 1G2 and extends the length
thereof. Preferably, the packing bar 171 is the same
thickness as the distance which the blade 2G1 extends
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383p
over the edge of the blade holder 162, i.e.,
approximately 0.75 inches. The width of the packing bar
171 is dependent upon the thickness of the core material
which is being produced. For example, if core having a
thickness of approximately 2 inches (5 centimeters) is to
be produced, the packing bar 171 would have a width of
approximately 1.50 inches (3.81 centimeters) since the
thickness of the blade 161 is approximately 0.50 inches.
Referring to FIGURES 5 and 6D, the cutting
assembly 154 further includes a camshaft assembly 176
operatively associated with the knife assembly 156 for
providing a horizontal reciprocating double scissors
action to the reciprocating knife 158. The camshaft
assembly 176 is mounted behind the knife assembly 156 and
is seated on a table 178 in an interior chamber 180 of
third station 114.
The camshGft assembly 17G includes a rotatable
camshaft 182 having a pair of cams 183 and 184, a pair of
fly wheels 18G, and a pair of connecting rods 187 and
188. Each of the rods 187 and 188 has an end which
surrounds cam 183 and 184 respectively. The other ends
of connecting rods 187 and 188 are coupled to the ends of
connecting rods 164 of the blade holder 162. According
to the invention, the cams 183 and 184 are offset from
each other in a range between approximatel;r 15 to 20
degrees. The power to rotate the camshaft 182 is
supplied by the same machine drive motor (not shown)
identified earlier, which through the pull roll assembly
gear motor, provides the power to pull roll assembly 116.
3o Such power is supplied to the camshaft 182 via belt 192
which is mounted on a pulley 194 secured to the_end of
camshaft 182. The rotation of the camshaft 182 causes
the rotation of cams 183 and 184 which causes the
longitudinal movement of rods 187 and 188 as depicted in
FIGURES GA-6D, which in turn causes the reciprocating
WO 96/00150 PCTIUS94107150
i ~ i 9383t~
- .b
doubta scissors action of reciprocating k::ife 158
relative to stationary knife 160.
More particularly and, referring to_FIGURE 6A,
at the start of a cutting cycle, both rods 187 and 188
move forward in the direction of stationary knife 160,
with the rod 187 moving forward an incrementally greater
distance than the rod 188 such that the right half of
reciprocating knife 158 is caused to swivel forwardly
about center point 193 while the left half of
reciprocating knife 158 is caused to swivel rearwardly
about the center-point 193 approximately the same
distance which the right half of knife 158 swivels
forwardly.
At the half-cut or single scissors cut paint of
the cutting cycle (FIGURE 6B), rod 187 has completed its
forward movement and is beginning its rearward movement
away from the stationary knife 160 while rod 188
continues its forwardly movement such that the right half
of reciprocating knife 158 has completed its cutting and
0 is beginning to swivel rearwardly about center-point 193
away from stationary knife 160 and the left half of
reciprocating knife 158 has swiveled forwardly about
center point 193 in the direction of stationary knife 160
to begin its cutting.
At the full-cut or double scissors cut point of
the cutting cycle (FIGURE 6C?, the rod 188 has moved yet
further forwardly and the rod 187 has continued to move
rearwardly such that the right half of reciprocating
knife 158 has continued its rearward movement from
'_.0 stationary knife 160 and the left half of reciprocating
knife 158 has moved forwardly into its cutting position
over the stationary knife 160. In the full-open point of
the cutting cycle (FIGURE 6D), the reciprocating knife
158 has completed its full cut and the rod 188 has moved
?5 back rearwardly away from stationary knife 160 while rod
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219383
187 has ended its rearward movement and is beginning once
again to move forwardly towards the stationary knife 1G0
to start the next cutting cycle (FIGURE GA).
According to the invention, the cutting
assembly 254 is capable of performing in excess of 700
such cutting cycles per minute, which is an improvement
over currently accurate cutting assemblies of more than
300 cycles per minute. Further, and unlike current knife
assemblies, the knife assembly 15G cuts the paper rather
than chops it.
The third station 114 also includes a packing
assembly 19G comprised of a packing table 198 and the
packing bar 171 which is mounted to the front of the
reciprocating knife 158 (FIGURES 3 and 4A-4B). Pneumatic
jacks 208 (FIGURES 4A and 4B), operable to adjust the
height of table 198, are positioned beneath the table
198.
The machine 20 further includes a moveable run-
off table 22G, with an inclined top 228, which is
positioned adjacent to and abuts the end of packing table
298 (FIGURES 1B and 4B).
According to the invention, the machine 20
produces a continuous web of honeycomb material as
_ described below.
