Note: Descriptions are shown in the official language in which they were submitted.
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CONTINUOUS PLATFORM CUTTING APPARATUS AND METHOD
BACKGROUND OF THE INVENTION
The present invention relates to apparatus and continuous methods for shaping
the surface of a slab of compressible or cellular polymer material, such as
polyurethane foam. A blade cuts portions of the material from the slab after
the slab
is passed through a predetermined gap and has been compressed between a
compression roller and a patterned surface of a moving platform. The
predetermined
gap preferably is created at a region where the platform is adjacent to or
driven by a
drive roller.
Several methods and apparatus for cutting slabs of cellular polymer materials
have been disclosed in the prior art. For example, U.S. Patent No. 4,700,447
to Spann
discloses convolute-cutting slabs of polyurethane foam by compressing a slab
or pad
of foam between a pair of rolls with opposed spaced projecting fingers
arranged in a
pattern and cutting the foam with a saw blade transversely just as it emerges
from the
rolls. The cut slab is then separated into two pads each with convolute-cut
surfaces
forming a series of peaks separated by valleys. The valleys formed on one pad
are
formed by slicing away foam which becomes a mating peak or projection on the
other
pad. Spann then shaves the peaks to form a more planar top surface. As noted
in
Spann, convolute cutting alone produces only rounded peaks and rounded
valleys, and
it is difficult, if not impossible, to produce a cut surface with peaks having
substantially flat top surfaces or with recesses having substantially straight
side walls.
The convolute usually is intended to form the classic symmetrical and
repeating "egg
crate" pattern of peaks and valleys. To achieve a planar upper surface at
other than
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the recessed portions, the tops of the peaks must be cut or shaped in a second
step.
Compressible cellular polymer materials may also be cut using a hot wire
cutter. A slab of such material is cut by moving the slab relative to one or
more hot
wires as shown, for example, in U.S. Patent No. 4,683,791 (Demont). Only
straight
cuts in regular or symmetrical patterns may be formed using a hot wire cutter.
See
also U.S. Patent No. 4,915,000 (MacFaxlane) and U.S. Patent No. 5,573,350
(Stegall).
Shapes may be cut into the surface of a slab of cellular polymer material
using
a punch cutting apparatus, such as disclosed in U.S. Patent No. 5,299,483 (Ber-
Fong).
A block of the cellular material is pressed against a template so that a
portion of the
material is forced through an opening in the template. The exposed material is
then
cut by a blade and removed, leaving a recess or cavity in the slab. This
method cuts
one block of material at a time, and only one surface at a time.
U.5. Patent No. 4,351,211 (Azzolini) compresses a block of foam material
against a template or die having an aperture therein using a pair of plates
with concave
and convex portions. The compressed foam is transversely cut along the
template as
it is held between the plates. More complex cut regions may be obtained than
when
using a template without the plates with raised and depressed portions, but
only one
block is cut at a time. Other template or pattern cutting methods are shown in
U.S.
Patent No. 3,800,650 (Schroder) and U.S. Patent No. 3,653,291 (Babcock).
The surface of a cellular polymer material may be shaped by molding or
embossing, as opposed to cutting. U.5. Patent No. 4,383,342 (Forster), for
example,
discloses injecting the foam-forming composition in a mold cavity. After
sufficient
curing time, the individual foamed article is removed from the mold. Other one-
shot
molding techniques are known to persons of skill in the art. The molded
cellular
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polymer product generally forms a tough skin at the surfaces that were in
contact with
the mold.
Continuous and semi-continuous molding processes are also known. These
processes have the same drawbacks associated with one-shot molding techniques.
For
example, U.S. Patent Nos. 4,128,369 and 4,290,248 (Kemerer, et al.) disclose
an
apparatus and method for impression molding thermoplastic products. The
thermoplastic material in a liquid state is injected between compressed
traveling belt
molds. As the belt molds travel away from the point of introduction of the
thermoplastic, they are cooled, which in turns cools the thermoplastic
material. The
hardened molded thermoplastic material is removed from between the belts to
form
the finished product. Kemerer does not show a method for cutting or shaping a
cellular polymer material, such as polyurethane foam.
