COMPOSITE ARTICLE ASSEMBLY SYSTEMS AND METHODS
A composite article assembly arrangement includes mechanized assembly station tooling for supporting certain composite article assembly methodologies with a view toward a preferred lid assembly application. First assembly station tooling includes a stationary main base plate, opposed intermediate compactor plates, and opposed outer plates, which compactor plates and outer plates are movable relative to the stationary main base plate. One or more continuous webs bearing thermoformed first and second workpieces are directed through the mechanized assembly station tooling, which operates to both separate the first and second workpieces from the web(s) as directed therethrough and assemble the first and second workpieces in one clapping movement of the compactor plates and outer plates relative to the main base plate. Alternative assembly station tooling operates to direct first composite elements into assembled relation with stationary second composite elements for forming basic composites to which successive composite elements are similarly added.
This application is a divisional and continuation-in-part patent application claiming the benefit of pending U.S. Patent Application No. 16/661,765 filed in the U.S. Patent and Trademark Office (USPTO) on 23 Oct. 2019, which application claims the benefit of expired U.S. Provisional Patent Application No. 62/749,627 filed in the USPTO on 23 Oct. 2018 the specifications and drawings of which are hereby incorporated by reference thereto.
BACKGROUND OF THE INVENTION Field of the InventionThe present invention relates generally to certain production line systems and associated methods for forming composite articles as applied to exemplary two-piece lid assemblies. More particularly, the present invention relates to production line assembly tooling stations having all-in-one functionality whereby, either in a single bi-directional clapping movement or a unidirectional movement, first and second workpieces are assembled into a composite article and removed from a preferred web conveyor.
Brief Description of the Prior ArtU.S. Pat. No. 7,353,582 ('582 Patent), issued to MacKenzie et al., discloses a Method for Assembling a Closure Tab to a Lid. The '582 Patent describes a method and apparatus for assembling a first thermoformed workpiece, such as a tab closure, to a second thermoformed workpiece, such as a lid. The invention described by the '582 Patent relates to an automated manufacturing line for making a composite thermoformed article from first and second thermoformed workpieces by automatically assembling the first thermoformed workpiece to the second thermoformed workpiece. The automated manufacturing line comprises a thermoforming station for thermoforming the first and second thermoformed workpieces in a plastic sheet, a trim station for trimming at least the first thermoformed workpiece from the plastic sheet; and an assembly tooling station for assembling the first thermoformed workpiece onto the second thermoformed workpiece to form the composite article.
U.S. Pat. No. 7,523,534 ('534 Patent), issued to MacKenzie et al., discloses a Method for Assembling a Closure Tab to a Lid. Similar to the '582 Patent, the '534 Patent describes certain methods for assembling a first thermoformed workpiece, such as a closure tab, to a second thermoformed workpiece, such as a lid. The assembly tooling station of the '534 Patent further describes a carrier mechanism that moves between a first position, where it picks the first thermoformed workpiece, and a second position, where it assembles the first thermoformed workpiece to the second thermoformed workpiece. A suction device can be added to the carrier to pick the first thermoformed workpiece as it is trimmed from the sheet and hold the first thermoformed workpiece as it is carried to the second thermoformed workpiece. Additionally, a force reliever can be added to the carrier to control the amount of force applied by the carrier to the first and second thermoformed workpieces as they are assembled.
United States Patent Application Publication No. 2009/0283526, authored by Pierce et al., discloses a Molded, Recyclable, Compostable Cellulose Fiber Lid Assembly for a Container. The Pierce et al. publication describes a lid assembly, comprising a dome portion, a rim-receiving portion, and a compression ring are configured to attach to a container and provide a seal between the lid assembly and the container. The lid assembly is made of a reusable, recyclable, and compostable material, such as molded paper, pulp, natural cellulose fibers cellulose fiber, tapioca, wood, agricultural recycled crop materials, plastics (PLA), clay, metals, petro-plastics, silicone, PVC's, and PET styrene.
The prior art perceives a need for a substantially simultaneous, dual-action composite article assembly system and method that operates to eliminate the structural requirement to carry a second workpiece to a first workpiece for article assembly. The state of the art teaches complex systems for workpiece transfer within a three-dimensional space, leading to inefficiency in workpiece-to-workpiece assembly. To overcome the structural requirement of carrying workpieces to other workpieces, the prior art perceives a need for a single step motion whereby workpieces can be removed from thermoformed webs and in the single step motion be assembled with one another. The present invention attempts to address this perceived need by providing certain composite article assembly methodologies supported by all-in-one assembly tooling stations and associated production line technology, as summarized in more detail hereinafter.
SUMMARY OF THE INVENTIONAmong the many objectives of this invention is the provision of a composite article assembly production line or arrangement comprising an all-in-one assembly tooling station for supporting certain composite article assembly methodologies as exemplified by two-piece lid assemblies. The all-in-one assembly tooling stations according to the present invention essentially comprise a stationary main base plate, opposed intermediate compactor plates, and opposed outer plates, which compactor plates and outer plates are movable relative to the stationary main base plate.
One or more continuous webs bearing thermoformed workpieces, exemplified by upper lid bodies and lower lid bodies, are directed through the assembly tooling stations, which stations operate to both separate the workpieces from the web(s) as directed therethrough and assemble the workpieces in one clap-like or clapping movement of the compactor plates and outer plates relative to the main base plate. The main base plate comprises an axial alignment chamber or cavity that operates to mechanically or structurally maintain axial alignment of the workpieces as they are assembled to form the composite article.
The composite article assembly method supported by the all-in-one assembly tooling stations according to the present invention may be said to comprise the basic steps of forming workpieces exemplified by upper lid bodies or disks and lower lid bodies or primary lid formations via state-of-the-art thermoforming station(s). The workpieces are then placed or directed into axial alignment with one another along an assembly alignment axis extending through the assembly site or chamber(s) of the main base plate of the all-in-one assembly tooling station(s).
Once placed into axial alignment with one another, the workpieces are directed toward one another within the assembly tooling station along the assembly alignment axis or alignment axes in the case of multiple assembly chambers formed in the main base plate. When directed toward one another, distance between the respectively aligned workpieces is decreased to the point when aligned upper workpieces approaches zero, and the first and second workpieces are assembled under the forced and directed engagement into one another to form composite articles exemplified by two-piece lid assemblies.
Central to the practice of the present invention are the steps of directing the first and second workpieces toward one another within the assembly tooling station along the assembly alignment axis, and assembling the first and second workpieces along or in parallel relation relative to the assembly alignment axis within the all-in-one assembly tooling station(s) as performed in a single clap-like or clapping movement of opposed tooling as exemplified by intermediate compactor plates and outer plates opposite the stationary main base plate within which workpiece assembly occurs.
The present invention is believed centered on the substantially simultaneous, dual-action (with sequential momentary delays as may be required), workpiece-cut and workpiece-to-workpiece assembly step whereby the opposed tooling is directed towards one another for directing a first workpiece (e.g. an upper lid body or disk) into engagement with a second workpiece (e.g. a lower lid body or primary lid formation) for forming composite articles. In other words, when the first workpiece is cut from the web it is directed (not carried)) into assembled relation with the second workpiece also being cut from the web during one clap-like, to-and-fro, or back and forth tooling movement within the all-in-one assembly tooling station(s) thereby providing a composite formed article or two-workpiece assembly.
The step of forming first workpieces and second workpieces via the primary body-forming or thermoforming stations comprises or includes the step of forming the such workpieces on at least one continuous web. However, the present invention further contemplates the formation of such workpieces or composite formed articles on at least a pair of, or at least two continuous webs, directing the pair or at least two continuous webs via at least two separate primary thermoforming stations in a web-to-station flow or direction (i.e. into or toward a singular all-in-one assembly tooling station).
The composite article assembly method according to the present invention further comprises the step of removing (e.g. via a select cutting process) a select body formation from the at least one continuous web before directing first and second workpieces toward one another within the assembly tooling station, which select body formation is selected from the group consisting of the first workpieces and the second workpieces. The select cutting process may be selected from the group consisting of a die-cutting process or a circular knife-cutting process.
