초록 ▼

This invention pertains to apparatus and methods for intermittently creating ultrasonic bonds in sequentially advancing work piece segments, in a nip. The work piece segments are up to about 0.25 inch thick. The apparatus comprises a frame, anvil support apparatus supporting an anvil, and horn suppo

This invention pertains to apparatus and methods for intermittently creating ultrasonic bonds in sequentially advancing work piece segments, in a nip. The work piece segments are up to about 0.25 inch thick. The apparatus comprises a frame, anvil support apparatus supporting an anvil, and horn support apparatus supporting an ultrasonic horn. The ultrasonic horn and anvil are collectively mounted and configured such that the ultrasonic horn and anvil can be brought together to define the nip. The frame, anvil support apparatus, and horn support apparatus collectively are sufficiently rigid that the horn and anvil can be brought together with interference levels of about 0.000 to about 0.008 inch at a raised bonding portion in combination with defining sufficient nip pressure to develop ultrasonic bonds in work piece segments passing through the nip. The method comprehends bringing a back-up roll, mounted above the ultrasonic horn, into engagement with the ultrasonic horn, to directly support the horn. First and second support rolls can be used to releasably support opposing sides of the outer surface of the ultrasonic horn, preferably below the axis of the horn, whereby the support rolls can be used to lift the horn into engagement with the back-up roll.

대표청구항 ▼

This invention pertains to apparatus and methods for intermittently creating ultrasonic bonds in sequentially advancing work piece segments, in a nip. The work piece segments are up to about 0.25 inch thick. The apparatus comprises a frame, anvil support apparatus supporting an anvil, and horn suppo