A method of embossing a foam surface using a patterned metallic embossing
belt or band is shown in U.S. Patent 4,740,258 (Breitscheidel). The foam is
heated
and then pressed against the embossing belt. The belt is removed after the
foam
surface cools. The embossed surface by design has a hardened skin. No method
for
cutting or shaping the foam is disclosed.
U.S. Patent No. 5,534,208 (Barry discloses a continuous rotary method for
surface shaping synthetic foams in which the foam is compressed between a
compression roller and a die roller having raised and recessed portions. The
portions
of the foam extruded into the recesses in the die roller are cut away. The
compressed
foam portions return to an uncompressed state after passing through the
rollers. As a
result, a mirror-image pattern to the pattern on the surface of the die roller
is cut on
the surface of the foam. The diameter of the die roller limits the length of
the shaped
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foam article that may be formed.
The prior art does not disclose an apparatus or a continuous method for
shaping a compressible or cellular polymer material by cutting to form
recesses of
various depths and various symmetrical and non-symmetrical shapes. Nor does
the
prior art disclose a method for shaping a slab of compressible or cellular
polymer
material of unlimited length using a movable patterned platform, such as an
endless
belt, as the template for cutting the surface of the slab. Nor does the prior
art disclose
a method fox forming a profile cut product without the hardened skin or hard
spots
associated with molded or embossed products. Nor does the prior art disclose
continuously cutting compressible or cellular polymer materials, such a
polyurethane
foam, with an apparatus that includes a movable patterned platform, such as an
endless belt or a series of connected panels defining at least one recess into
which the
cellular material may be compressed before cutting the material transversely
with a
knife blade.
SUMMARY OF THE INVENTION
A continuous method for shaping a compressible or cellular polymer material,
such as polyurethane foam, by cutting and removing portions of the material is
disclosed. A slab of cellular polymer material is compressed between a
compression
roller and a surface of a moving patterned platform. The moving patterned
platform is
interposed between the compression roller and a cooperating surface, such as
the
surface of a drive roller. Because the moving patterned platform may be formed
from
a flexible material, the compression force preferably is applied at a region
where the
platform is adj acent to a solid surface of the drive roller. In a less
preferred
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embodiment, the moving patterned platform is interposed between the
compression
roller and a follower roller and the compression force is applied at a region
where the
platform is adjacent to a solid surface of the follower roller. A knife blade
is
positioned downstream from the compression roller and the point at which the
compression force is applied, preferably with the blade interposed between the
compression roller and the patterned platform. The slab surface is cut
transversely by
the blade just as the slab emerges from between the compression roller and the
moving patterned platform, thus trimming off portions of the cellular material
that
filled the recesses in the patterned platform. In an alternate embodiment, the
blade is
positioned so that it shaves a fine scrim layer of foam from the slab surface,
and
makes deeper cuts into the slab in the regions in which the polymer material
has filled
the recesses in the patterned platform. If the patterned platform defines
upstanding
projections, instead of or in addition to recesses, the projections force a
portion of the
foam material away from the blade and less material is cut from the slab
surface in
those regions.
The patterned platform may be an endless belt or a series of movable panels or
plates or any other structure that may travel in a continuous circuit or path.
Where the
patterned platform is an endless belt, the belt is placed over a series of
rollers wherein
at least one such roller is driven by a motor. The belt may be engaged to the
roller
with interconnecting gears or ribs so that the rotation of the drive roller
causes the belt
to travel. Where the patterned platform is formed by a series of
interconnected panels,
such as metal plates, the panels preferably are connected movably to a chain
and
sprocket drive system. Thus when the sprocket is driven, such as by a motor,
the
sprocket drives the chain and the panels interconnected to the chain.
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The patterned platform may define at least one recess, which may be a hole or
void through the platform, but preferably is a cut-out portion that does not
pass
through the entire thickness of the platform. The recess may be provided as a
simple
or complex geometric shape. Where more than one recess is defined in the
platform,
the recesses may be of the same or different shapes, may be interconnected or
separated, may be symmetrical or non-symmetrical, and may be repeating or non-
repeating on the patterned surface of the patterned platform. The recesses may
be cut
to different depths in the platform. Several separate series of different
recesses may
be provided on one patterned platform.
