Apparatus for shaping honeycomb core

Details Apparatus for shaping honeycomb core Apparatus for shaping honeycomb core

1998-10-29

2001-02-13

Pyon, Harold (Department: 1722)

Plastic article or earthenware shaping or treating: apparatus

Preform reshaping or resizing means: or vulcanizing means...

Including both heating and cooling means

C425S394000, C425S407000

Reexamination Certificate

active

06186766

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to methods and apparatus for shaping settable materials, and more particularly to a method and apparatus for shaping flat honeycomb core into a contour shape.
BACKGROUND OF THE INVENTION
One known method of shaping honeycomb core includes placing the core on a series of horizontal support rods and sliding the combination into an oven. The core is heated to its forming temperature, i.e., the particular temperature at which the core becomes shape-able. Once the core is properly heated, the support rods and core are removed from the oven and the rods are retracted laterally to either side. This causes the core to fall loosely onto a lower die. A worker then correctly aligns the core relative to the die. The heated core is pressed for a period of time between the lower die and an upper die that is shaped in the reverse-image of the lower die (i.e., male/female die pair). The upper and lower dies continue to hold the core until it cools in the ambient air to a set temperature. Once set, the dies recede, and the shaping process is complete.
There are a number of disadvantages associated with the above method. A first disadvantage is that extra energy is required to heat the core in order to compensate for heat lost during transfer of the core from the rods to the lower die and heat lost to the dies during pressing. The core must be heated to a particular temperature in order to bring it to a malleable state. Even if the initial temperature of the core is correctly adjusted, the forming temperature is adversely affected because the dies continue to absorb heat from the core during pressing. This reduces the amount of time available for pressing the core at the required forming temperature. A second disadvantage is that after the core is pressed at its proper forming temperature, the core must be allowed to cool to a particular temperature while still being held at its new shape. If the core is released prior to reaching this set temperature, it will tend to return (i.e., spring back) toward its original shape. This cool down period is longer than desired when using the above method due to the slow rate of heat dissipation from the upper and lower dies.
Many of these disadvantages are addressed in the method and apparatus described in U.S. Pat. No. 5,780,074. In particular, the '074 patent describes an embodiment for forming a settable material in which the material is placed on a flexible support, transferred to and from an adjacent oven, and then pressed between the flexible support and an upper male die. After pressing, the flexible support and upper die continue to hold the core until it has cooled in the ambient air to its set temperature. Once cooled, the upper die recedes. Shaping of the material is complete. The '074 patent thus reduces the problems associated with core heat loss prior to and during forming. The '074 patent also reduces the cool down time required for setting the material, since the flexible support dissipates heat much faster than a (typically metal) lower die.
If has been found in using the above '074 process, however, that the production time required to manufacture a large number of shaped panels is unacceptably high. This is partly due to the time required to ambiently cool the material to its set temperature while being held in its new shape. The '074 addressed this need in part, by providing an embodiment in which the lower, female die is eliminated. This allows heat to dissipate more quickly from the core, thus causing it to reach its set temperature faster. The upper, male die, however, yet remains as an impediment to the dissipation of heat from the core. Therefore, a continued need for a shaping method and apparatus exists that provides faster, more efficient technique for bringing the core to its set temperature during the cool down period. The present invention is directed to fulfilling this need.
SUMMARY OF THE INVENTION
In accordance with aspects of the present invention, an improvement to an apparatus for shaping a layer of settable material is described. The apparatus includes an upper die located in a forming area, opposed tensioning assemblies, a flexible support rotatably connected between the opposed tensioning assemblies for supporting the settable material, and a regulation system operably engaged with the opposed tensioning assemblies for maintaining tension between the opposed tensioning assemblies. During use, the settable material is shaped by the relative pressing between the upper die and the flexible support. An improvement is provided that includes a plurality of openings in the flexible support and a cooling system for providing cool air to the settable material during a cool down period. The cool air is provided in the forming area at a location beneath the flexible support so that during use the cool air passes through the plurality of openings in the flexible support to the settable material.
In accordance with other aspects of this invention, one embodiment is provided in which the cooling system includes first and second air conditioning units, first and second cool air plenums, and ducting connecting the first cool air plenum with the first air conditioning unit and the second cool air plenum with the second air conditioning unit. The first and second cool air plenums are oriented to face one another from opposed sides of the forming area beneath the flexible support. The plenums are adapted to direct cool air through the flexible support at the position of the settable material.
In accordance with further aspects of this invention, a second embodiment is provided in which the cooling system includes a number of air conditioning units, a cool air output grate connected to the number of air conditioning units. The grate is located in the forming area beneath the flexible support (such as in the floor). The grate is positioned to direct cool air through the flexible support at the position of the settable material.
In accordance with still other aspects of this invention, the present invention further includes inhibiting the transfer of heat into the forming area by placing one or more insulating skirts about the forming area. In one embodiment, the present invention further includes temperature sensing means insertable in the settable material prior to pressing. The temperature sensing means indicate when the settable material has reached its formed temperature. In one embodiment a control system automatically controls the level of cool air output from the cooling system using the information received from the temperature sensing means.
In accordance with still further aspects of this invention, an improvement to a method of shaping a layer of settable material, such as a honeycomb core, is provided. The method includes placing the layer of settable material on a flexible support, translating the flexible support with settable material to a heat source, heating the settable material to a desired forming temperature, translating the flexible support with settable material from the heat source to an adjacent forming area, and pressing the settable material using a die having a particular shape. The pressing occurs between the die and the flexible support by tensioning the flexible support so that the settable material is forced to conform to the shape of the die. An improvement is provided including using a flexible support having a plurality of openings therethrough and cooling the settable material using a cooling system. The cooling system includes one or more cool air plenums positioned in the forming area at a location beneath the flexible support.


REFERENCES:
patent: 2385544 (1945-09-01), Salisbury
patent: 2443596 (1948-06-01), Cahill
patent: 2456675 (1948-12-01), Chaille
patent: 2783815 (1957-03-01), Tegarden
patent: 2882952 (1959-04-01), Johnson
patent: 3557277 (1971-01-01), Broderson et al.
patent: 3655475 (1972-04-01), Stelling, Jr. et al.
patent: 3658974 (1972-04-01), Low
patent: 3871811 (1975-03-01), Barry et al.
patent: 4160006 (1979

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