US3851684A

US3851684A - Method and apparatus for assembling flexible sheet material into frames

Info

Publication number: US3851684A
Application number: US00358474A
Authority: US
Inventors: A Wyrick
Original assignee: Individual
Current assignee: Individual
Priority date: 1973-05-09
Filing date: 1973-05-09
Publication date: 1974-12-03
Anticipated expiration: 1991-12-03

Abstract

The present disclosure is directed to an automated method for assembling flexible sheet material into a grooved frame and an apparatus for performing the method, wherein a pair of generally transversely spaced carriage means carrying pressing rollers are selectively, cyclically, sequentially and intermittently moved relative to each other in a generally transverse direction so that the rollers are effective to roll the flexible material into spline grooves formed in window frames and the like, thereby eliminating the necessity for longitudinally moving and/or rotating said frame during the assembling operation.

Description

Unite tees Wyrick [4 1 Dec. 3, 1974 [22] Filed:

[ METHOD AND APPARATUS FOR ASSEMBLING FLEXIBLE SHEET MATERIAL INTO FRAMES [76] Inventor: Auvis Malvin Wyrick, PO. Box 853,

Magnolia, Ark. 71753 May 9, 1973 [21] Appl. No.: 358,474

[52] US. Cl. 140/109, 29/200 B, 29/448, 29/462 [51] Int. Cl B2lf 33/00 [58] Field of Search 140/108, 109; 29/417, 462, 29/448, 525, 33 F, 200 R, 200 B Primary ExaminerC. W. Lanham Assistant Examiner-Victor A. Di Palma Attorney, Agent, or Firm-Cushman, Darby & Cushman [5 7] ABSTRACT The present disclosure is directed to an automated method for assembling flexible sheet material into a grooved frame and an apparatus for performing the method, wherein a pair of generally transversely spaced carriage means carrying pressing rollers are selectively, cyclically, sequentially and intermittently moved relative to each other in a generally transverse direction so that the rollers are effective to roll the flexible material into spline grooves formed in window frames and the like, thereby eliminating the necessity for longitudinally moving and/or rotating said frame during the assembling operation.

14 Claims, 3 Drawing Figures H L l Ill 7 36 n :1 5;

I28 26 30 30 B0 32 6 25 /24 L Mtz 2a 92 72 941 A26 l2 78 //6 //8 PATENTEL E55 3 I974 SIEEI 20F 3 METHOD AND APPARATUS FOR ASSELING FLEXIBLE SHEET MATEAL INTO vali BACKGROUND OF THE INVENTION BRIEF DESCRIPTION OF THE PRIOR ART Heretofore, the conventional steps for effectively assembling screen wire mesh into generally rectangular spline grooves on door or window frames were done manually. The manual method required the presence of several operators to accurately hand roll the mesh into each spline groove. Not only does the manual operation require several operators, but it additionally requires cumbersome steps, wherein the individual doing the rolling must either change his position or reorientate the frame so that all the sides of the generally rectangular spline groove have the meshed rolled therein. Quite apparently, the manual method suffers from several distinct disadvantages, among which is the fact that it requires the expenditure of many man hours and capital.

Another prior art method for screening frames is disclosed in the US. Pat. No. 2,695,445, to Johnson et al., wherein there is described a method for rolling screen mesh into a frame as the mesh and frame sequentially move along on two conveyors oriented at right angles to each other. While this method continuously assembles screens, it does so in a manner which requires complicated equipment and greater floor space, thereby resulting in an uneconomical and inefficient method.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to overcome the aforementioned disadvantages prevalent in the prior art. This object is accomplished by an automatic method and an apparatus for performing the method, wherein flexible sheet material, preferably screen mesh, is rolled into a generally rectangular groove formed in a frame that is stationarily secured on a working table. The apparatus of the invention comprises at least two pairs of pressing rollers, wherein each pair of rollers is carried by a first and second movable carriage means. The carriage means are mounted for selective, cyclical, sequential, intermittent and transverse movement relative to each other. The method is accomplished by tensioning flexible sheet material over the rectangular groove in the frame and thereafter actuating the first of the movable carriage means so that the pair of pressing rollers thereon is effective on its working stroke to'engage and press the flexible sheet material into a first pair of opposed parallel grooves in the frame. After performing this step of the operation, the first movable carriage reverses its initial direction of movement and returns to the starting position. During this return, the rollers are lifted upwardly from the table so that they will not contact other structures. Also, the first carriage contacts a relay switch that causes the second carriage to perform its working stroke movement. This movement is generally transverse to the working and return strokes of the first carriage and by means of the pressing rollers is efi'ective to roll the flexible sheet materials into the second pair of opposed parallel grooves forming the sides of the generally rectangular grooved frame. After completion of this working stroke, the second movable carriage is returned to its initial position. Thus, the screen mesh is expeditiously rolled into the grooves by a cyclical, sequential and intermittent motion of the two movable carriages. This automatic method and apparatus for accomplishing the same is a vast improvement over the aforementioned prior art techniques, in that a greater number of frames can be screened in a manner that uses less complicated machinery, fewer man-hours of labor, and less capital outlay.

Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I. is a generally planar view of the flexible sheet assembling apparatus made in accordance with the principles of this invention;

FIG. 2 is a front elevational view of the apparatus as shown in FIG. ll; and

FIG. 3 is a side elevational view of the apparatus illustrating other features of the apparatus.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Proceeding, therefore, to describe the invention in detail, reference should be made to FIG. 1 of the drawings. As is seen in FIG. I, the screening apparatus 10 is mounted upon a frame 12. The frame includes two pairs of parallel generally elongated guide bars 14a, 14b, that are secured in a transverse fashion to the frame. Furthermore, the first pair 14a is vertically spaced from the second pair 14b for reasons that will later become obvious.

Attached to each pair of guide bars 14a, Mb by means to be hereinafter described, are a first and second movable carriage l6, and 18, respectively, that are mounted for cyclical, sequential, intermittent and transverse movement relative to one another.

The first and second movable carriages are generally identical in structure. Each carriage means includes at least two

parallel journal housings

20, 20 and

sideplates

22, 22, movable in unison relative to the guide bars 14a, Mb. The journals permit the carriages to move relative to the guide bars. Extending between and connected to each pair of side plates is a transverse bar 24. Also extending between and rotatably attached to each of the side plates 22 is an elongated roller bar 26. The roller bars carry a plurality of twin pressing rollers 28 that are preferably arranged in pairs and are spaced at intervals relative to each other. The roller bars are actuated to rotate by means, hereinafter described, so that the pressing rollers can be lowered and raised during both the working and return strokes of the carriages, thereby only contacting the flexible sheet material M. (See FIG. 2). While the material to be later described is screen wire mesh, other flexible sheet materials can also be used, for instance, plastic. Each of the rollers has a circumferential pressing edge and a carriage 30.. The carriage is selectively movable relative to the roller barsso that the spacing between each of the carriages can be varied and in this way accommodate various dimensioned articles to be screened.

Extending laterally inwardly from each journal is a pair of flanges 32. Fastened to each flange is one end of a conventional chain belt 36. Although a chain belt is hereindescribed in the preferred embodiment, it is to be understood that other equivalent structures which function in a like manner can be used, for instance, a V-belt.

A first and second set of

sprockets

36, 38 are operatively connected to each chain connected to each journal. The sets of

sprockets

36, 38 are conventionally mounted for rotation on brackets 40 that extend outwardly from the frame 12. Arranged so as to be connected between respective ones of the sets of sprockets is a drive shaft 42. The drive shaft rotates the sprockets, by means hereinafter described, thereby moving both I

carriages

16, 18.

Two

variable speed motors

44,46 are suitably attached to the frame 12. Any conventional drive transmission can be used to impart rotation of the motors to the drive shafts 42.

As shown in this embodiment, the transmission is comprised of sprockets 48 each of which are attached Each of the pressing rollers 28 attached to the roller bars 26 can be regulated so as to vary the pressure exerted thereby on various types of flexible sheet material. In this manner, a greater variety of flexible sheet material can be rolled into the grooves. The device for effecting this change in pressure is more clearly depicted in FIG. 2.