The composite article assembly method may further preferably comprise or include the step of forming first and second workpieces on the least one continuous web via the at least one thermoforming station such that the first and second workpieces are formed in spaced and alternating relation to one another. The at least one continuous web may be further directed through a secondary body-forming station as exemplified by pre-punch stations after forming the first and second workpieces via the primary thermoforming station(s). The secondary body-forming stations function to form secondary formations as exemplified by sip holes, air vents, or other similar secondary apertures in select workpieces as selected from the group consisting of the first and second workpieces.
When the production line is built around a single, continuous web, the composite article assembly method may further preferably comprise the step of directing the spaced and alternating first and second workpieces through a loop mechanism so as to axially align the first and second workpieces within the singular assembly tooling station for forming composite articles. Bearing in mind that the all-in-one assembly tooling stations all provide a basis for the described methodology, the methodology may further preferably comprise the step of directing the first and second workpieces into a stationary plate structurally enhancing axial alignment of the first and second workpieces during the step of assembling the first and second workpieces along the assembly alignment axis.
The present invention may further preferably comprise the step of directing at least two or a series of workpieces into a portion of the stationary plate before directing a first of the series of workpieces into assembled relation with a singular second workpiece. In other words, a series of workpieces (e.g. disks) may be directed into a disk-guiding shaft of the main base plate before a first of the workpieces (e.g. disks) is expelled, discharged or otherwise directed from the disk-guiding shaft into engagement with an underlying lid depression of a workpiece (e.g. a lower lid body). It will thus be understood that the disk-guiding shaft of the stationary plate may temporarily store at least one workpiece for later discharge as governed by the operator.
The present invention embraces the concept of adjusting tooling features in a manner that cooperates with inherent resiliency of materials to provide for better assembly characteristics. For example, a compactor shaft and compactor head may be finely adjusted so as to resiliently deform a first workpiece prior to separation from the web and directed transfer through the disk-guiding shaft into engagement with the underlying workpiece. Accordingly, the present methodology contemplates the step of resiliently deforming a select body formation before the step of assembling the first and second workpieces along the assembly alignment axis within the assembly tooling station, which select body formation is selected from the group consisting of the first and second workpieces. The step of resiliently deforming the select body formation functions to adjustably enhance workpiece assembly.
An alternative multi-piece composite article assembly method according to the present invention essentially involves the centralized use of a conveyor, preferably in the form of a thermoformable web, provided or outfitted with a series of multiple, axially alignable composite elements. The composite elements are formed or provided upon a first face of the planar web conveyor facing a first direction. The conveyor may preferably be directed through a first loop mechanism such that the first face first faces a second direction opposite the first direction when exiting the loop mechanism. First and second composite elements are then axially aligned within the mechanized assembly station tooling along an assembly alignment axis.
Once the first and second composite elements are axially aligned, the first composite element is directed toward the second composite element within the mechanized assembly station tooling along the assembly alignment axis. The first composite element and the second composite element are then assembled along the assembly alignment axis within the mechanized assembly station tooling thereby forming a basic composite. The method may further comprise the step of twisting the conveyor at a twist portion downflow from the basic composite assembly site for re-orienting the assembly alignment axis for successive elemental alignment and assembly.
The steps of directing the first composite element toward the second composite element within the mechanized assembly station tooling along the assembly alignment axis and assembling the first composite element with the second composite element along the assembly alignment axis within the mechanized assembly station tooling are preferably performed by unidirectionally moving the first composite element along the assembly alignment axis toward the second composite element as fixed in position within the tooling.
It is contemplated the conveyor primarily functions as an element-conveying mechanism. In certain applications, the carrier conveyor may be preferably exemplified as a web type conveyor with the multiple, axially alignable composite elements being thermoformed therein before entry into the mechanized assembly station tooling that operates to form composite articles. Sets of the multiple, axially alignable composite elements are preferably positioned upon the first face of the conveyor in spaced and alternating relation to one another.
The multi-piece composite article assembly methodology may further comprise the step(s) of directing successive composite elements into assembled relation with the basic composite within the mechanized assembly station tooling along successive assembly alignment axes thereby forming a complex composite. The mechanized assembly station tooling may preferably alignment cavities formed in alignment plate(s) of the tooling such that composite elements may be directed therethrough or thereinto for enhancing axial alignment of the composite elements when assembling the composite elements along the assembly alignment axis within the mechanized assembly station tooling.
The present specifications further contemplate certain workpiece stacking methodology or workpiece cutting methodology for providing a stacked series of workpieces for ease of packaging. The workpiece stacking or cutting methodology according to the present invention contemplates the essential steps of stacking a series of web sheets atop one another into a web sheet stack. Each web sheet may provide at least one, but preferably a series of workpiece sites. The web sheet stack may thus preferably comprise at least one stack of web-based workpieces.
The web sheet stack may be positioned in (inferior) adjacency to a shaft-receiving plate assembly, which shaft-receiving plate assembly comprises at least one, but preferably a series of shaft-receiving apertures or bores. The at least one stack of web-based workpieces are preferably positioned in adjacency to the shaft-receiving aperture(s). At least one tubular shaft, but preferably a plurality of tubular shafts may be directed through the web sheet stack via the shaft-receiving aperture(s) thereby separating the web-based workpieces from the series of web sheets and forming a stacked series of workpieces within the tubular shaft.
The stacked series of lid formations or workpieces are linearly directed into the tubular shaft as the tubular shaft is directed through the web sheet stack. In this regard, each tubular shaft preferably comprises a tubular shaft end, which tubular shaft end is preferably outfitted with a cutting implement or knife. The cutting implement cuts through the web sheet stack as the tubular shaft is directed therethrough. The tubular shaft preferably comprises external threads, and the shaft receiving aperture or bore is preferably outfitted with a thread-driving interface. The thread-driving interface and external threads are cooperable for converting rotational motion to linearly directed motion thereby directing the tubular shaft linearly through the web sheet stack.
Other secondary objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated or become apparent from, the following brief descriptions of the drawings and the accompanying drawing figures.
Other features and objectives of the invention will become more evident from a consideration of the following brief descriptions of patent drawings.
Referring now to the drawings with more specificity, the following specifications generally describe certain systemic production line arrangements and methods of forming composite articles or two-workpiece assemblies supported thereby as well as certain methods for precision part adjustments, including part-trimming methods. The production line arrangements and methods of composite article formation according to the present invention preferably involve single station or so-called “all-in-one” mechanized assembly station tooling methodology. A continuous web 20 carries web blanks through a thermoforming station 100 for forming lower lid bodies or primary lid formations as at 10 and upper lid bodies or disks as at 19 (i.e. first and second workpieces 10 and 19, respectively) for further delivery to a proprietary die setup within a press assembly.
The upper lid bodies or disks 19 are carried by a support cone carrier element 11 (the support cone carrier element with attached disk element 19 is referenced at 11). The upper lid bodies or disks 19 are insertable into the lower lid bodies or primary lid formations 10 for assembly into lid assemblies 13. The upper lid bodies or disks 19 are removed from the web 20 via the single tooling station assembly methodology as carried by the support cone carrier element 11. Once the disks 19 are removed from the support cone carrier element 11, the support cone carrier element is referenced at 12 as generally illustrated and referenced in introductory
Before entry into the all-in-one, mechanized assembly station tooling (comprising manufacturing components and/or mechanized machinery required for production, including die configurations setup within a press frame assembly), the lower lid bodies or primary lid formations 10 and/or upper lid bodies or disks 19 may preferably be directed through a pre-punch station as at 101 for die-cutting or punching sip holes, air vents, or other secondary apertures therein. The lower lid bodies or primary lid formations 10 and the upper lid bodies or disks 19, supported and carried by the support cone carrier elements 11, are arranged on the web 20 in spaced relation to one another in an alternating manner as generally depicted in
The web 20 carrying the lower lid bodies or primary lid formations 10 and the upper lid bodies or disks 19 is preferably directed through a loop mechanism 102 in certain preferred embodiments such that alternating lower lid bodies or primary lid formations 10 and upper lid bodies or disks 19 are directed into axial alignment (as at assembly alignment axis 110) with one another for assembly of the upper lid bodies or disks 19 into the lower lid bodies or primary lid formations 10 during a single cutting and disk-to-lid insertion movement.