The patterned platform may define at least one upstanding projection. The
projection may be provided as a simple or complex geometric shape. Where more
than one projection is defined on the platform, the projections may be of the
same or
different shapes, may be inter-connected or separated, may be symmetrical or
non-
symmetrical and may be repeating or non-repeating the patterned surface of the
patterned platform. The projections may have different heights. The patterned
platform may include a combination of recesses and upstanding projections.
As the slab travels with the patterned platform and is compressed between the
compression roller and patterned platform (with recesses), a portion of the
cellular
material fills the recesses in the patterned platform. Greater amounts of
cellular
material are cut from the slab in regions that have been compressed into the
recesses
in the patterned platform because this material has been forced to one side of
the
cutting edge of the blade in these regions. The cut portions are removed from
the slab
after it passes the knife. The resulting profile cut product has on its cut
face a series
of cut regions that substantially correspond in pattern and shape in mirror
image to the
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recesses provided in the patterned platform. The cut regions in the slab are
also cut
deeper in those regions that correspond to the deeper recesses in the
patterned
platform. However, due to the varying compression factors for cellular polymer
materials, the depth of cut of the cut regions usually is not identical to the
depth of the
recesses within the patterned platform.
Also disclosed is an apparatus for continuously shaping a compressible or
cellular polymer material, such as polyurethane foam, by cutting and removing
portions of the material. A compression roller and a cooperating surface, such
as the
surface of a driver roller, compress a slab of cellular polymer material. A
surface of
the moving patterned platform, interposed between the compression roller and
the
cooperating support surface, defines one or more recesses that hold a portion
of the
cellular material as it is compressed. In a preferred embodiment, the
cooperating
surface is the solid surface of a drive roller. In a less preferred
embodiment, the
moving patterned platform is interposed between the compression roller and a
follower roller and the compression force is applied at a region where the
platform is
adjacent to a solid surface of the follower roller. Preferably, the
compression roller is
motor driven. The patterned platform is also preferably motor driven.
A knife blade is positioned downstream from the compression roller and the
point at which the compression force is applied, preferably with the blade
interposed
between the compression roller and the patterned platform. The slab surface is
cut
transversely by the blade just as the slab emerges from between the
compression roller
and the moving patterned platform, thus trimming off those portions of the
cellular
material that filled the recesses in the patterned platform. In an alternate
embodiment,
the blade is positioned so that it shaves a fine scrim layer of material
(e.g., foam) from
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the slab surface, and makes deeper cuts into the slab in the regions in which
the polymer material has filled the recesses, but preferably the blade cuts
away foam material only from those portions of the surface at which it is
intended that voids or recesses be formed. If the patterned platform defines
upstanding projections, instead of or in addition to recesses, the projections
force a portion of the material (e.g., foam) away from the blade and less
material is cut from the slab surface in those regions.
The cut foam product has a series of recesses or projections defined in
its surface. If the drive roller drives the patterned platform at one speed
and
l0 the compression roller is driven at a different speed, the blade cuts the
foam
material to form angled side walls that are greater than or less than 90~ as
measured from the base of a cut recess or the top surface of a projection
formed on the surface of the cut foam slab. The difference in platform speed
as compared to the compression roller speed causes one surface of the slab to
enter the predetermined gap prior to the other surface of the slab.
Accordingly, in one aspect of the present invention there is provided a
method for shaping a cellular polymer material by cutting portions from a
surface of the material, comprising:
establishing a predetermined gap between a compression roller and a
cooperating surface;
interposing in the gap between the compression roller and the
cooperating surface a moving patterned platform forming a continuous circuit
and defining at least one recess, wherein the at least one recess has a
predetermined depth;
driving the compression roller and the moving continuous patterned
platform so that the surface speed of the compression roller is different from
the speed at which the moving continuous patterned platform is driven;
continuously feeding a slab of the cellular polymer material through
the gap between the compression roller and the cooperating surface and
compressing the slab while a surface of the slab is adjacent to the moving
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patterned platform so that the at least one recess is substantially filled by
a
portion of the cellular polymer material when the slab is compressed as it is
passed through the gap between the compression roller and the cooperating
surface; and
transversely cutting from the slab with a blade, as the slab emerges
from the gap between the compression roller and the cooperating surface, at
least a fraction of the portion of the cellular material received within the
recess of the patterned platform.