This invention pertains to apparatus and methods for intermittently creating ultrasonic bonds in sequentially advancing work piece segments, in a nip. The work piece segments are up to about 0.25 inch thick. The apparatus comprises a frame, anvil support apparatus supporting an anvil, and horn support apparatus supporting an ultrasonic horn. The ultrasonic horn and anvil are collectively mounted and configured such that the ultrasonic horn and anvil can be brought together to define the nip. The frame, anvil support apparatus, and horn support apparatus collectively are sufficiently rigid that the horn and anvil can be brought together with interference levels of about 0.000 to about 0.008 inch at a raised bonding portion in combination with defining sufficient nip pressure to develop ultrasonic bonds in work piece segments passing through the nip. The method comprehends bringing a back-up roll, mounted above the ultrasonic horn, into engagement with the ultrasonic horn, to directly support the horn. First and second support rolls can be used to releasably support opposing sides of the outer surface of the ultrasonic horn, preferably below the axis of the horn, whereby the support rolls can be used to lift the horn into engagement with the back-up roll. urther based on said measured temperature. 13. The process of claim 12 further comprising the step of comparing the measured temperature to a set temperature. 14. The process of claim 13 wherein the temperature comparing step is carried out by one from an operator and a processing unit. 15. The process of claim 13 further comprising the step of decreasing a parameter chosen from the level of vacuum, a period of heating time and a period of vacuum draw when the measured temperature is more than the set temperature. 16. The process of claim 13 further comprising the step of increasing a parameter chosen from the level of vacuum, a period of heating time, and a period of vacuum draw when the measured temperature is less than the set temperature. 17. The process of claim 13 further comprising the step of decreasing a parameter chosen from the period of heating time and the period of vacuum draw when the measured vacuum is more than the set vacuum. 18. The process of claim 13 further comprising the step of increasing a parameter chosen from the period of heating time and the period of vacuum draw when the measured vacuum is less than the set vacuum. 19. The process of claim 12 further comprising the step of comparing the measured vacuum to a set vacuum. 20. The process of claim 19 wherein the vacuum comparing step is carried out by one from an operator and a processing unit. 21. The process of claim 19 further comprising the step of increasing the vacuum level when the measured vacuum is less than the set vacuum. 22. The process of claim 19 further comprising the step of decreasing the vacuum level when the measured vacuum is more than the set vacuum. 23. A method for vacuum forming a sheet comprising the steps of: heating the sheet; placing the sheet in a vacuum mold; measuring the temperature of the sheet; vacuum drawing the sheet in the mold; and adjusting the vacuum drawing step as a function of the temperature of the sheet measured in said measuring step. 24. The process of claim 23 further comprising the step of measuring the vacuum drawn. 25. The process of claim 24 further comprising the step of comparing the measured temperature of the sheet to a preferred temperature. 26. The process of claim 25 further comprising the step of comparing the measured vacuum to a preferred vacuum. 27. The process of claim 26 wherein the vacuum comparing step is carried out by one from an operator and a processing unit. 28. The process of claim 25 wherein the temperature comparing step is carried out by one from an operator and a processing unit. 29. A vacuum forming process comprising the step of: positioning a sheet in proximity to a vacuum mold; heating the sheet; vacuum drawing the sheet in the mold with at least one vacuum level; measuring the vacuum drawn on the sheet; repeating the proceeding steps; and adjusting the heating step as a function of the vacuum measured on at least one previous sheet. 30. The process of claim 29 further comprising the step of comparing the measured vacuum to a set vacuum. 31. The process of claim 30 wherein said vacuum comparing step is carried out by one from an operator and the processing unit. 32. The process of claim 30 further comprising the step of increasing the vacuum level when the measured vacuum level is less than the set vacuum level. 33. The process of claim 30 further comprising the step of decreasing the vacuum level when the measured vacuum level is more than the set vacuum level. 34. The process of claim 29 further comprising the step of measuring the temperature of the sheet, and wherein said drawing step includes adjusting the vacuum level as a function of the temperature of the sheet. 35. The process of claim 34 further comprising the step of comparing the measured temperature to a set temperature. 36. The process of claim 35 wherein said temperature comparing step is carried out by one from an operator and a processing unit. 37. A process for forming a material compr ising the steps of: providing the material; adding an amount of heat to the material for a period of time; providing a mold; providing a level of vacuum for a period of time to draw the material into conformity with the mold to form the material; monitoring at least one of the level of vacuum drawn on the material and the period of time the vacuum is drawn on the material; and adjusting at least one of the amount of heat added to the material and the period of time the amount of heat is added to the material wherein said adjusting is a function of said monitoring step. 38. The process of claim 37 further comprising the step of controlling the draw of the material by the vacuum for a period of time with a clamping device. 39. The process of claim 37 further comprising the step of comparing a parameter chosen from the amount of heat added to the material, the period of time the amount of heat is added, the level of vacuum and the period of time the vacuum is drawn to a value chosen from a preferred amount of heat added to the material, a preferred period of time the amount of heat is added, a preferred level of vacuum, and a preferred period of time the vacuum is drawn. 40. The process of claim 39 wherein said comparing step is carried out by at least one from an operator and a processing unit. 41. The process of claim 40 wherein the processing unit displays said comparing step graphically for a human to view and consequently respond to said comparing step by adjusting at least one chosen from the amount of heat added to the material, the period of time the amount of heat is added, the level of vacuum, and the period of time the vacuum is drawn when a circumstance is met during said comparing step, said circumstance chosen from the amount of heat added to the material is not equal to the preferred amount of heat added to the material, the period of time the amount of heat is added is not equal to the preferred amount period of time the heat is added to the material, the level of vacuum is not equal to the preferred level of vacuum, and the period of time the vacuum is drawn is not equal to the preferred period of time the vacuum is drawn. 