In this regard, and central to the practice of the present invention, is a substantially simultaneous, dual-action (with sequential momentary delays as may be required), cut-from-web and disk-to-lid or workpiece to workpiece assembly step. In other words, when the upper lid body or disk 19 is cut from the web 20, it is directed (e.g. pushed (i.e. not carried)) into assembled relation with the lower lid body or primary lid formation 10 also being separated (e.g. cut) from the web 20 during one clap-like, to-and-fro, or back and forth tooling movement within the all-in-one assembly tooling station(s) or mechanized assembly station tooling according to the present invention.
As prefaced above, the upper lid bodies or disks 19 are never carried for later assembly with the lower lid bodies or primary lid formations 10, but directed axially after being removed from the web 20 into assembled relation with the lower lid bodies or primary lid formations 10. The assembled lower lid bodies or primary lid formations 10 and upper lid bodies or disks 19 thus form lid assemblies 13, which lid assemblies 13 are collected and preferably directed into a stacked relation or manner as generally depicted in
After the dual cutting-assembling action of the all-in-one assembly station tooling, the disk-departed support cone carrier elements 12 (i.e. support cone carrier element without disk 19) of the web 20 continue in the web flow direction of the web 20 with disk-departed apertures as at 22 in alternating relation with lower lid body-departed apertures as at 23. A series of upper lid bodies or disks 19 and associated disk-departed apertures or disk holes 22; and lower lid bodies 10 and associated lower lid body-departed apertures or lid holes 23 are comparatively illustrated and referenced in
Further comparatively referencing
It will be understood from a comparative consideration of
In such an arrangement, each print of five consecutive rows of lower lid bodies or primary lid formations 10 will advance through the disk-punching side of the all-in-one assembly tooling station represented on the left side of
Referencing
The second intermediate compactor plate 14 opposes the main base plate 30 and interfaces between the main base plate 30 and an outer plate 15 having a lid support base 46 and a lid support body 45. The reader will note that the (arcuate) disk 19 is insertable into a lid depression 21 (thermo)formed in the lower lid body 10 via the (arcuate) compactor head 18, which lid depression 21 comprises a rear or inner depression surface 40 (opposing a lid support depression top surface 41) and a top or outer depression surface. The compactor head 18 opposes inner or rear disk surface and the outer or frontal disk surface opposes the rear or inner depression surface when the lower lid bodies 10 and the upper lid bodies 19 are placed into axial alignment for forming lid assemblies 13.
Comparatively referencing
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The second production line arrangement according to the present invention is believed highly beneficial for high volume production in which composite articles or two-piece lid assemblies 13 are provided in two alternating colors (i.e. lower lid bodies or primary lid formations 10 provided with first coloration and upper lid bodies or disks 19 provided with second coloration different than the first coloration). For example, the application may call for white lower lid bodies or primary lid formations 10 with black upper lid bodies or disks 19, and vice versa. If a first thermoforming station 100 forms lower lid bodies 10 and upper lid bodies 19 from a web 20 with first coloration, the second thermoforming station 100 may form lower lid bodies 10 and upper lid bodies 19 with second coloration.
Comparatively referencing
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In this regard, the reader will note that web 20 with upper lid bodies or disks 19 being carried by support cone carrier elements 11 proceeds through the loop mechanism 102 to flip over and feeds into the opposite side of all-in-one assembly tooling station 103 for subsequent and simultaneous punching and insertion of the upper lid bodies or disks 19 into the lower lid body or primary lid formations 10. The second trimming-packaging station 104 receives assembled lid assemblies 13 from the web 20 after being processed by the all-in-one assembly tooling station 103.
In other words, the all-in-one assembly tooling station 103 punches the upper lid body or disk 19 from the support cone carrier element 11 thereafter assembling the upper lid body or disk 19 into the lower lid body or primary lid formation 10 while still on the web 20 or web-attached after advancing through the loop mechanism 102. The dual action die-cut and directed movement of the upper lid body or disk 19 into engagement with the lid depression 21 of the lower lid body or primary lid formation 10 allows for increased efficiency of assembling the upper lid bodies or disks 19 into the lower lid bodies or primary lid formations 10 without the requirement for temporarily holding or carrying the disk 19 and/or moving it by changing directions as generally described by state-of-the-art systems and methods.
Referencing
The embodiments depicted in
The die-cut type lid trimming process begins when the web 20 is immovably pressed between the intermediate compactor plates 14 and the main base plate 30. The upper lid body or disk 19 is trimmed-inserted into the lower lid body or primary lid formation 10. The lid punch 60 is attached to the outer plate 15 and the lid support body 45 is suspended via springs 58 on the top of the lid punch 60 as generally depicted in
The combination of conically shaped walls of the lid support body 45, as suspended from the lid punch 60 on springs 58, allows the lid support top surface 33 and the lid support rim top 35 to touch corresponding surfaces of the lid top rear surface 38 and lid ring rear surface 36 before the lid top outer surface 39 touches the lid nest ceiling 32. The lid rim outer surface 37 touches the lid nest rim surface 34 before the web 20 is securely pressed between the main base plate 30 and the second intermediate compactor plate 14.
The precision adjustment of alignment happens the moment before the lower lid body 10 and the web 20 are immovably pressed between the main base plate 30 and the second intermediate compactor plate 14 and the lid punch 60 is pressed against the back surface of the lower lid body 10 and the lid punch 60 cutting edge 61 is pressed against the lid edge perimeter 62. The lid punch 60 trims the lower lid boy 10 out of the web 20 and pushes it to the limit of lid die opening 65 at the same time pressing the lower lid body 10 further into the lid nest 31.
The trimmed lid assembly 13 is immovably pressed between the lid nest surface 31 and the surface of lid support body 45 and the springs 58 are compressed and the lid punch 60 is pressed against the bottom of the lid support body 45. The upper lid body or disk 19 is trimmed and pushed by the compactor head 18 into the lid depression 21 as generally depicted and referenced in
Simultaneously, the compactor shaft 17 continues advances forward until compactor head 18 pushes the lid edge perimeter 62 of the trimmed lid assembly 13 beyond the plane of the web 20 through lower lid body-departed aperture 23 (the lid hole or lower lid body-departed aperture 23 is formed on the web 20 after the lower lid body 10 is punched therefrom) to the compactor's assembly push limit 25 of the compactor shaft 17 as generally depicted in
As the outer plate 15 (as an extended plate portion of the outer pin support plate 16) with the lid punch 60 continues reversing movement, the access opening plate 9 (as an extended plate portion of the first or second intermediate compactor plate 14) also starts moving in reverse direction (as generally illustrated in
The access opening plate 9 moves in reverse direction until the lid assembly 13 is removed from the lid support body 45 by the lid stripper element or step 43 as generally depicted in
Simultaneously, the first intermediate compactor plate 14 with compactor shaft 17, the disk punch 50, and the outer pin support plate 16 with push pin 49 reverses direction and starts moving to the position generally depicted in
The functional part movements within the all-in-one assembly tooling station(s) happen simultaneously or nearly simultaneously in a tightly synchronized manner in relatively short periods of time, such that a full cycle is possibly as short as half a second. The drawings submitted in support of these specifications do not precisely depict the exact sequence of each function, but rather attempt to depict the relative position of different parts during the process of performing a particular function of all-in-one assembly tooling station. In general, plates 9/14 and 15/16 move in synchronized manner, simultaneously in a direction towards the stationary main base plate 30 and in reverse direction back to the starting point. In this way, the clap-like or clapping movement and the moniker “clapper” may be said to fairly and accurately describe plate movement character.