In accordance with another aspect of the present invention there is
1o provided a method for shaping a substantially planar surface of a cellular
polymer material by cutting a portion from the surface of the material to form
a recess therein, comprising:
establishing a predetermined gap between a circumferential surface of
a compression roller and a circumferential surface of a drive roller;
rotating the compression roller at a first rotational speed to cause the
circumferential surface of the compression roller to have a first surface
speed;
rotating the drive roller at a second rotational speed to cause the
circumferential surface of the drive roller to have a second surface speed
different from the first surface speed;
2o interposing in the gap between the compression roller and the drive
roller a patterned platform forming a continuous circuit and defining at least
one recess, wherein the at least one recess has a predetermined depth, and
wherein the patterned platform is driven at least in part by the drive roller
and
has a surface speed substantially matching the second surface speed of the
drive roller;
continuously feeding a slab of the cellular polymer material through
the gap between the compression roller and the drive roller and compressing
the slab while the substantially planar surface of the slab is adjacent to the
patterned platform so that the at least one recess is substantially filled by
a
portion of the cellular polymer material when the slab is compressed as it is
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passed through the gap between the compression roller and the drive roller;
and
transversely cutting from the slab with a blade, as the slab emerges
from the gap between the compression roller and the drive roller, at least a
fraction of the portion of the cellular material received within the recess of
the
patterned platform to form the recess in the substantially planar surface of
the
slab, wherein said recess has an angled sidewall.
In accordance with yet another aspect of the present invention there is
provided an apparatus for shaping a slab of cellular polymer material by
cutting and removing portions of the material from an outer surface of the
slab, comprising:
a compression roller and a drive roller, said compression roller
rotatable on an axis and having its outer surface spaced apart from the drive
roller to define a predetermined gap therebetween so that the compression
roller exerts a compressive force against the slab of cellular polymer
material
as said slab is passed through said gap between the compression roller and the
drive roller;
a continuous patterned platform driven by the drive roller, said
patterned platform having an outer surface and being interposed in the gap
2o between the compression roller and the drive roller and moveable with
relation thereto, said outer surface of said patterned platform defining at
least
one recess to receive a portion of the cellular polymer material when a region
of the slab is passed through said gap and compressed between the
compression roller and the drive roller, wherein the at least one recess has a
predetermined depth; and
a blade for cutting the cellular polymer material as the slab emerges
from the gap between the compression roller and the drive roller;
said blade positioned adjacent to the gap and to the outer surface of
the patterned platform to cut a portion of the cellular material received
within
the recess of the patterned platform.
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Using the apparatus and method according to the invention, a profile
cut cellular product in which portions have been cut from both the upper and
lower surface may be formed by feeding the slab through the apparatus twice.
First, one surface is cut, then the cut product is inverted and fed through
the
apparatus a second time to cut its opposite surface.
DESCRIPTION OF THE FIGURES
Numerous other objects, features and advantages of the invention shall
become apparent upon reading the following detailed description taken in
to conjunction with the accompanying drawings, in which:
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FIG. 1 is a schematic perspective view of one embodiment of a continuous
platform cutting apparatus that may be used to practice the invention;
FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. l;
FIG. 3 is a side elevational view of the apparatus shown in FIG. l;
FIG 4 is a schematic perspective view of an alternate moving platform for a
continuous platform cutting apparatus that may be used to practice the
invention;
FIG. 5 is a fragmental side elevational view of a cellular polymer
underlayment mat defining patterned recesses that have been cut into the mat
using
the continuous platform cutting apparatus and method of the invention;
FIG. 5A is a fragmental side elevational view in cross-section taken along
line
5-5 of FIG 5;
FIG. 6 is a top plan view of the mat of FIG. 5;
FIG. 7 is a schematic side elevational view in partial cross-section showing a
second embodiment of a continuous platform cutting apparatus that may be used
to
practice the invention;
FIG. 8 is a partial schematic side elevational view in partial cross-section
showing a modification to the second embodiment of FIG. 7; and
FIG. 9 is a partial schematic side elevational view in partial cross-section
showing a third embodiment of a continuous platform cutting apparatus that may
be
used to practice the invention.