Initially, and referring to FIGURE 1A, the
sheets of material 30-35 are unwound from rolls 27 and
the brakes 4G on shafts 28 are operable to control the
speed and tension at which the sheets of material unwind
from the rolls 27. Then, as shown in FIGURE 1B, the
sheets of material 30-34 are fed into the first station
52 through the deck GO thereof and through brake roller
assemblies G4-G8, respectively. More particularly, and
as the sheets 30-34 travel through the brake roller
assemblies 64-68 respectively, each of the sheets 30-34
wraps around the shaft G9 of brake roller assemblies G4-
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- 18 - ~ 193830
68, respectivel;r, then between shafts G9 and 70, around
shafts 70 and 72, and then generally vertically upwardly
towards sheet manifold assemblies 73-77, respectively.
Sheet 35, on the other hand, is fed upwardly
through the brake roller assembly 92 which is secured to
the top of the upper frame member 58. More par-t:i-cularly,
sheet 35 is fed around shaft 94 of brake roller assembly
92, then between shafts 94 and 9G and then generally
horizontally forwardly in the direction of arrow B and
into the second station 98.
The brake roller assemblies G4-68 are
advantageous since~they assure that the sheets 30-34
remain taut, flat and unwrinkled as they travel
vertically upwardly through the first station 52 towards
the manifold assemblies 73-77. In a like manner, brake
roller assembly 92 assures that the sheet 35 remains
taut, flat and unwrinkled as the sheet 35 travels
horizontally into and through the second station 98.
. Still referring to FIGURE 1B, the sheets 30-34
then travel past sheet manifold assemblies 73-77,
respectively. For example, and referring to FIGURE 2,
sheet 32 is fed between bars 78 and 79 and manifold 82 of
sheet manifold assembly 75. As the sheet 32 travels past
the manifold 82, a plurality of spaced apart parallel
lines of adhesive 230 are applied longitudinally to the
face 42 of sheet 32. Lines of adhesive 230 are similarly
applied to the face 42 of sheets 30, 31, 33 and 34. The
lines of adhesive 230 on sheets 31 and 33 are offset from
the lines of adhesive on sheets 30, 32 and 34 since the
holes in manifolds 82 of manifold assemblies 74 and 76
are offset from the holes in manifolds 82 of manifold
assemblies 73, 75 and 77.
After adhesive has been applied to the sheets
30-34, and as sho~dn in FIGURE 1B, they wrap around
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_ - ~PEAI~S 2 9rJA~i ~~~
19
X193830
rollers 100-104, respectively of the second station 98
and then generally horizontally through second station 98
in the direction of compression roller assembly 105 and
towards pull roll assembly 11G. In the second station
98, the sheets 30-35 are superimposed and adhered to each
other to form a six-ply composite web of material-232
having an inner face 234 and an outer face 23G (FIGURE
4A). The six-ply composite web 232 is formed by
superimposing sheet 35 over sheet 34 with adhesive face
42 of sheet 34 contacting and adhering to face 44 of
sheet 35. Then, sheet 34 is superimposed over sheet 33
with adhesive face~.42 of sheet 33 contacting and adhering
to face 44 of sheet 34. Further, sheet 33 is
superimposed over sheet 32 with adhesive face 42 of sheet
32 contacting and adhering to face 44 of sheet 33. Then,
sheet 32 is superimposed over sheet 31 with adhesive face
42 of sheet 31 contacting and adhering to face 44 of
sheet 32. Finally, sheet 31 is superimposed over sheet
3o with adhesive face 42 of sheet 30 contacting and
adhering to face 44 of sheet 31 to complete the six-ply
composite web 232.
Referring to FIGURE 4A, the web 232, traveling
in the direction of arrow B, then passes between the
rollers 100 and 10G of compression roller assembly 105
where the sheets 30-35 comprising the web 232 are
compressed to improve the bond between the sheets and
thus the integrity of web 232. The compressive force
applied to the web 232 may be varied by adjusting the
position of the roller 10G on roller support lOGa.
3o After passing through the compression roller
assembly 105, the web 232 passes through the slitter
assembly 107 and, more particularly, between shafts 108a
and 108b of slitter assembly 107. There, the web 232 may
be cut vertically along its edges by the slitter blade
110. According the invention, the slitter blade 110 and
the roll guide
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WO 96100150 PCTlLJS94l07i50
_ ' ~ 93830
111 may be slid tc any posi~ion along the length of the
shafts 108a and 108b, respectively to allow the slitting
of the web 232 into two sections. For example, if it is
desired to slit the web 232 into two sections of ectual
width, the blade 110,and roll guide 111 would be moved to
the center of shafts 108a and 108b, respectively.