Referring now to
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Threads 69 of the disk-feeding screws 63 preferably operate to drive the disks 19 into assembly with the lid depression(s) 21. A disk guide screw 29 may also be positioned at the disk sip opening 78 to aid in proper disk rotational alignment. The screw extension 79 and thread roots 81 that engage outer edges of the disks 19 are further generally depicted and referenced in
The disk-feeding mechanism 80 more particularly functions to (a) retrieve an upper lid body or disk 19 from the disk die opening limit 47; (b) temporarily store multiple disks 19 in the disk-guiding shaft 56; (c) forward stored disks 19 towards lid depression(s) 21; and (d) drop an individual lower-most disk 19″ to be inserted into lid depression 21. Using vacuum suction 82 for inserting disk 19″ into lid depression 21 allows the temporary storage of multiple disks 19 in the disk-guiding shaft 56. The disk 19 is punched out and pressed to punch limit 47 at plane B of die opening 55.
From punch limit 47 to plane B, the disk 19 is engaged by thread-like disk-feeding mechanism 80 with disk-feeding screws 63 located in immediate adjacency to disk-guiding shaft 56.
Rotation of the screws 63 and 29 is preferably synchronized and engaged as one disk-feeding mechanism 80. At the punch limit 47 plane B threads 69 of the disk-feeding mechanism 80 “grab” an upper most disk 19′ from at least two opposite directions one of which is on disk-guiding screw 29 and forwards the upper most disk 19′ towards lid depression 21 one by one. The last or bottom-most disk 19″, at the end of the thread 69 at plane F of the disk-feeding screws 63 and disk-guiding screw 29 of the disk-feeding mechanism 80, is inserted into aligned lid depression 21 preferably by vacuum suction 82 through lid sip hole 68. The bottom part of the disk-guiding screw 29 extends below the last pitch of the thread 69 and below plane F screw extension 79 into lid depression 21 thereby guiding the bottom most disk 19′″ all the way into lid depression 21 and preventing it from circular dislocation.
There may be multiple disks 19 in transition to lid depression 21 in the disk-feeding mechanism 80. The disk-feeding mechanism 80 could conceivably accommodate a large number of disks 19, perhaps on the order of thousands of disks 19, while also accommodating as few as 2-10 disks 19. Having multiple disks 19 in the disk-feeding mechanism 80 at the starting cycle allows disks 19 to be inserted into approaching lower lid bodies or primary lid formations 10, which bodies or formations 10 have no need to then wait when web 20 moves through the loop 102 and the first support cone carrier element 11 aligns with the conical countersink 54 of the main base plate 30. In other words, the disk-feeding mechanism 80 may eliminate dependence on the synchronization of movements of disk punch 50 and ensuing assembly of upper lid bodies or disks 19 into lid depression(s) 21 in tandem with other tooling operations.
This alternative arrangement, for example, not only eliminates the need for compactor shaft 17, but also gives the operator more options in terms of placement of disks 19 with a one-to-one ratio with lower lid bodies 10 on the web 20, and in different configurations and arrangements. For example, disks 19 could be separately formed and fed to the disk punch 50 from separate direction or the number of rows of disks 19 could follow the same number of rows of lower lid bodies 10. Disks 19 may further be punched out and temporarily stored in the disk-feeding mechanism 80. When rows of lower lid bodies 10 start aligning with the disk-feeding mechanism 80, disks 19 may be sequentially and successively inserted into sequential and successive lid depressions 21 row by row.
The reader will note that to minimize effect of building pressure and vacuum in chamber 26 created between plane C (i.e. the top of the compactor's head nest 24) and plane D (i.e. the bottom of the disk-guiding shaft 56 (See
The reader will further note that the disk 19 could be inserted into lid depression 21 by vacuum suction through lid support vacuum/pressure access line 67 which may be aligned with lid sip hole 68, or by combination vacuum suction through lid sip hole 68 and by pressure from compactor head 18. In this regard, vacuum/pressure access line 67 at lid support body 45 may be preferably aligned with lid sip hole 68 and may serve as vacuum/pressure release from the disk-guiding shaft 56 and disk-feeding mechanism 80. The disk-guiding shaft 56 may thus serve as certain disk storage means whereby disks 19 are stored within the disk-guiding shaft 56. An upper-most disk as at 19′ is positioned in superior adjacency to stored disks 19 such that a lower-most disk 19′″ is insertable into lid depression 21 during the compaction process described hereinabove. This process provides a built-in storage supply of disks 19 so as to provide flexibility for the system.
Referencing
Comparatively referencing
Fixating screws 84 may preferably operate to secure the push pin screws 83 into preferred placement for adjusting the compactor head 18 a distance 85 thereby further resiliently deforming the support cone carrier element 11′ a horizontal support cone carrier element deformation distance 86. The support cone carrier element 11 comprises a support cone carrier element shoulder as at 87 and the direction of size expansion is referenced at 88 once the disk 19 is punched and pushed from the disk-guiding shaft 56, the diameter of which equals to D0 (default diameter). The internal resistivity or resilient force of the material construction of the disk 19D pushes the outer diameter of the disk in the direction 88 to D2 or its relaxed diameter. The adjustments enabled by way of the screws 83 (and 84) and inherent resiliency of the material construction thereby allow the provider to adjust disk dimensions while holding punch and die dimensions constant.
It will thus be understood that a method for precision adjustment of dimensions of parts made from resilient (e.g. plastic) material during die cutting is supported by the foregoing. When precision of fitted parts exemplified by the upper lid body or disk 19 is part of the protocol or practice, adjustments are sometimes necessary to adjust for precision, and state of the art practices typically require the manufacturer to cut new tool dies and punches. To avoid forming new tool dies and punches, the present invention provides for flexibility in that the dimensions (e.g. size or diameter) of the upper lid body or disk 19 (as an example) may be adjusted slightly to either side with the same diameter of punch and die by manipulating the structure of the part when it still on the web 20 and just before the punch drives it into the die thereby providing an effective way of dimensional precision control.
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Comparatively referencing
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The conically shaped locator ring 52 presses against back surface of the support cone carrier element 11 with springs 58 not fully compressed. The lower lid body 10 is pressed by the lid support body 45 against lid nest 31 with springs 58 not fully compressed. The web 20 is also not fully pressed between the main base plate 30 and the intermediate compactor plates 14. At this position, alignment of the lower lid body 10 and the support cone carrier element 11 (with disk 19) respectively eliminates deficiency, if any. The described position of mechanical parts are presented for illustrative purposes primarily and do not necessarily represent actual positions of various mechanical components at any given moment.
Referencing
Simultaneously, the circular cutting mechanism 70 as generally and comparatively depicted in
The knife blade tip point 71 preferably extends just as far as required to cut or slice through material thickness (for example, if material thickness is .015″, the knife blade tip of knife blade 70 extends 0.016″-0.020″ from the top surface of the material thickness). A pressure ball 72 keeps pressure against the material thickness at the time of circular rotation of knife blade tip point 71. The needle bearing 76 helps to keep constant pressure and rotation of the base ring 73 at the same time. It will be understood that the outer surface 77 of the base ring 73 may be outfitted with a gear or timing pulley for rotation means.
Referencing
Disk-departed apertures or holes 22 are formed in the web 20 at the support cone carrier element(s) 12 where the disks 19 have been removed, and lower lid body-departed apertures or holes 23 have been formed in the web 20 where lower lid bodies 10 have been removed. The web 20 is then ready to advance the next row(s) of lower lid bodies 10 and support cone carrier elements 11 (with disks 19) as generally depicted in FIG. Nos. 63 and 64. The assembled lid assembly 13 is preferably held on the lid support body 45 by vacuum suction through vacuum/pressure access shafts or channels 44 or by other means. The lid assemblies 13, as assembled, are then ready to be packaged.
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The assembled lid assemblies 13 are dropped down to a packaging chute preferably by way of a mechanical push mechanism or with help of vacuum/pressure or under direction of its own weight. The reader will note that just before lid stripper element(s) or step(s) 43 touch the lid perimeter edge 62, the vacuum suction is preferably disengaged to release the lid assemblies 13.