The device includes a vertically extending support bracket 56, a tension type coil spring 56, a chain link 60 and a sprocket 62 attached to the rotatable bar 26. The vertical support bracket extends upwardly from the frame 12 and is supported thereby by a pair of inclined braces 64. At the top of the support bracket 56 is a flange 66 having a conventional screw-threaded means 66 extending through an aperture (not shown) which is suitably attached to the coil spring 58. The opposite end of the coil spring is conventionally secured to the chain link 60. The chain link in turn is connected to the sprocket 62. By vertically adjusting the screwthreaded means 68, the tension in the coil spring can be varied. This change in tension is efiective to vary the force the pressing rollers can impart by slightly rotating the roller bar 26 so that the rollers move upwardly or downwardly relative to the screen mesh M.

As seen in FIG. 1, a bed 70 is defined by a plurality of transversely extending bars 72 upon which a support surface or working table 76 is securely mounted. Located at opposite ends of the table are a clamp mechanism 76 and a roller tension mechanism 78.

The screen clamp mechanism is defined by two clamps 80 attached to a plate 82 extending along one end of the working table. The two clamps are pivotally movable between an engaged position and a disengaged position. In the engaged position, the clamp is in a generally horizontal position and contacts the screen mesh M, while in the disengaged position the clamps are in a generally inclined position. One end of the respective clamps has attached thereto a vertical rod 84 that is effective to pivot the clamps about a pivot axis defined by a shaft (not shown) which extends through the clamps and mounting brackets 86 associated with each of the clamps. Any conventional means (not shown) can be effective to impart movement to the clamps.

Located at the opposite end of the working table 74 is the tension roller mechanism 78. This mechanism as shown more clearly in FIGS. 1 and 2 is comprised of a drive roller 88 and a driven roller 90 having a clearance therebetween for the passage therethrough of the screen mesh M. One of the transverse bars 72 has affixed thereto an electric motor 92. The electric motor is connected to the drive roller 88 by a conventional chain and sprocket arrangement 94. When the electric motor is operated the drive roller cooperates with the driven roller so that the screen mesh M is drawn in a direction away from clamps 80.

The clamp mechanism 76 and the roller tension mechanism 78 are effective to operate simultaneously so that one end of the screen mesh M is held by the clamps while the other end is pulled in a direction away from the clamps so as to apply the tension required.

As more clearly depicted in FIG. 2, the screen mesh is wound in a roll 96 about a shaft 98. The shaft is rotatably secured by conventional means to a mounting device 100 attached to the side of the frame 12. Located at the side of the frame 12 are a pair of variable speed control switches 102 each operative with one of the respective

variable speed motors

44, 46 for adjusting the speed of the latter.

A starter switch 104 is comprised of a longitudinally extending bar 106 that is effective to operate the variable speed motor 44 when the starter bar 106 is pulled away from a mounting bracket 108.

A press switch 110 attached to the frame 12 is operatively connected to the clamp mechanism 76 and tension roller mechanism 78 so as to simultaneously actuate the two mechanisms. Mounted for sliding adjustment on the frame 12 is a reversing switch 112 and a relay switch 114. The reversing switch is selectively adjustable on the frame so as to preferably be positioned at a distance from the endmost extremity of a conventionally grooved window or door frame 116 mounted on elements 118 on the table (See FIG. 1). In this manner, the reversing switch is positioned so that it will not be contacted by the first carriage 16 until the pressing rollers 28 have rolled the screen mesh into the whole longitudinal extent of the first pair of opposed grooves that extend in one of the transverse directions along the frame 1 16. The reversing switch 1 12 is selectively operated to effect movement through the working and return strokes of the first carriage. By being adjustable the reversing switch can accommodate window or door frames of different lengths. When the reversing switch is contacted it is also effective to release the clamps 80 and cease the operation of the roller tensioning mechanism 78.

During the return stroke of the first carriage, the relay switch 114 is contacted. The relay switch is operably connected to the variable speed motor 46 so as to actuate the latter and initiate the working stroke of the second carriage 18.

As seen in FIG. 3, there is another reversing switch 120 and a cut-off switch 122. The reversing switch is also capable of selective adjustment relative to the thereby accommodating frames 116 of various lengths.

