MXPA02003265A

MXPA02003265A - Continuous platform cutting apparatus and method.

Info

Publication number: MXPA02003265A
Application number: MXPA02003265A
Authority: MX
Inventors: Denney Denys
Original assignee: Foamex Lp
Priority date: 2000-07-28
Filing date: 2000-07-28
Publication date: 2002-09-18
Also published as: ES2257308T3; WO2002009915A1; EP1305148B1; CA2386015A1; AU2000263847A1; DE60025923T2; DE60025923D1; ATE317315T1; CA2386015C; EP1305148A1

Abstract

An apparatus and method for shaping a slab of compressible or cellular polymer material (80), such as polyurethane foam, cuts portions of the material from one surface of the slab. A moving patterned platform (32), preferably an endless belt or a series of interconnected panels, is interposed in a predetermined gap formed between a compression roller (56) and a drive roller (18) and defines at least one recess (36) or at least one projection (320) or a combination of recesses and projections. When the slab is compressed between the compression roller and the platform, a portion of the material fills the recess or recesses in the moving platform. At least a portion of the compressed material within the recess(es) is then cut from the surface of the slab by a blade (76) just as the slab emerges from between the compression roller and the platform, leaving a profile-cut surface with cut-out portion(s) corresponding in pattern and shape to the recess(es) provided in the moving patterned platform. Alternatively, a portion of the material is forced away from the blade (76) by the projection or projections (320) so that a portion of compressed material is not cut by the blade (76).

Description

APPARATUS AND CONTINUOUS PLATFORM CUTTING METHOD BACKGROUND OF THE INVENTION The present invention relates to a continuous apparatus and methods for forming the surface of a thin plate of compressible or cellulosic polymeric material, such as polyurethane foam. A sheet cuts the portions of the plate material after the plate is passed through a predetermined passage and has been compressed between a compression roll and a patterned surface of a movable platform. The predetermined pitch is preferably created in a region where the platform is adjacent to or driven by a drive roller. Various methods and apparatuses for cutting plates of cellulosic polymeric materials have been described in the prior art. For example, US Pat. No. 4,700,447 to Spann discloses convolutional polyurethane foam cutting plates formed by compressing a foam pad or plate between a pair of rollers with opposite, projecting projection projections, placed in a pattern and cutting the Crosswise foam with a just saw blade as it emerges from the rollers. The cutting plate is then separated into two pads with convolutional cutting surfaces that form a series of peaks separated by valleys. The valleys REF. 136949 formed on a pad are formed by cutting the foam which takes the form of a bill or coupling projection on the other pad. Spann then shaves the peaks to form a flatter upper surface. As noted by Spann, the convolutional cut only produces rounded peaks and valleys, and it is difficult, if not impossible, to produce a cutting surface with peaks having substantially flat upper surfaces or with cavities having substantially straight side walls. Convolution is generally desired to form the classic, symmetric and repetitive "egg box" pattern of peaks and valleys. To obtain a flat top surface without the recessed portions, the surfaces of the peaks must be cut or formed in a second stage. The compressible cellulosic polymeric materials can also be cut using a hot wire cutter. A plate of such material is cut by moving the plate relative to one or more hot wires as shown, for example, in U.S. Patent No. 4,683,791 (Demont). Only straight cuts in symmetrical or regular patterns can be formed using a hot wire cutter. See also U.S. Patent No. 4,915,000 (MacFarlane) and U.S. Patent No. 5,573, 350 (Stegall).

The shapes can be cut on the surface of a plate of polymeric cellulosic material using a perforation cutting apparatus, such as that described in U.S. Patent No. 5,299,483 (Ber-Fong). A block of the cellulosic material is pressed against a template so that a portion of the material is forced through an opening in the template. The exposed material is then cut by a sheet and removed, leaving a cavity or slit in the plate. This method cuts one block of material at a time, and only one surface at a time. In the North American Patent No. 4,351,211 (Azzolini) a block of foam material is compressed against a template or die having an opening therein using a pair of plates with concave and convex portions. The compressed foam is cut transversely along the template while being retained between the plates. The most complex cutting regions can be obtained by using a template without the plates with the portions raised and pressed, however only one block is cut at a time. Other template or pattern cutting methods are shown in the Patents North American Nos. 3,800,650 (Schroder) and 3,653,291 (Babcock). The surface of a cellulosic polymeric material can be formed by molding or stamping, which is contrary A.I jMfc¿ <; fa to the cut. U.S. Patent No. 4,383,342 (Forster), for example, describes the injection of a foaming composition into a mold cavity. After a sufficient healing time, the article made of individual foam is removed from the mold. Other injection molding techniques are known to those skilled in the art. The molded cellulosic polymer product generally forms a tough layer on the surfaces that contact the mold. The continuous and semi-continuous molding processes are also known. These processes have the same disadvantages associated with injection molding techniques. For example, U.S. Patent Nos. 4,128,369 and 4,290,248 (Kemerer, et al.) Describe an apparatus and method for thermoplastic products molded by printing. The thermoplastic material in a liquid state is injected between the compressed molds traveling on a belt. As the belt molds travel from the point of introduction of the thermoplastic, they are cooled, which in turn causes the cooling of the thermoplastic material. The hardened molded thermoplastic material is removed from between the belts to form the finished product. Kemerer does not show a method of cutting or forming a cellulosic polymeric material, such as polyurethane foam.