It will thus be understood that the pre-positioning of untrimmed lower lid bodies or primary lid formations 10 and upper lid bodies or disks 19 on the web 20 allows the tooling carrying/holding plates 9/14 and 15/16 to move in one horizontal or vertical direction back and forth relative to stationary main base plate 30 as generally depicted in
The arrangement of plates 9/14 and 15/16, enabling clap-like movements of opposed tooling, eliminates complicated directional movement changes of trimmed parts to assembly locations and returns and significantly simplifies synchronization of the different parts of mechanism timing and movements. The arrangement(s) further eliminate additional “over-stroke position” in order to insure there is no tab closure or disks 19 left in the die opening from prior cycles, since no disks/tab closures could be left in either the die opening 55 or disk-guiding shaft 56 following an assembly cycle. It should be noted, that the disk-guiding shaft 56 sidewalls may be preferably coated with Teflon-like coating or, alternatively, dimensioned to be just a bit smaller than the die opening 55.
These features allow disks 19, after being trimmed by disk punch 50 and pushed thereby to the die opening limit 47 (as depicted in
For example, the disk guide 57 prevents circular movement of the disks 19 after trimming as further directed to the lid depression 21. Effectively pre-positioning lower lid bodies 10 and disks 19 on the web 20 eliminates possibility for lower lid bodies 10 and disks 19 to deviate from pre-positioned state during the assembly process, creating simple, efficient and reliable two-piece or composite article assembly method allowing to make high speed inline assembly mechanism with any “over-stroke position” being a part of integrated linear movement of mechanism. The present invention further eliminates “standby positions” as there is no need pick up, hold, or carry the tab closures or disks. All of these eliminations provide certain simplified composite article assembly methodology enabled by the all-in-one assembly tooling stations for trimming and assembling multiple thermoformed workpieces as exemplified by lower lid bodies 10 and upper lid bodies or disks 19.
The reader will further recall that pre-positioned lower lid bodies 10 on the web 20 are pressed into countersink shaped lid nest 31 by conically shaped lid support body 45 as generally depicted in
The reader will further recall that the compactor head 18 conforms to the upper surface of the upper lid body or disk 19 and creates surface to surface contact as generally depicted in
The provision of a multiplicity of these types of formations (as generally depicted in
The following descriptions attempt to build upon the concepts originally disclosed in U.S. patent application Ser. No. 16/661,765 ('765 Application) from which these specifications claim a benefit. In this regard, the methods of assembly described in the '765 Application can be further applied to an assembly mechanism incorporating assembly tooling whereby primary tooling station(s) are designed to act as holding stations for the main bodies and assembling a composite article carried or conveyed by a continuous web 20 to a multitude of secondary tooling stations. This alternative assembly methodology may thus be referred to as a mechanized assembly conveyor with peripheral assembly tooling stations.
The multitude (two or more) of secondary tooling stations are positioned opposite the primary tooling station(s), and each secondary tooling station is designed to cooperate with a corresponding primary tooling station for centering and directing each part or element pre-positioned on an element-carrying web as at 20 towards a corresponding part or element centered and directed in pre-assembled position at the primary tooling (station) for subsequent punching or die-cutting for detaching the part or element from the element-carrying web 20 and assembling each part or element of the composite article in proper sequential order.
In other words, multiple parts or elements are prepositioned on the element-carrying web 20 for assembly with corresponding parts or elements in a properly predesignated assembly order. The element-carrying web 20 acts as a moving assembly conveyor bringing each prepositioned and predesignated part or element to a designated tooling station for subsequent punching or die-cutting from the element-carrying web 20 and directing the punched or die-cut element into assembled position at the composite article position within the system in predetermined sequence.
This methodology allows the manufacturer to assemble or build composite articles of significant complexity (e.g. a gearboxes or bearing assemblies) with multiple parts and moving engagements. It is further contemplated that this alternative method of assembly according to the present invention is designed so as to provide a high speed assembly line whereby parts or elements are made (e.g. by methods of thermoforming, stamping, etc.) and assembled in a continuous, conveyor-like manner whereby a web as at element-carrying web 20 acts as a conveyor belt thereby eliminating steps of element storage, retrieval, and out-of-line movements during the process of assembling the composite article.
The proposed method of composite article assembly may be utilized in many different fields of application and is simpler, and more effective than a robotic assembly line often involving complex, relatively higher cost equipment, and a multitude of three-dimensional movements of each part element requiring relatively more time to complete assembly.
It is noted that a primary advantage of certain manufacturing sites of the world is low labor costs. Composite article assembly is one of the most labor-intensive aspects of assembling composite articles. The proposed methodology harnesses preexisting or state of the art part formation methods (e.g. thermoforming, stamping, etc,) whereby parts are pre-formed according to such methods and remain on the element-carrying web 20 acting as a conveyor. Each part is formed and positioned in particular order upon the element-carrying web 20 so that web-departing elements as punched out or die cut from the web 20 are assembled into a composite article assembly in a singular linear movement.
Citing thermoforming methods as a primary example, it is noted that the cost of many composite articles made by thermoforming methods is typically calculated by a markup percentage of the raw material cost, and in many cases the raw material costs are the largest portion of the overall costs of finished articles. While thermoforming methods provide effective, high speed methods of manufacturing, costly difficulties arise when thermoformed article elements require assembly into a composite article. The proposed alternative method described in more detail hereinafter minimizes costs incurred during the assembly phase of otherwise thermoformed elemental parts.
Central to the practice of this alternative methodology is the element-carrying web as at 20 used as an assembly line conveyor. Tooling plates are positioned adjacent the element-carrying web conveyor 20 and comprise multiple element-nesting cavities. The element-nesting cavities are preferably positioned and dimensioned or configured to fit multiple parts thereby allowing the manufacturer to form and assemble multiple parts into one composite article.
The parts or elements, as formed or outfit upon the element-carrying web 20, are particularly positioned and sequenced such that the positions and sequencing operates to align matable parts as they move along the element-conveying web 20 in pre-loop and post-loop portions of part conveyance. When pre-loop and post-loop matable parts are positioned into axial alignment, a web-detachable part may be linearly directed in a singular direction into assembled relation with opposing parts to form composite articles. This uni-directional movement is a departure from the bi-directional movement of opposed tooling as discussed hereinabove in connection with the “clapping” action of opposed tooling portions.
As prefaced above, the element-carrying or element-conveying web 20 and the loop mechanism(s) 102 are central to the practice of this alternative methodology. In other words, looping web conveyors are key. Looping webs 20 allow the manufacturer to layer parts without disrupting the conveyor effect of the web 20. Further, for more complex articles multiple loop mechanisms 102 can be incorporated into the design for changing the relational spatial position of the element-carrying web 20 from typical parallel alignments to angled positions in order to position corresponding parts in proper axial alignment or linear position for assembly into the composite article. For example, the web 20 acting as conveyor can be turned or twisted 90 degrees as at portion 115 in
The following is an exemplary listing of fields of art or industries in which this alternative method of assembly may prove most useful. It is contemplated, for example, that the packaging industry provides any number of composite packaging products comprising articles having several parts as assembled together to form a composite article. This category further contemplates multilayered composite articles, including cups, lids, boxes, trays, etc. that requires multilayering. The lid assemblies described hereinabove, for example, are exemplary and may preferably comprise a series of components that may be assembled under the uni-directional movement of detached element into assembled relation with a fixed receiving part conveyed by the web 20.
It is further contemplated that the toy industry provides any number of toy-type composite articles comprising several simplistic parts assembled together in a safe manner. It is noted that toy parts typically do not require a high level of precision and durability, but usually require safety features with simple designs and low-cost manufacturing requirements. This category contemplates most articles comprising simple disposable devices comprising several parts and/or low frequency use devices.