The reversing switch 120 is also effective to cause the second carriage to initiate the return stroke so as to return it to the initial position. During this return stoke the second carriage will contact the cut-off switch 122 that stops operation of the motor 46. Although the electrical circuitry connecting the switches and the motors is not shown, it is believed such a circuit is obvious to one of ordinary skill in the art.

In order to insure that the pressing rollers 28 do not contact any structure other than the screen mesh positioned over the grooves, a plurality of tension relief bars 124 are positioned in the path of the first and second carriages. The tension relief bars are placed on elongated support members 126 of the frame. When the rotatable roller bar 26 carrying the pressing rollers 28 operatively contacts the tension relief bars, the roller bars pivot upwardly, thereby causing the pressing rollers to similarly move upwardly. Conversely, when the roller bars no longer operatively contact the tension relief bars, the pressing rollers pivot downwardly. The mechanism used to effectuate this pivoting of the roller bars is a cam link 128 attached to the bar at one end and having a cam roller 138 attached at the opposite end thereof. The cam rollers are effective to roll along and contact as well as follow the contours of the tension bars 124 and support members 126. At the initial or starting positions of the carriages, the rollers contact the tension bars causing the pressing roller to pivot upwardly out of contact with the surrounding structure. The tension relief bars are correlated to the position of the frame 116 so that the pressing rollers only pivot downwardly to contact the screen mesh M located over the spline grooves. At least two tension bars are shown on each support member 122 so as to raise and lower the pressing rollers at both ends of the stroke. Appropriate means (not shown) can selectively adjust the position of tension relief bars and in this manner accommodate window or door frames of various sizes.

From the foregoing detailed description of the preferred embodiment it should be understood that the apparatus operates in the following manner. The leading edgeof a screen mesh is inserted through the clearance between the roller 88, 90. The leading edge after being pulled through the rollers is passed over the window or door frame 116 until it is adjacent the end of the working table 74.

Thereafter, an operator actuates the press switch 108 to effect a clamping of the screen mesh and frame by the clamps 80. Simultaneously, the motor 92 is operated so as to rotate the drive roller 88 by the chain and sprocket arrangement as so as to cooperate with roller 90 and thereby apply a tension to the screen mesh.

After the clamping and the tensioning mechanisms have been effective to both stationarily secure and apply the tension required, the operator then pulls outwardly on the starter bar 186 so as to effectuate operation of the variable control motor 44. The variable control motor rotates the shaft 50 which effectuates move ment of the shaft $2 through the chain 54 and

sprockets

48, 52. The shaft 42 in turn rotates sprockets 36 which cooperate with the chains 38 connected to the journals 28 to move the first carriage 16. As the first carriage moves, the cam link 1128 moves therewith. Thusly, the cam roller 130 rides off the tension relief bar 124 and this causes the pressing rollers 28 to rotate downwardly and contact with the screen mesh M over the spline grooves in the frame 116. The pressing rollers then roll the screen mesh lVl into the spline grooves in such a manner as to secure a tight frictional engagement therebetween.

The first carriage will move in the working stroke along a path defined by the guide bars 14a. The first carriage moves in this path until it contacts the reversing switch 112. As noted the reversing switch can be adjusted relative to the frame 116 at a longitudinal distance away from the edge thereof, so as to permit the pressing rollers to effectively roll the screen mesh into the spline grooves along the longitudinal extent thereof. The cam rollers 1311 move along the support members 126 and as they near the end of the working stroke contact another tension relief bar 124. This bar is so positioned that the cam rollers contact it shortly after the pressing rollers finish rolling the screen mesh into the longitudinal extent of the spline grooves and cause the pressing rollers to rotate upwardly, thereby not contacting other structures.

Also occurring at the working of the sorking stroke is a contact of the first carriage with the reversing switch 112. This actuates the switch 1 12 so as to operatively release the clamps and deactivate the electric motor 92 so as to cease operation of the rollers 88, 90. In other words, the clamps are raised to their inclined position above the table by appropriate downward movement of the vertical rod 84. This raising of the clamps permits the pressing rollers of the second carriage to roll the screen mesh into the remaining spline grooves on the frame 116. The reversing switch 112 also activates the motor 44 so as to cause the first carriage to return to its original position.