A method of embossing a foam surface using a patterned metal stamping belt or belt is shown in US Patent 4,740,258 (Breitscheidel). The foam is heated and then pressed against the embossing belt. The belt is removed after the foam surface has cooled. The surface stamped by design has a hardened layer. No method is described for cutting or forming the foam. U.S. Patent No. 5,534,208 (Barr) discloses a continuous rotary method for synthetic foams forming surfaces wherein the foam is compressed between a compression roll and a die roll having raised and lowered portions. The portions of the extruded foam are cut into the cavities in the die roll. The compressed portions of foam return to an uncompressed state after passing through the rollers. As a result, a mirror image pattern of the pattern on the surface of the die roll is cut on the foam surface. The diameter of the die roll limits the piece that can be formed from the foam article formed. The prior art does not disclose an apparatus or a continuous method for forming a compressible or cellulosic polymer material by cutting and forming cavities of various depths and of various symmetrical shapes and asymmetrical The prior art does not disclose a method for forming a plate of compressible or cellulosic polymer material of unlimited length using a movable patterned platform, such as a continuous belt, such as the template for cutting the plate surface. The prior art also does not disclose a method for forming a profiled cutting product without the hardened layer or hard spots associated with the molded or patterned products. Nor does the prior art disclose continuously cut compressible or cellulosic polymeric materials, such as polyurethane foam, with an apparatus that includes a movable patterned platform, such as a continuous belt or a series of connected panels that define at least one cavity in the which the cellulosic material can be compressed before cutting the material transversely with a blade.