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to the apparatus as shown in FIGS. 1-3, a continuous platform
profile cutting apparatus for compressible or cellular polymer materials 10 is
supported on a first frame structure 12 and second frame structure 22. A shaft
14 is
mounted for rotation to the first frame structure 12, preferably with
bearings. A motor
16 drives the shaft 14. A drive roller 18 is mounted on shaft 14. The outer
surface of
the drive roller 18 may be covered or coated with a slip resistant material,
such as
urethane. Ribs or gear teeth 20 are provided around the outer end or
peripheral end
surfaces of the first drive roller 18. Alternatively, separate gears with
suitable gear
teeth may be provided at each end of the first drive roller 18.
Shaft 24 is mounted for rotation to the second frame structure 22, preferably
using bearings. A first follower roller 28 is mounted on shaft 24. The outer
surface of
the first follower roller 28 may be covered or coated with a slip resistant
material,
such as urethane.
A patterned platform, such as endless patterned belt 32, has a patterned
facing
surface 34 and an opposite surface 38. Belt 32 is mounted around the drive
roller 18
and first follower roller 28. The belt facing surface 34 defines recesses 36,
which may
be simple or complex shapes, simple geometric patterns, complex patterns,
~ symmetrical or repeating patterns ox non-symmetrical and non-repeating
patterns.
Rectangular 36 and circular 37 recesses are shown by way of example in FIG. 1.
The
recesses may be provided at various depths as discussed in more detail below.
Mating ribbed sections 39 on the outer edges of the belt opposite surface 38
mate with or engage the ribs or geax teeth 20 provided on the drive roller 18.
When
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the servo motor 16 drives shaft 14, which in turn rotates drive roller 18, the
endless
belt 32 travels around the drive roller 18 and the first follower roller 28.
The mated
ribbed sections 39 and ribs 20 and the frictional engagement between the
contacting
surfaces of the belt with the rollers keep the belt centered and aligned with
the rollers
as it travels a path around the rollers.
First idler roller 40 is mounted for rotation on shaft 42 which is held by a
portion 44 of the frame 12. First idler roller 40 is positioned at a point
between the
drive roller 18 and the first follower roller 28 to stabilize the movement of
the endless
belt 32.
Compression roller 46 is provided at a point between the drive roller 18 and
the first follower roller 28. The compression roller 46 is mounted for
rotation on shaft
48. The shaft 48 is held in a bearing recess within a frame 52. Tension
adjusting
means 54, such as a fluid cylinder or spring or series of springs, may act on
frame 52
to adjust the compression force applied.
The outer surface 47 of the compression roller 46 contacts the opposite
surface
38 of the belt 32 on which the ribbed portions 39 are provided. The outer
surface 47
of the compression roller 46 may be covered or coated with a slip resistant
material,
such as urethane. As shown best in FIG. 2, the surface 47 of the compression
roller
46 does not extend to the full outer periphery of the roller, leaving a recess
into which
the ribbed portions 39 extend so that the surface 47 of the roller 46 contacts
the
surface 38 of the belt 32. Greater slip resistance results when the amount of
surface
engagement between the belts 32 and the roller compression surface 47 is
increased.
Compression roller 56 with outer compression surface 60 is mounted for
rotation on shaft 58. The shaft 58 is held within frame 62. A motor 57 drives
shaft
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58. The roller 56 is separated from compression roller 46, leaving a space or
gap
through which the endless belt 32 travels between the compression surfaces of
the
rollers. The arrow 64 in FIG. 2 indicates the force applied against the frame
62 to
urge roller 56 to toward roller 46.
Referring to FIG. 3, knife blade 76 is held within casing 74. The blade 76
must have a sharp tip that is sufficiently sharp to cut cellular polymer
materials, such
as polyurethane foams. Because the blade 76 construction is known and
understood
by persons of skill in the art of cutting cellular polymer materials, such as
polyurethane foams, it will not be described in detail.