During return stroke of the first carriage, the relay switch 114 is contacted. The relay switch operates the variable speed motor 46 operatively connected with the second carriage 18. As noted, the chains 34 and sprockets 38 are effective to transmit the output of the variable speed motor 46 to the second carriage and cause it to move in its working and return strokes.

The tension relief bars 124 cause the pressing rollers 28 of the roller bar 26 to rotate downwardly. This insures the contact of the pressing rollers with the screen mesh above the spline grooves. in this manner the tension relief bars are effective to prevent the pressing rollers 28 from contacting material other than the screen mesh located above the spline grooves. Another tension relief bar situated at the end of the working stroke of the second carriage raises the rollers 28 away from contact with other structures.

The working stroke of the second carriage 18 continues until it contacts the reversing switch 120. This reversing switch causes the variable speed motor 46 to change the stroke of the second carriage. As the second carriage returns to itsinitial position, it contacts the cut-off switch 122 which is efiective to stop operation of the apparatus 10. Before the cut-off switch is contacted by the second carriage, the tension relief bar 124 located at the beginning of the working stroke is effective to rotate the pressing rollers upwardly. As noted, this upward pivotal movement results from the contact of the links 128 and cam roller 130 with the tension bar.

if it is desired to effectuate an adjustment of the pressure exerted by the pressing rollers, an operator can, by merely turning the screw threaded means 68 adjust the the screw threaded means is moved vertically upwardly or downwardly, the pressure rollers will pivot downwardly or upwardly, thereby varying the pressure exerted by the pressing rollers.

Thus, there is described a method and an apparatus for performing a method whereby a more efficient and effective manner of assembling flexible sheet material to frames is accomplished. For instance, the method and machine hereinabove described can if desired cycle in about 16 seconds and is effective to roll or screen approximately 120 units per hour. This work output represents production of two skilled workers using hand operated rolling means. Thusly, if two workers are operating the apparatus wherein one of the workers is placing vinyl spline after the mesh has been rolled into the spline grooves the work output of these two workers would be the full equivalent of four operators performing the same method manually.

Although the invention is shown and described hereinabove in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom wthin the scope of the invention, which is not to 'gbe limited to the details disclosed but is to be accord'tithe full scope of the following claims so as to embri'ce any and all equivalent structures and/or steps.

What is claimed as novel afid unobvious and desired to be protected by Letters Pat t is set forth in the appended claims.

What is claimed is:

1. Apparatus for assembling flexible sheet material into a grooved frame comprising:

a support surface;

means to affix the frame to the surface and the sheet material over the frame and the. grooves thereof;

a first carriage means having two rollers thereon;

means to move the first carriage means across the frame to roll the sheet material into the grooves on two sides of the frame;

a second carriage means having two rollers thereon;

and

means to move the second carriage means across the frame to roll the sheet material into the grooves on the remaining two sides of the frame.

2. The apparatus as defined in claim 1, wherein the means of affixing the frame to the surface and the sheet material over the frame and grooves thereof is comprised of:

a clamping means selectively operated for contacting the frame and the sheet material being held on the surface; and

roller means selectively cooperating with the clamping means and the sheet material for applying a tension to the sheet material over the frame.

3. The apparatus as defined in claim 1, wherein the movement of each of the first and second carriage means is in a path defined between a first position and a second position, with each of the second positions determined by the position of a separate reversing means, whereby the reversing means are effective to cause the first and second carriage means to return to the first po-.

sitions upon a contact therebetween.

4. The apparatus as defined in claim 3, further comprising:

a first actuation means that is activated by the first carriage means returning to the first position for actuating the means to move the second carriage means; and l g 5 a second actuation means that is activated by the second carriage means returning to the first position for deactivating the means moving second carriage means.

5. The apparatus as defined in claim 3, wherein the reversing means are reversing switches.

6. The apparatus as defined in claim 4, wherein the first actuation means is a relay switch.

7. The apparatus as defined in claim 4, wherein the second actuation means is a cut-off switch.

8. The apparatus as defined in claim 4, further comprising:

means operatively associated with the first and second carriage means that are effective to selectively raise and lower the rollers thereon for insuring that the rollers will roll the sheet material into the grooves as long as the rollers are vertically adjacent the grooves.