Thereafter, and as,shown in FIGURES 1B and 4A,
the web 232 travels past web manifold 112 where a
plurality of spaced apart parallel lines of adhesive 237
(FIGURE 3), similar to lines of adhesive 230, are applied
longitudinally to the face 236 of web 232 and, more
particularly, face 42 of sheet 35.
Referring to FIGURES 18, 3, 4A and 4B, the web
232 is then pulled through and between rotating rollers
118 and 120 of pull roll assembly 116 by the ribs 122
thereon which contact web 232. The lines of adhesive 237
on face 236 of web 232 remain undisturbed as the web 232
is pulled therebetween since they pass between ribs 122.
The pressure or bias of ribs 122 on the web 232 may be
varied by adjusting the position of the roller 120 on
roller support 121.
According to the invention, the speed of the
pull rollers 118 and 120 may be varied to vary the speed
at which the web 232 is pulled through the pull roll
assembly 116. The speed of the pull rollers 118 and 120
thus not only controls the speed of the web 232 but also
the speed at which the sheets of material 30-35 unwind
from the rolls 27 and travel through the first and second
stations 52 and 98, respectively.
-30 Referring to FIGURES 3 and 4A-4B, the web 232
then travels downwardly over the surface of the curved
support 124 past.the cutting assembly 154 into abutting
relation with the surface of the packing table 298 of
packing assembly 196. At this point, the web 232 is cut
.35 into a plurality of successive web strips 238 by the
.- ' WO 96/00150 PC~'/US9~/07150
1 Z~ 9383
- 21 -
reciprocating knife 158. To cut a single strip 238, the
reciprocating knife 158 must complete one full double
scissors cutting cycle as described earlier-arid as shown
in FIGURES 6A-6D. Mare particularly, the motion of the
reciprocating knife 158 as shown in FIGURES 6A and 6B
scissor cuts the left half of the web 232 horizontally
along the width thereof (as viewed from FIGURE 3) while
the motion of the reciprocating knife 158 as shown in
FIGURE 6C scissor cuts the right half of web 232 (as
1.0 viewed from FIGURE 3) horizontally along the width
thereof. After one cutting cycle has been completed and
a strip 238 has been cut, the web 232 is advanced once
again into abutting relation with the surface of the
packing table 198 just prior to the start of the next
cutting cycle so that the next strip 238 can be cut.
Each of the strips 238 has a width determined by the
height of the packing table 198 and a length equal to the
width of the web 232. The inner and outer faces 234 and
236 respectively of web 232 now become the faces of the
strips 238.
According to the invention, the curved support
124, in combination with the spring line assemblies 138
and line assemblies 143, allow the web 232 to be
continuously fed and advanced towards the cutting
?5 assembly 154 into abutting relation with the surface of
the packing table 198 during each successive cutting
cycle without any buckling or wrinkling of the web 232.
To assure the production of a honeycomb web of
even thickness, it is imperative that the web 232 be cut
:30 into a plurality of web strips 238 of even width. In
order to produce web strips 238 of even thickness, the
web 232 which is advanced toward the cutting assembly 154
must be free of wrinkles or buckles. This is
accomplished by assuring that, immediately prior to the
35 start of a cutting cycle, the web 232 is positioned flat
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against the surface of the curved support 124 anti the
packing table 198 as shown in FIGURES 3 and 4A. When so
positioned, the web 232 is free of wrinkles_and strips
238 of even width may be cut.
However, at the end of a cutting cycle, and as
a result of the movement of reciprocating knife 158
coupled with the continuous downward movement of the web
232 towards the packing table 198, the web 232 is caused
to bubble or wave away from the surface of the curved
support 124 and thus wrinkles or buckles are formed
(FIGURE 4B).
In order to remove such wrinkles from the web
232, the web 232 must be returned to the surface of the
curved support 124 prior to the start of the next cutting
cycle. This is accomplished by the spring line
assemblies 138 and line assemblies 143 (FIGURES 3, 4A and
4B). As a result of its bubbling away from the surface
of the curved support 124, the web 232 comes into contact
with and exerts an outward force to lines 142 which
causes the springs 140 attached to spring bar 130 to
expand. Once the web 232 has completed its outward
bubble movement, the springs 140 then contract and the
lines 142 exert an inward force to the web 232 which
causes the web 232 to return to the surface of the curved
support 124 prior to the start of the next cutting cycle.
The curved support 124 is preferably constructed of
expanded material such as metal to allow the removal of
the air disposed between the web 232 and sheet 124. It
is understood that the frequency of the bubbling may be
as great as 700 times per minute when the cutting
assembly 154 is set to perform 700 cuts per minute.