The blade 76 is positioned adjacent to the compression rollers 46, 56 so that
the sharp tip of the blade is adjacent to or just beyond the point at which
the outer
surfaces 47, 60 of the compression rollers 46, 56 act to their greatest extent
to
compress material that is placed between the rollers (i.e. the predetermined
gap). The
blade 76 is also positioned between the compression surface 60 of compression
roller
56 and the patterned facing surface 34 of endless belt 32 so that the blade
tip is close
to tangential contact with the facing surface 34. The blade 76 should be
positioned so
that it will not cut the compression surface 60 of the roller 56 or the
patterned facing
surface 34 of the belt 32. The blade 76 should not interfere with the rotation
of the
rollers 46, 56 or the movement of the belt 32. Blade orientation may be
adjusted so
that the tip of the blade is moved closer or farther from the nip between
roller 46 and
roller 56.
~In one embodiment as shown best in FIGS. 2 and 3, as a slab 80 of cellular
rilaterial, such as polyurethane foam, is fed between the compression suxface
60 of
compression roller 56 and the patterned facing surface 34 of the endless belt
32, the
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slab 80 is compressed by the rollers 46, 56. When the slab 80 travels into the
nip or
space or predetermined gap between the rollers 46, 56, portions of the
compressed
slab material are held within the recesses 36 defined within the facing
surface 34 of
the belt 32.
Knife blade 76 cuts transversely portions of the slab 80 just as the slab 80
emerges from between the compression rollers 46, 56. As shown in FIG. 3, the
cuts
into the slab 80 are made in the regions corresponding to those regions in
which slab
material had been compressed within recesses 36 defined in the facing surface
34 of
the belt 32. A portion of the material that was held within a recess in the
belt is cut
away from the slab before the compressed cellular material is able to recover
to its
uncompressed state as it emerges from the compression rollers. Portions of the
slab
surface not compressed into the recesses or voids in the facing surface 34 of
the belt
32 may or may not be cut, depending upon the position of the blade 76.
After the slab is cut as it emerges from the rollers, the cut-away portions 88
are removed as waste, leaving a resulting profiled cellular material 90. The
resulting
product 90 has recesses 92 substantially corresponding in shape to the
recesses 36
provided in the patterned face surface 34 of the endless belt 32. Slabs of
cellular
material may thus be provided with profiled surfaces with an endless array of
patterns,
whether symmetrical or non-symmetrical, simple or complex, or repeating or non-
repeating. For example, alternatively the cut-away portion 88 might be a
separate
profiled cellular material product 90.
Preferably, only portions of the slab that have been compressed into recesses
are cut away, resulting in less'waste to remove from the surface of the slab
as it
emerges from the cutting apparatus. In contrast to prior cutting methods, the
waste
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material does not fall away and contaminate the apparatus, but is carried away
by the
belt 32. The waste may then be swept or vacuumed off the belt as it continues
to
travel along its path defined by the position of the rollers 18, 28.
Long slabs of cellular material may be continuously fed into and shaped by the
continuous platform cutting apparatus. The method may be used to cut multiple
products continuously from a single slab of material. The recesses and/or
projections
formed in a single patterned platform may be arranged in separate
configurations for
different products. Alternately, repeating recess patterns may be formed in
the
patterned platform. In addition, patterned platforms of different lengths may
be used
to form finished cut products of different lengths.
An example of a profile-cut product 300 made according to the invention is
shown in FIGS. 5 and 6. The profile cut product 300 represents a cellular
polymer
insulating barrier or underlayment that will be installed in the interior of a
motor
vehicle between the floor surface and the carpeting. The upper surface 310 of
the
underlayment has been cut to provide complex patterns of recesses. As shown in
FIG.
6, generally rectangular-shaped recesses 312 have been cut into the surface of
the
product 300. In addition, more complex shaped recesses, such as
interconnecting
generally oval shaped recesses 314 and interconnecting straight-edged and
curved-
edged recesses 316, may be cut into the cellular material. For the
underlayment for a
motor vehicle, preferably one surface, here what has been referred to as the
upper
surface 310, is cut and the opposite surface remains uncut. The cut surface of
the
underlayment is placed adjacent to the motor vehicle surface so that the voids
and
recesses in the underlayment mate with shaped portions projecting from the
vehicle
surface. In this manner, the underlayment may be provided so as to match the
contour
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of the vehicle interior surface. Once the underlayment is installed in the
vehicle,
carpet or other covering may be installed adjacent to the uncut and generally
smooth
surface of the underlayment.