It is further contemplated that other target industries may include: the furniture industry generally, and specifically accessories for the furniture industry such as simple guides, sliders, turn table-like devices; the medical industry particularly disposable medical devices; the construction industry for spacer devices, washers for fasteners, sliders, etc.; the vehicle industry in terms of particularly simple accessories such as cup holders, trays, clamps, other composite plastic parts; the home goods industry embracing simple gearboxes, and bearing-based goods (e.g. the lazy Susan); the defense industry, particularly simple decoys, and disposable devices requiring light weight and relative durability at low cost; and the sourcing industry.
Other fields of art in which the presently described methodology is particularly applicable are the aerospace industry and vehicle manufacturing industry in terms of carbon fiber and carbon graphite material construction. These are composite materials made out of layers or base materials such as fiber resin or fiber mesh impregnated with resin which are combined under high heat processes. As elements comprising such materials traverse through the heat stations, it is contemplated that a fiber mesh conveyor may operate to move the parts through the heat stations and subsequently to assembly stations as otherwise achieved a continuous thermoformable web during thermoforming processes.
It is noted that thermoforming, vacuum-forming, and press-forming processes are similar in nature and usually comprise the following attributes: (a) male and female molds or stamps; (b) sheets of plastic, carbon fiber, metal or paper tightly mimicking mold; (c) individual parts separately attached to the web (mesh, paper pulp layer, sheet) or easily could be on the web after forming is complete; and (d) parts are detached from the web for next operation or assembly in many applications. The presently described methodology keeps formed parts on the web as long as it practical to utilize such a web (mesh, paper pulp layer, sheet) as conveyor for bringing formed parts through loops, twists, etc. to properly configured assembly station tooling for composite element alignment for subsequent assembly with other parts prepositioned on the same web or even made by different process and intersected with the present methodology.
This alternative methodology is contemplated to provide assembly support for any device that is built in layers that does not require high precession and durability and can be provided at relatively low cost, including most disposable or low frequency use devises for different industries. In an effort to depict an exemplary composite assembly or article of manufacture,
The generic, four-piece “turn table” type composite article 300 is presented as an exemplary composite article and comprises a first composite element as at 310; a second composite element as at 311; a third composite element as at 312; and a fourth composite element as at 313.
The first set of four individual web-carried or web-conveyed composite elements 310-313 are juxtaposed opposite a second set of four individual web-conveyed composite elements 310-313 moving upwardly from top-to-bottom including a second composite element 311, a third composite element 312, a fourth composite element 313, and a first composite element 310. The second set of four individual web-conveyed composite elements 310-313, having looped through the loop mechanism 102, all face a second direction as at arrow 114 opposite the first direction 113.
The reader will note the axial alignment as at assembly alignment axis 111 of the first and second individual composite elements 310 and 311 at upper and lower portions of the figure. The spacing as at 112 between the center axis of the second composite element 311 and the center axis of the third composite element 312 is preferably the same as the spacing 112 between the center axis of the third composite element 312 and the center axis of the fourth composite element 313 as conveyed by the web 20. The spacing 112 between the centers of the second through fourth composite elements 311-313 enables the first composite element 310 to travel the same distance between the first, second and third alignment cavities 321, 322, and 323.
Comparatively referencing
First composite elements 310 are depicted after looping through the loop mechanism 102. A first composite element 310 is positioned into axial alignment as at assembly alignment axis 111 with a second composite element 311 at a first alignment cavity 321 of the mechanized assembly station tooling with alignment plate 325 for forming a second-to-first composite element assembly or basic composite.
The second fourth-third-second-first element composite or complex composite 316 down-web from the first complex composite 316 is conveyed along the web conveyor 20 away from the second loop mechanism 102 with a 90-degree twist or turn at a twist or turn portion 115 in the web conveyor 20 for re-orienting the assembly alignment axis 111 of the second fourth-third-second-first element composite in a second dimension orthogonal to the first dimension for successive composite assembly at a fourth alignment cavity as at 324.
It is contemplated that the fourth alignment cavity 324 at down-web assembly station tooling (and successive tooling stations) can be used to add-on other outside or peripheral features such as a separately made shaft for insertion into the exemplary generic “turn table” type complex composite 316 while still attached to the web conveyor 20. The inherent flexibility of the web conveyor 20 allows the web conveyor 20 to traverse loop mechanisms 102 and twist or turn portions 115 so as to re-align the plane of the web conveyor 20 for further re-orienting the assembly alignment axes 111 and enabling further add-on elemental features directed thereto from differing directions.
The first, downwardly directed portion of the web conveyor 20 is directed through a first die portion of the press frame 330 before entering the loop mechanism 102. After traversing the loop mechanism 102, the web conveyor 20 is redirected upwardly and a second portion of the web conveyor 20 is directed through a second die portion of the press frame 330. Exposed elemental voids (as exemplified by void-surrounding support cone carrier elements 12) are shown in the second portion of the web conveyor 20 upwardly exiting the press frame 330.
The reader will further note that certain plates of the mechanized assembly station tooling exemplified by press frame 330 may preferably comprise dedicated cavities for assembling differing parts into the final composite article exemplified by the composite article 300. For example, at some point of assembly, the composite article may stop at an alignment cavity (not specifically illustrated) designed to drop-in metal or plastic balls (made in separate process) in order to provide bearings to make the generic “turn table” composite article 300 more efficient. The cavities may further provide dual functionality, as both an assembly-alignment cavity and as an outside element receipt site (e.g. a site to receive add on features such as drop-in bearings (made in a separate process).
The web conveyor 20 with thermoformed and/or prepositioned elements carried thereby is conveyed to successive sites of assembly with the elements arranged in a predetermined order or sequence and is directed through a series of loop mechanisms 102 and alignment cavities to place each part in position for simplistic linear motion for the assembly of the composite article. One of the most important functions of the web conveyor 20 is to convey composite elements within the simplest motions for the assembly.
This alternative assembly methodology may involve human interaction, robotic interaction, and different delivery mechanisms with the primary goal being to align parts or composite elements with a proper order and location in the mechanism during composite article construction and to do so in the way such that assembly movements are highly accurate with assembled composite elements being correctly placed within the finally formed composite article. In other words, the presently described alternative methodology envisions a thermoforming web that acts as a conveyor with prepositioned parts that traverses through a series loops, turns and intervals bringing each composite element to its proper location in proper sequential order for full composite assembly with a high degree of accuracy and consistency.
Referring back to
A single tubular shaft as at 200 is depicted having a diameter sufficient to accept a stack 204 of cut lid formations or workpieces 205. A shaft-receiving plate assembly 201 comprises shaft-receiving apertures 211 outfitted with certain interface means 207 for driving externally located threads 206 formed on the exterior of the tubular shaft 200 and extending the length of the tubular shaft as at arrows 208. The shaft-receiving plate assembly 201 is positioned in adjacency to a stack 202 of web sheets 203 such that the successively stacked workpieces 215 are positioned adjacent the apertures 211.
As the interface means 207 drives the external threads, the tubular shaft 200 rotates at a high rate of speed as at arrows 212 and is thus directed into the stack 202 of web sheets 203 for cutting through the web sheets 203 and separating lid formations or workpieces 205 from the successive sheets 203. The end 209 of the tubular shaft 200 is outfitted with a cutting implement or knife 210 that cuts through the successive web sheets 203 as it is directed as at arrow 213. Each of the web sheets 203 has a material thickness 221 (e.g. 0.02 inches) generally extending in a material plane 220. The cutting implement or knife tip 222 extends a distance from shaft end plane 223 greater in magnitude than the material thickness 221 to cut through the material thickness 221.
While the above descriptions contain much specificity, this specificity should not be construed as limitations on the scope of the invention, but rather as an exemplification of the invention. In certain embodiments, the basic invention may be said to essentially teach or disclose certain composite article assembly or two-workpiece assembly methodologies essentially based on the all-in-one assembly tooling stations through which one or more continuous webs 20 may be directed as described in more detail hereinabove. The concepts described hereinabove, though directed to a two-piece lid assembly method, naturally apply to two-workpiece assemblies whereby a first and second workpiece may be assembled to form a two-workpiece ensemble or composite article according to the methods and apparatus discussed above.