42. The process of claim 39 further comprising the step of adjusting at least one parameter chosen from the amount of heat added to the material, the period of time the amount of heat is added, the level of vacuum, and the period of time the vacuum is drawn when a circumstance is met during said comparing step, said circumstance chosen from the amount of heat added to the material is not equal to the preferred amount of heat added to the material, the period of time the amount of heat is added is not equal to the preferred amount period of time the heat is added to the material, the level of vacuum is not equal to the preferred level of vacuum, and the period of time the vacuum is drawn is not equal to the preferred period of time the vacuum is drawn. 43. The process of claim 42 wherein said adjusting step is carried out by one from an operator and a processing unit. 44. The process of claim 39 further comprising the step of activating an alarm when a circumstance is met during said comparing step, said circumstance chosen from the amount of heat added to the material is not equal to the preferred amount of heat added to the material, the period of time the amount of heat is added is not equal to the preferred amount period of time the heat is added to the material, the level of vacuum is not equal to the preferred level of vacuum, and the period of time the vacuum is drawn is not equal to the preferred period of time the vacuum is drawn. 45. The process of claim 44 further comprising the step of one from an operator and a processing unit responding to the alarm by adjusting at least one from the amount of heat added to the material, the period of time the amount of heat is added, the level of vacuum, and the period of time the vacuum is drawn. 46. The process of claim 37 comprising m onitoring at least one from the amount of heat added to the material and the period of time the heat is added to the material. 47. The process of claim 37 wherein the material is vacuum formed to a substrate to manufacture a vehicle door panel. 48. The process of claim 47 wherein the material is a heat activated adhesive backed fabric. 49. A vacuum wrapping process comprising the steps of: heating a sheet; measuring the temperature of the sheet; positioning the sheet in proximity to a substrate; and vacuum drawing the sheet against the substrate; and adjusting said vacuum drawing step as a function of the temperature of the sheet measured in said measuring step. 50. A process for vacuum forming a sheet of material comprising the steps of: positioning the sheet in proximity to a mold; and vacuum drawing the sheet against the mold, said vacuum drawing step including adjusting the vacuum to draw a plurality of levels of vacuum in a staged sequence wherein the staged sequence includes at least one portion where the vacuum drawn is increased, then decreased, then increased. 51. The process of claim 50 further comprising the step of monitoring criterion associated with the sheet and adjusting the vacuum levels in response to the criterion measured. 52. The process of claim 51 wherein the criterion is chosen from the temperature of the sheet, the thickness of the sheet, and the vacuum level drawn. 53. A method for vacuum wrapping a sheet onto a substrate comprising the steps of: placing the substrate in a vacuum mold; positioning the sheet in proximity to the substrate; measuring the temperature of the sheet in the vacuum mold; and vacuum drawing the sheet toward the substrate, said vacuum drawing step including varying the vacuum to draw a plurality of levels of vacuum over time, wherein the plurality of vacuum levels are varied based on the measured temperature of the sheet. 54. The process of claim 53 further comprising the step of monitoring criteria associated with the sheet and varying the vacuum in response to the criteria. 55. The process of claim 54 wherein the criteria is chosen from the temperature of the sheet, the thickness of the sheet, and the vacuum level drawn. 56. A vacuum wrapping process comprising the steps of: placing a substrate in a vacuum mold; positioning a fabric in proximity to the substrate; drawing a first vacuum on the fabric until the fabric is brought into conformity with a portion of the substrate; measuring the temperature of the fabric; drawing a second vacuum on the fabric until the fabric is brought into conformity with a remainder of the substrate, said drawing of said second vacuum initiated based on the measured temperature of the fabric; and releasing the substrate and fabric from the mold. 57. The vacuum wrapping process of claim 56 further comprising the step of releasing the fabric to control the movement of the fabric when drawn by at least one of the first and second vacuums. 58. A method of vacuum forming an article from a material comprising the steps of: providing a formable material; positioning the formable material in proximity to a mold; sequentially drawing a plurality of vacuums on the formable material measuring the plurality of vacuums to establish a measured vacuum profile; comparing the measured vacuum profile to a preferred vacuum profile; and selectively adjusting at least one of the plurality of sequentially drawn vacuums based on said comparing step. 59. The vacuum forming process of claim 58 wherein a first criterion includes bring the formable material into conformity with a portion of the mold. 60. The vacuum forming process of 59 wherein a second criterion includes bringing the formable material into conformity with the remainder of the mold. 61. The vacuum forming process of claim 60 further comprising the step of releasing the formable material to control the movement of the formable material toward the mold during said dra wing step. 62. A method for vacuum forming a sheet comprising: heating the sheet; measuring the temperature of the sheet; placing the sheet in a vacuum mold; vacuum drawing the sheet in the vacuum mold; repeating the proceeding steps; and adjusting the vacuum drawing step as a function of the temperature measured during said temperature measuring step of at least one previous sheet. 63. A vacuum wrapping process comprising: heating the sheet; positioning the sheet in proximity to a substrate; drawing a vacuum to pull the sheet against the substrate; measuring the vacuum applied to the sheet; and adjusting the heating step as a function of the vacuum measured during said vacuum measuring step. 64. A vacuum wrapping process comprising the steps of: heating a substrate; placing the substrate in a vacuum mold; positioning a fabric in proximity to the substrate; drawing a first vacuum on the fabric until a first preselected criterion is met; drawing a second vacuum on the fabric until a second preselected criterion is met; monitoring a physical characteristic of the fabric; and adjusting at least one of said first vacuum drawing step and said second vacuum drawing step based on said monitoring step.