The depth of the recesses 36, 37 of the belt 32 are typically a small fraction
of
the depth of the corresponding cuts to be made in the surface of the foam
material 80.
Because of the compression factor of the foam against the pattern belt 32, a
shallow
depression 36, 37 in the pattern belt 32 yields a much deeper depression in
the foam.
For example, a 5/8 inch thick sheet of foam material compressed against a
depression
36 of 20 thousands of an inch in the patterned belt, in the apparatus 10
described
above, yielded approximately a %a inch deep depression in the foam sheet 80.
The
spacing between the belt surface 34 and the roller surface 56, if all other
factors are
equal, determines the compression factor of the foam and consequently, the
ratio of
patterned belt depth to foam cut depth. The depth of cut in the foam can be
reduced
for a given pattern belt recess depth or projection height by increasing the
spacing
between the roller surface 56 and the belt surface 34, thus reducing the
compression
factor.
Where the belt 32 is driven at the same speed as the roller 56, the cut
product
has recesses (or projections) formed with sidewalk substantially perpendicular
(90 °)
to the top surface of the product. The angle of the cut sidewalls may be
varied by
driving the belt 32 at a different speed than the speed roller 56 is driven.
When
different drive speeds are used one surface of the slab 80 will enter the
predetermined
gap before the other surface. The drive speed may be adjusted continually as
the foam
material slab 80 is introduced into the gap. In this way, side wall angles may
be the
same ar different in different regions of the cut product. Referring to FIG
SA, the
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recess is cut with substantially perpendicular (90 °) sidewalls 340,
but there is shown
in phantom outline a recess cut with angled sidewalls 342. When the
compression
roller is driven at 25 feet per minute surface speed and the patterned
platform runs at
35 feet per minute surface speed, the cut product has recesses with side walls
cut at an
angle of about 110 ° to 115 °. However, the cut angle is about
90 ° when both surfaces
are driven at the same speed.
For certain applications, it may be desired to cut both the upper and lower
surfaces of a slab of cellular material. If the apparatus shown in FIGS. 1-3
is used for
this purpose, once the slab has been fed between the compression rollers and
cut on
one side, the slab may then be inverted and fed between the compression
rollers so
that it may be profile-cut on the opposite surface.
The endless belt 32 preferably is formed from a flexible material such as
rubber or silicone rubber or urethane. The belt 32 is thick enough to
withstand the
compressive forces, preferably about 0.375 inches or more, and has a durometer
of
about 35 or higher, preferably 75 or higher, most preferably at least 90.
Alternatively,
the belt may be formed of fiberglass reinforced polyurethane or other
composite
materials suitable for endless belts with such thickness and durometer.
As shown in FIG. 4, rather than using an endless belt, the patterned platform
200 may be constructed as a continuous or endless series of inter-linked
panels driven
by chain and sprocket. The series of plates 208, preferably formed from metal
or
other sturdy substrate, are mounted on shafts 210. The shafts 210 are held for
rotation
within bearing sleeves 212. Y-shaped follower bars 214 are connected at one
end to
the shafts 210 and at the other two ends to members 204 holding together the
links
202 of a chain. The chain links 202 are driven by sprockets (not shown), which
in
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turn are driven by motors (not shown).
The plates 208 may define one or more recesses 216, or portions of recesses
216a. The recesses may be cut through a portion or through the entire
thickness of a
plate. The recesses may be formed in rectangular, circular or other geometric
shape.
The recesses may be cut in non-uniform, non-symmetrical and not repeating
shapes.
The recesses need not be contained wholly within a single plate. Rather, a
recess
defined by one plate may complement the recess defined by an adjacent plate to
form
larger or more complex recess shapes.
When a series of plates are used as the patterned platform, the slab of
cellular
material will be pressed against the plates by a compression roller (not shown
in FIG.