The essential composite article assembly or two-workpiece assembly method according to the present invention may be said to comprise the basic steps of forming upper lid bodies or disks as at 19 (i.e. a first workpiece) and lower lid bodies or primary lid formations as at 10 (i.e. a second workpiece) via a primary body-forming station as exemplified by thermoforming station(s) 100. The upper lid bodies or first workpieces 19 and the lower lid bodies or second workpieces 10 are then positioned into axial alignment along an assembly alignment axis as at 110 within an all-in-one assembly tooling station as variously exemplified.
Once positioned into axial alignment with one another, the upper lid bodies or first workpieces 19 and the lower lid bodies or second workpieces 10 are directed toward one another within the assembly tooling station along the assembly alignment axis 110 so as to close the distance between the respectively aligned upper lid bodies/first workpieces 19 and the lower lid bodies/second workpieces 10. When the distance between the respectively aligned upper lid bodies/workpieces 19 and lower lid bodies/workpieces 10 approaches zero, the upper lid bodies 19 engage the lower lid bodies 10 and, due to the size and shape thereof, assemble under the (forced and) directed engagement into one another to form two-piece lid assemblies 13.
As earlier described, the steps of (a) directing the upper lid bodies or disks 19 and the lower lid bodies or primary lid formations 10 toward one another within the assembly tooling station along the assembly alignment axis 110, and (b) assembling the upper lid bodies or disks 19 with the lower lid bodies or primary lid formations 10 along the assembly alignment axis 110 within the all-in-one assembly tooling station(s) are performed in a single clap-like or clapping movement of opposed tooling as exemplified by the plate with access opening 9 or intermediate compactor plates 14 (i.e. combination plates 9/14 when forming multiple workpiece assemblies in side-by-side, staggered relation to one another), and the outer plates 15 or the outer pin support plates 16 (i.e. combination plates 15/16 when forming multiple workpiece assemblies in side-by-side, staggered relation to one another) opposite the stationary main base plate 30 within which upper lid body-to-lower lid body assembly occurs.
It will be recalled that the present invention is believed centered on the substantially simultaneous, dual-action, web-cut and disk-to-lid assembly step whereby the opposed tooling is directed towards one another for directing an upper lid body or disk 19 into engagement with a lower lid body or primary lid formation 10 for forming lid assemblies 13. In other words, when the upper lid body or disk 19 is cut from the web 20 it is directed (e.g. pushed (i.e. not carried)) into assembled relation with the lower lid body or primary lid formation 10 also being removed from the web 20 during one clap-like, to-and-fro or back and forth tooling movement within the all-in-one assembly tooling station(s) according to the present invention.
The step of forming upper lid bodies or disks 19 and lower lid bodies or primary lid formations 10 via the primary body-forming station (e.g. thermoforming stations 100) comprises or includes the step of forming the upper lid bodies 19 and the lower lid bodies 10 on at least one continuous web 20 via at least one primary body-forming station. Certain alternative methodology according to the present invention involves forming the upper lid bodies 19 and the lower lid bodies 10 on at least a pair of, or at least two continuous webs 20 as generally depicted in
The composite article assembly method according to the present invention further comprises the step of removing a select body formation from the at least one continuous web 20 before directing upper lid bodies 19 and lower lid bodies 10 toward one another within the assembly tooling station, which select body formation is selected from the group consisting of the upper lid bodies 19 and the lower lid bodies 10. In other words, either the upper lid body 19 or the lower lid body 10 is preferably separated (e.g. via a select cutting process) from the web 20 before it is further directed toward the other body of the two bodies 19 or 10 for further assembly into lid assembly 13. The select cutting process may be selected from the group consisting of a die-cutting process or a circular knife-cutting process.
The composite article assembly method may further preferably comprise or include the step of forming upper lid bodies 19 and lower lid bodies 10 on the least one continuous web 20 via the at least one body-forming station such that the upper lid bodies 19 and the lower lid bodies 10 are formed in spaced and alternating relation to one another as variously exemplified and illustrated (e.g. See
When the production line is built around a single, continuous web 20, the composite article assembly method may further preferably comprise the step of directing the spaced and alternating upper lid bodies 19 and lower lid bodies 10 through a loop mechanism as exemplified by loop mechanism 102 so as to axially align the upper lid bodies 19 and lower lid bodies 10 within the singular assembly tooling station for forming lid assemblies 13. Bearing in mind that the all-in-one assembly tooling stations all provide a basis for the described methodology, the methodology may further preferably comprise the step of directing the upper lid bodies 19 and lower lid bodies 10 into a stationary plate as exemplified by the stational main base plate 30 for structurally or mechanically enhancing axial alignment of the upper lid bodies 19 and the lower lid bodies 10 during the step of assembling the upper lid bodies 19 with the lower lid bodies along the assembly alignment axis 110.
Comparatively referencing
In other words, as discussed hereinabove, a series of upper lid bodies 19 may be directed into the disk-guiding shaft 56 of the main base plate 30 before a first of the upper lid bodies or disks 19 (i.e. the lower-most disk 19″) is expelled, directed, or discharged (e.g. via the disk-feeding mechanism 80) from the disk-guiding shaft 56 into engagement with an underlying lid depression 21 of a lower lid body 10. It will thus be understood that the disk-guiding shaft 56 of the main base plate 30 may temporarily store at least a second of the at least two first select body formations in the stationary plate exemplified by the main base plate 30.
The step of directing upper lid bodies 19 and lower lid bodies 10 into the stationary plate exemplified by the main base plate 30 may further preferably comprise the step of directing upper lid bodies 19 and lower lid bodies 10 into a series of cavities or chambers are exemplified by the axially aligned conical countersink 54, the disk-guiding shaft 56, and the lid nest 31. Referencing
Each of these cavities or chambers respectively comprises a select assembly alignment axis as at 110. The select alignment axes 110 are parallel to one another. The upper lid bodies 19 are assembled with lower lid bodies 10 in side-by-side relation within the stationary main base plate 30 in opposite directions defined by or along the select alignment axes 110. In other words, for example, a first upper lid body 19 is directed into engagement with a first lower lid body 10 in a first direction and a second upper lid body 19 is directed into engagement with a second lower lid body 10 in a second direction opposite the first direction in side-by-side relation to the first upper lid body 19 and first lower lid body 10 as generally depicted in
Referencing
The composite article assembly methodology according to the present invention further contemplates the step of directing force into a select body formation via vacuum/pressure application as enabled, for example, via the compactor push pin vacuum/pressure access channel 48, vacuum/pressure access channels 44, pressure/vacuum release channel 59, and lid support vacuum/pressure access line 67. The select body formation may be preferably selected from the group consisting of the upper lid bodies 19, the lower lid bodies 10, and the two-piece lid assemblies 13. In this last regard, it will be recalled that force may be directed into the lid assemblies 13 for re-directing formed lid assemblies 13 toward the packaging station(s) according to the present invention. The composite article assembly method according to the present invention may further comprise the step of directing composite articles or lid assemblies into stacked relation as generally depicted throughout the drawings submitted in support of these specifications.
Referencing
Once the first and second composite elements are axially aligned, the first composite element is directed toward the second composite element within the mechanized assembly station tooling along the assembly alignment axis. The first composite element with the second composite element are then assembled along the assembly alignment axis within the mechanized assembly station tooling thereby forming a basic composite as at 314. The method may further comprise the step of twisting the conveyor at a twist portion for re-orienting the assembly alignment axis for successive elemental alignment and assembly as discussed hereinabove.
The steps of directing the first composite element toward the second composite element within the mechanized assembly station tooling along the assembly alignment axis and assembling the first composite element with the second composite element along the assembly alignment axis within the mechanized assembly station tooling are performed by unidirectionally moving the first composite element along the assembly alignment axis toward the fixed second composite element. This is performed in distinction to the clapping movement of opposed plate tooling as discussed in connection with other alternative methodologies.