9. The apparatus as defined in claim 8, wherein the means selectively raising and lowering the rollers comprises:

follower means operatively connected to the rollers on both the first and second carriage means; and relief means adjustably positioned relative to both paths of the first and second carriage means for contact with the follower means so that when the follower means contacts the relief means the rollers are raised from the sheet material and the frame.

10. The apparatus defined in claim 9, wherein the follower means is a cam follower and the relief means are at least one generally elongated bar upon which the cam follower selectively rides.

11. The apparatus as defined in claim 1, wherein each of the rollers of both the first and second carriage means are selectively adjustable relative to the first and second carriage means for accommodating frames of various sizes.

12. The apparatus as defined in claim 1 further comprising:

means for selectively varying the magnitude of pressure the rollers exert on the sheet material, thereby providing a range of pressure that permits different types of sheet material to be rolled into the grooves.

13. A method of assembling at a single work station flexible sheet material into a four-sided groovedframe having a groove in each side thereof forming first and second pairs of grooves in opposed sides thereof, said method comprising the steps of a) securing said frame to a stationary support with the sheet material overlying said frame and said grooves therein, said sheet material having the upper surface thereof facing away from said frame,

b) applying two rollers on a first movable carriage to said upper surface of said sheet material to roll said material into said first pair of grooves in opposed frame sides as said carriage moves, and

c) applying two rollers on a second movable carriage to said upper surface of said sheet material to roll said material into said second pair of grooves in opposed frame sides as said second carriage moves.

14. A method as recited in claim 13 comprising the further step of applying a spline along each of said grooves to secure said sheet material therein.

Claims

1. Apparatus for assembling flexible sheet material into a grooved frame comprising: a support surface; means to affix the frame to the surface and the sheet material over the frame and the grooves thereof; a first carriage means having two rollers thereon; means to move the first carriage means across the frame to roll the sheet material into the grooves on two sides of the frame; a second carriage means having two rollers thereon; and means to move the second carriage means across the frame to roll the sheet material into the grooves on the remaining two sideS of the frame.

2. The apparatus as defined in claim 1, wherein the means of affixing the frame to the surface and the sheet material over the frame and grooves thereof is comprised of: a clamping means selectively operated for contacting the frame and the sheet material being held on the surface; and roller means selectively cooperating with the clamping means and the sheet material for applying a tension to the sheet material over the frame.

3. The apparatus as defined in claim 1, wherein the movement of each of the first and second carriage means is in a path defined between a first position and a second position, with each of the second positions determined by the position of a separate reversing means, whereby the reversing means are effective to cause the first and second carriage means to return to the first positions upon a contact therebetween.

4. The apparatus as defined in claim 3, further comprising: a first actuation means that is activated by the first carriage means returning to the first position for actuating the means to move the second carriage means; and a second actuation means that is activated by the second carriage means returning to the first position for deactivating the means moving second carriage means.

8. The apparatus as defined in claim 4, further comprising: means operatively associated with the first and second carriage means that are effective to selectively raise and lower the rollers thereon for insuring that the rollers will roll the sheet material into the grooves as long as the rollers are vertically adjacent the grooves.

9. The apparatus as defined in claim 8, wherein the means selectively raising and lowering the rollers comprises: follower means operatively connected to the rollers on both the first and second carriage means; and relief means adjustably positioned relative to both paths of the first and second carriage means for contact with the follower means so that when the follower means contacts the relief means the rollers are raised from the sheet material and the frame.

12. The apparatus as defined in claim 1 further comprising: means for selectively varying the magnitude of pressure the rollers exert on the sheet material, thereby providing a range of pressure that permits different types of sheet material to be rolled into the grooves.

13. A method of assembling at a single work station flexible sheet material into a four-sided grooved frame having a groove in each side thereof forming first and second pairs of grooves in opposed sides thereof, said method comprising the steps of a) securing said frame to a stationary support with the sheet material overlying said frame and said grooves therein, said sheet material having the upper surface thereof facing away from said frame, b) applying two rollers on a first movable carriage to said upper surface of said sheet material to roll said material into said first pair of grooves in opposed frame sides as said carriage moves, and c) applying two rollers on a second movable carriage to said upper surface of said sheet material to roll said material into said second pair of grooves in opposed frame sides as said second carriage moves.