A.) so that a portion of the material is compressed into the recesses in the
plates and is
cut away from the slab by a knife blade just as the cellular material emerges
from the
compression roller. A support platform 222 is provided below the plates 208 to
support the plates when compression forces are exerted on them by the
compression
roller.
FIG. 7 shows a preferred embodiment of the invention. Like reference
numerals in FIG. 7 refer to like elements as shown in FIGS. 1-3 because the
apparatus
300 in FIG. 7 is similar to the apparatus 10 shown in FIGS. 1-3. There is
provided a
drive roller 18 that travels in the direction indicated by the arrow 302. The
outer
surface of the drive roller 18 is provided with teeth 20. The apparatus also
includes
follower roller 28.
A belt 32 has a patterned surface 34 with one or more recesses 36 and has an
opposite surface 38. Mating ribs or teeth 39 are proved on the opposite
surface 38 of
the belt. The teeth 39 engage the teeth 20 provided on the drive roller 18. As
the belt
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travels along a path around the drive roller 18 and follower roller 28, it
also contacts
the outer surfaces of first and second idler rollers 40, 40'.
A compression roller 56 mounted on a shaft 58 is provided with an outer
surface 60. In this apparatus 300, the compression roller 56 is positioned
close to the
outer surface of the drive roller 18 to define a predetermined gap between the
outer
surface 60 a.~zd the roller 18. The roller 56 position is adjustable, such
that the outer
surface 60 of the roller may be closer or farther from the outer surface of
the drive
roller 18 to change the gap. The belt 32 travels between the outer surface 60
of the
compression roller 56 and the outer surface of the drive roller 18.
A slab of compressible material 80 is fed into the gap between the patterned
surface 34 of the belt 32 and the outer surface 60 of the compression roller
56. The
gap is set to a distance that causes the compressible material to be
compressed
between the outer surface 60 of the compression roller 56 and the patterned
surface 34
of the belt 32. Portions of the compressible material are forced into the
recesses 36
formed into the patterned surface 34 of the belt 32.
A knife blade 76 held within knife casing 74 is positioned just downstream
from the gap. Just as the compressible material 80 passes through the gap,
portions of
the slab 80 held within the recess 36 are cut by the blade 76. The cut slab
emerges
with a profile-cut surface with recesses. The cut-away portions 88 are
separated from
the slab 80 and are carned away by the belt 32 to be removed, either by
falling away,
by manual removal or by vacuum.
The apparatus in FIG. 8 shows a modification to the apparatus of FIG. 7. To
more smoothly compress the slab 80 of compressible material between the
compression roller 56 and the moving patterned endless belt 32, idler rollers
304 and
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306, and a follower roller 308 are provided. A belt 310 travels in a circuit
defined by
the compression roller 56 and the follower roller 308 and idler rollers 304,
306. A
narrowing gap is defined between the belt 308 and the belt 32. The gap is
widest
between the follower roller 308 and the belt 32 and progressively narrows or
closes
between the idler roller 306 and the belt 32 and between the idler roller 304
and the
belt 32. As the slab 80 passes between the belt 32 and the belt 308 and
through the
progressively narrowing gap, the compressible material is compressed to a
greater
degree, until the greatest compression in the predetermined gap between the
compression roller 56 and the belt 32.
FIG. 9 shows a belt 32' modified to include raised projections 320 projecting
from the patterned surface 34'. Some cut products axe formed by cutting away a
scrim or thin layer from the surface along the'entire length of the slab 80.
With
projections 320 provided on the belt 32', cut products can be formed without
cutting
away material where portions of the slab passing through the predetermined gap
are
held to one side of the blade 76 by the projections 320.
The apparatus and methods according to this invention might be used to make
profile cut products for a variety of end uses. In addition to motor vehicle
carpet
systems, profile cut products might be made for other vehicle interior
applications,
such as head liners, side panels and dash panels. Profile cut products might
also be
used for mattresses, mattress pads, pillows, furniture cushions, filters,
sports
equipment, footwear components and packaging. The above list is intended to be
representative and not exhaustive as to all the possible applications for the
invention.
While preferred embodiments of the invention have been described and
illustrated here, various changes, substitutions and modifications to the
described
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embodiments will become apparent to those of ordinary skill in the art without
thereby departing from the scope and spirit of the invention.