It is contemplated the (web) conveyor primarily functions as an element-conveying mechanism. In certain applications, the carrier conveyor may be preferably exemplified as a web type conveyor with the multiple, axially alignable composite elements being thermoformed therein before entry into the mechanized assembly station tooling that operates to form composite articles. Sets of the multiple, axially alignable composite elements are preferably positioned upon the first face of the conveyor in spaced and alternating relation to one another.
The multi-piece composite article assembly methodology may further comprise the step(s) of directing successive composite elements into assembled relation with the basic composite within the mechanized assembly station tooling along successive assembly alignment axes thereby forming a complex composite as at 316. The mechanized assembly station tooling may preferably alignment cavities formed in an alignment plate of the tooling such that composite elements may be directed therethrough for enhancing axial alignment of the composite elements when assembling the composite elements along the assembly alignment axis within the mechanized assembly station tooling.
Referencing
The web sheet stack 202 may be positioned in (inferior) adjacency to a shaft-receiving plate assembly as at 201, which shaft-receiving plate assembly 201 comprises at least one, but preferably a series of shaft-receiving apertures or bores as at 211. The at least one stack of web-based lid bodies or workpieces 215 are preferably positioned in adjacency to the shaft-receiving aperture(s) 211. At least one tubular shaft 200, but preferably a plurality of tubular shafts as at 200 may be directed through the web sheet stack 202 via the shaft-receiving aperture(s) 211 thereby separating the web-based lid bodies or workpieces 215 from the series of web sheets 203 and forming a stacked series of lid formations or workpieces as at 204.
The stacked series of lid formations or workpieces 204 is linearly directed into the tubular shaft 200 as the tubular shaft 200 is directed through the web sheet stack 202. It will be recalled the tubular shaft 200 preferably comprises a tubular shaft end as at 209, which tubular shaft end 209 is preferably outfitted with a cutting implement or knife as at 210. The cutting implement 210 cuts through the web sheet stack 202 as the tubular shaft 200 is directed therethrough. The tubular shaft 200 preferably comprises external threads as at 206, and the shaft receiving aperture or bore 211 is preferably outfitted with a thread-driving interface as at 207. The thread-driving interface 207 and external threads 206 are cooperable for converting rotational motion as at 212 to linearly directed motion 213 for directing the tubular shaft 200 linearly through the web sheet stack 202.
Although the composite article formations exemplified by lid assemblies and packaging systems and methods according to the present invention have been described by reference to a number of different embodiments, aspects, and features, it is not intended that the novel combinations or assemblies be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosure, the appended drawings, and the following claims.
Claims
1. A two-piece lid assembly method, the two-piece lid assembly method comprising the steps of:
- axially aligning upper lid bodies and lower lid bodies within mechanized assembly station tooling along an assembly alignment axis;
- directing the upper lid bodies and the lower lid bodies toward one another within the mechanized assembly station tooling along the assembly alignment axis; and
- assembling the upper lid bodies with the lower lid bodies along the assembly alignment axis within the mechanized assembly station tooling thereby forming two-piece lid assemblies.
2. The two-piece lid assembly method of claim 1 wherein the steps of:
- directing the upper lid bodies and the lower lid bodies toward one another within the mechanized assembly station tooling along the assembly alignment axis; and
- assembling the upper lid bodies with the lower lid bodies along the assembly alignment axis within the mechanized assembly station tooling are performed in a single clapping movement of opposed tooling.
3. The two-piece lid assembly method of claim 2 wherein the step of axially aligning upper lid bodies and lower lid bodies within the mechanized assembly station tooling along an assembly alignment axis occurs via at least one continuous web.
4. The two-piece lid assembly method of claim 3 comprising the step of thermoforming upper lid bodies and lower lid bodies in spaced and alternating relation to one another upon the at least one continuous web.
5. The two-piece lid assembly method of claim 4 comprising the step of directing the spaced and alternating upper lid bodies and lower lid bodies through a loop mechanism for axially aligning the upper lid bodies and lower lid bodies within the mechanized assembly station tooling.
6. The two-piece lid assembly method of claim 1 comprising the step of directing the lower lid bodies and upper lid bodies into a stationary plate for enhancing axial alignment of the upper lid bodies and lower lid bodies during the step of assembling upper lid bodies with lower lid bodies along the assembly alignment axis.
7. The two-piece lid assembly method of claim 6 comprising the step of directing at least two first select body formations into the stationary plate before directing a first of the at least two first select body formations into assembled relation with a singular second select body formation, the first and second select body formations being selected from the group consisting of the upper lid bodies and the lower lid bodies.
8. The two-piece lid assembly method of claim 7 comprising the step of temporarily storing at least a second of the at least two first select body formations in the stationary plate.
9. The two-piece lid assembly method of claim 1 comprising the step of resiliently deforming a select body formation before the step of assembling upper lid bodies with lower lid bodies along the assembly alignment axis within the mechanized assembly station tooling, the select body formation being selected from the group consisting of the upper lid bodies and the lower lid bodies, the step of resiliently deforming the select body formation for adjustably enhancing upper lid body to lower lid body assembly.
10. A multi-piece composite article assembly method, the multi-piece composite article assembly method comprising the steps of:
- providing a conveyor with multiple, axially alignable composite elements upon a first face of the conveyor, the first face facing a first direction;
- directing the conveyor through a first loop mechanism such that the first face faces a second direction opposite the first direction;
- axially aligning first and second composite elements within mechanized assembly station tooling along an assembly alignment axis;
- directing the first composite element toward the second composite element within the mechanized assembly station tooling along the assembly alignment axis; and
- assembling the first composite element with the second composite element along the assembly alignment axis within the mechanized assembly station tooling thereby forming a basic composite.
11. The multi-piece composite article assembly method of claim 10 comprising the step of twisting the conveyor for re-orienting the assembly alignment axis for successive elemental alignment.
12. The multi-piece composite article assembly method of claim 10 the steps of:
- directing the first composite element toward the second composite element within the mechanized assembly station tooling along the assembly alignment axis; and
- assembling the first composite element with the second composite element along the assembly alignment axis within the mechanized assembly station tooling are performed by unidirectionally moving the first composite element along the assembly alignment axis toward a fixed second composite element.
13. The multi-piece composite article assembly method of claim 10 wherein the conveyor is a singular continuous web and the multiple, axially alignable composite elements are thermoformed in the continuous web.
14. The multi-piece composite article assembly method of claim 10 wherein sets of the multiple, axially alignable composite elements are positioned upon the first face of the conveyor in spaced and alternating relation to one another.
15. The multi-piece composite article assembly method of claim 10 comprising the step of directing successive composite elements into assembled relation with the basic composite within the mechanized assembly station tooling along successive assembly alignment axes for forming a complex composite.
16. The multi-piece composite article assembly method of claim 10 comprising the step of directing the first composite element through a first plate-based cavity for enhancing axial alignment of the first and second composite elements when assembling the first composite element with the second composite element along the assembly alignment axis within the mechanized assembly station tooling.
17. A workpiece trimming method, the workpiece trimming method comprising the steps of:
- stacking a series of web sheets atop one another into a web sheet stack;
- positioning the web sheet stack in adjacency to a shaft-receiving plate assembly, the shaft-receiving plate assembly comprising at least one shaft receiving aperture; and
- directing at least one tubular shaft through the web sheet stack via the shaft-receiving aperture thereby trimming web-based workpieces from the series of web sheets and forming a stacked series of workpieces.
18. The workpiece trimming method of claim 17 wherein the stacked series of workpieces are linearly directed into the tubular shaft as the tubular shaft is directed through the web sheet stack, the tubular shaft for collecting the stacked series of workpieces.
19. The workpiece trimming method of claim 17 wherein the tubular shaft comprises external threads and the shaft-receiving plate assembly is outfitted with a thread-driving interface, the external threads being driven via the thread-driving interface for converting rotational motion to linearly directed motion and directing the tubular shaft through the web sheet stack.
Type: Application
Filed: Jul 13, 2020
Publication Date: Apr 29, 2021
Inventor: Pavel Savenok (Wheaton, IL)
Application Number: 16/927,904