The line assemblies 143 extending between the
line bars 126 and 128 are particularly advantageous when
the web 232 is cut into wide strips 238. More
particularly, when the web 232 is cut into wide strips
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238, th~ere.:~is,.a tendency for the bubble in the web 23~ to
start closer to the top of support 124 and a tendency for
the bubble to bubble a greater distance away from the
surface of support 124 in the region between the line bar
128 and the pull roll assembly IlG. The line assemblies
143 assure that the web 232 is returned to the surface of
the curved support 124 prior to the start of each
shortened cutting cycle.
The plurality of cut web strips 238 (FIGURES 4A
1o and 4B), positioned vertically on top of the packing
table 198, are then packed and adhered to each other on
the packing table 198 to form a continuous honeycomb web
240 having a thickness equal to the width of the strips
238 and a length equal to the length of the strips 238.
More particularly, and referring to FTGURES 4A and 4B,
the packing bar 171 secured below the reciprocating knife
158 pushes a web strip 238 which has just been cut away
from the cutting assembly 154 into abutting relation with
a previously cut strip 238. The adhesive face 236 of the
strip 238 which has just been cut is abutted against and
adhered to the face 234 of the previously cut web strip
238 which is already part of the continuous honeycomb web
240. As strips 238 are continually cut, advanced, and
then packed, the honeycomb web 240 is caused to advance
onto the inclined run-off table 226 where the web 240 is
further compressed and the adhesive is allowed to
completely dry.
According to the invention, the number of
pounds of web 240 which can be produced is dependent upon
the speed of the web 232, the number of cuts which
machine 20 has been set up to perform and the width of
the strips 238 which are cut. That is, as the speed of
web 232 and the number of cuts per minute are increased,
more strips 238 are cut and thus more honeycomb web 240
is produced. Similarly, the number of pounds of
wo 9s~ooiso PcTms9a~omso
2193330
~ L
honeycomb web 240 produced will increase as the width o~
the strips 238 is increased.
With machine 20 according to the present
invention, the speed~of the web 232 and the length of the
cutting cycle of cutting assembly 154 may be simply and
efficiently adjusted while the machine 20 is in operation
since both the speed of the pull rollers 118 and 120 and
the cutting cycle length are simultaneously controlled
through the machine drive motor lnot shown) which drives
i.0 both the pull roll assembly 116 ar_d the cutting assembly
154.
According to the invention, the adjustment of
a drive motor control dial lnot shown) on the drive
motor, while machine 20 is operating, automatically and
simultaneously adjusts both the speed of pull rolls 118
and 120 and the cutting cycle length of cutting assembly
154. Thus, and unlike currently available machines,
there is no need to stop the machine and change gears or
-, other parts to vary the speed of the web 232 and the
0 cutting assembly 154.
Additionally, with the machine 20 according to
the present invention, and unlike other machines, the
width of strips 238 and thus the thickness of the
honeycomb web 240 may be simply varied by adjusting the
height of the packing table 198 and the speed of the
machine drive motor. For example, to produce honeycomb
web 240 of greater thickness, the table 198 would be
lowered to increase the width of the web strips 238 which
are cut and the speed of the machine drive motor would be
?0 increased to increase the speed of the cutting assembly
154. To produce honeycomb web 240 of lesser thickness,
the table 198 would be appropriately elevated so that web
strips 238 of lesser width are produced and the speed of
the machine drive motor would be decreased.
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Still further, with machine 20 according to the
present invention, the size of the cells which comprise
the honeycomb web 240 may be quickly and efficiently
varied. The cell size of web 240 is determined by the
distance between holes (not shown) in adhesive manifolds
82 and 112. For example, to produce a web 240 having a
cell size of approximately 0.50 inches (1.27
centimeters), manifolds 82 and 112 having holes therein
spaced apart a distance of approximately 1.0 inches (2.54
centimeters) are used. To produce a web 240 having a
cell size of approximately 0.25 inches (O. G3 centimeters)
requires the use of manifolds 82 and 112 having holes
therein spaced a distance of 0.50 inches. Thus,
according to the invention, the switch from production of
0.50 inches cell size web to 0.25 inch cell size web
simply requires the change of manifolds 82 and 112. With
machine 20, the changeover is a procedure requiring
approximately 15-30 minutes. With prior machines, the
cell size changeover might take well over one hour.
The foregoing is illustrative of the principles
of the invention. Further, since numerous modifications
and changes will readily occur to those skilled in the
art, it is not desired to limit the invention to the
exact construction and operation shown and described.
Accordingly, all suitable modifications and equivalents
may be resorted to while still falling withi:. the scope
of the invention.
n ~EIdQ~ Stir