BRIEF DESCRIPTION OF THE INVENTION A continuous method for forming a compressible or cellulosic polymeric material, such as polyurethane foam, by cutting and removing portions of the material is described. A plate of polymeric cellulosic material is compressed between a compression roll and a surface of a movable shaped platform. The mobile patterned platform is interposed between the compression roller and a surface It is also a cooperator, just like the surface of a control roller. Because the movable shaped platform can be formed of a flexible material, the compression force is preferably applied in a region where the platform is adjacent to a solid surface of the drive roller. In a less preferred embodiment, the movable patterned platform is interposed between the compression roller and a follower roller and the compression force is applied to a region where the platform is adjacent to a solid surface of the follower roller. A blade is placed downstream of the compression roller and from the point at which the compression force is applied, preferably with the blade interposed between the compression roller and the patterned platform. The plate surface is cut transversely by the sheet just as the plate emerges from between the compression roller and the movable patterned platform, thereby adjusting the portions of the cellulosic material that fill the cavities in the patterned platform. In an alternative embodiment, the sheet is placed in such a way that it shaves a layer of thin foam canvas from the plate surface, and makes deeper cuts within the plate in regions where the polymeric material has filled the cavities in the patterned platform . If the modeled platform defines the straight projections, instead of or in addition to the cavities, the projections force a portion of the foam material away from the sheet and therefore less material is cut off from the plate surface in these regions. The patterned platform can be a continuous belt or a series of movable panels or plates or any other structure that can travel in a continuous circuit or path. Where the patterned platform is a continuous belt, the belt is placed on a series of rollers where at least one roller is driven by a motor. The belt can be attached to the roller with interconnection gears or protrusions in such a way that rotation of the control roller causes the belt to travel. Where the patterned platform is formed by a series of interconnected panels, such as metal plates, the panels are preferably movably connected to a pinion and chain drive system. Thus when the pinion is driven, for example by a motor, the pinion drives the chain and the panels interconnected to the chain. The patterned platform may define at least one cavity, which may be a hole or void through the platform, but is preferably a cutting portion that does not pass through the entire thickness of the platform. The cavity can be provided as a simple or complex geometric shape. Where more than one cavity is defined in the platform, the cavities may be the same or different shapes, be interconnected or separate, be symmetrical or asymmetric, and be repeated or not repeated on the patterned surface of the modeled platform. The cavities can be cut to different depths on the platform. Several separate series of different cavities can be provided on a modeled platform. The modeled platform can define at least one straight projection. The projection can be provided as a simple or complex geometric shape. Where more than one projection is defined on the platform, the projections may be of the same or different shapes, be interconnected or separated, be symmetric or asymmetric and be repeated or not repeated on the patterned surface of the modeled platform. The projections can have different heights. The modeled platform can include a combination of cavities and straight projections. As the plate travels together with the patterned platform and is compressed between the compression roller and the modeled platform (with cavities), a portion of the cellulosic material fills the cavities in the patterned platform. Greater amounts of cellulosic material are cut from the plate in the regions that have been compressed into the cavities in the patterned platform because this material has been forced to one side of the edge? of the leaf in these regions. The cut portions are removed from the plate after the blade passes. The resultant shaped cutting product has on its cutting face a series of cut regions that substantially correspond to the pattern and shape in mirror image to the cavities provided in the patterned platform. The cut regions in the plate are also deeper cut in the regions that correspond to the deepest cavities in the modeled platform. However, due to the varying compression factors for the cellulosic polymeric materials, the depth of the cutting of the cutting regions is generally not identical to the depth of the cavities within the patterned platform. Also disclosed is an apparatus for continuously forming a compressible or cellulosic polymeric material, such as polyurethane foam, by cutting and removing portions of the material. A compression roller and a cooperating surface, such as the surface of a control roller, compress a plate of cellulosic polymer material. A movable patterned platform surface, interposed between the compression roller and the cooperating support surface, defines one or more cavities that retain a portion of the cellulosic material as it is compressed. In a preferred embodiment, the surface cooperating is the solid surface of a control roller. In a less preferred embodiment, the movable patterned platform is interposed between the compression roller and a follower roller and the compression force is applied to a region where the platform is adjacent to a solid surface of the follower roller. Preferably, the compression roller is driven by motor. The modeled platform is also preferably motor driven. A blade is placed downstream of the compression roller and from the point at which the compression force is applied, preferably with the blade interposed between the compression roller and the patterned platform. The plate surface is cut transversely by the sheet as the plate emerges from between the compression roller and the movable patterned platform, thereby adjusting the portions of the cellulosic material that fill the cavities in the patterned platform. In an alternative embodiment, the sheet is placed so that it shaves a layer of thin canvas of material (eg, foam) from the plate surface, and makes deeper cuts within the plate in the regions where the polymeric material has filled the cavities, but preferably the sheet cuts the foam material only from the portions of the surface on which it is desired that the voids or cavities are formed. If the modeled platform defines Straight projections, instead of or in addition to the cavities, the projections force a portion of the material (eg foam) away from the sheet and therefore less material is cut from the plate surface in these regions. The cut foam product has a series of cavities or projections defined on its surface. If the control roller moves the patterned platform at a speed and the compression roller moves at a different speed, the sheet cuts the foam material to form angled side walls that are greater or less than 90 ° as measured from the base of a cutting cavity or of the upper surface of a projection formed on the surface of the cutting foam plate. The difference in speed of the platform compared to the speed of the compression roller causes one surface of the plate to enter the predetermined pitch before the other plate surface. Using the apparatus and the method according to the invention, a cellulose product of profiled cut in which the portions have been cut from the upper and lower surface, can be formed by feeding the plate twice through the apparatus. First, a surface is cut, then the cut product is inverted and fed through the apparatus a second time to cut its opposite surface.

* DESCRIPTION OF THE FIGURES Numerous objects, features and advantages of the invention will become apparent upon reading the following detailed description taken in conjunction with the accompanying drawings, wherein: Figure 1 is a schematic perspective view of an embodiment of a continuous platform cutting apparatus that can be used to practice the invention; Figure 2 is a cross-sectional view taken along line 2-2 of Figure 1; Figure 3 is a side elevational view of the apparatus shown in Figure 1; Figures 4 and 4A are schematic perspective views of an alternative mobile platform for a continuous platform cutting apparatus that can be used to practice the invention; Figure 5 is a fragmentary side elevational view of a cellulose polymeric base mat defining the patterned cavities that have been cut on the mat using the continuous platform cutting apparatus and method of the invention; Figure 5A is a fragmentary side elevational view in cross section taken along line 5-5 of Figure 5; K < ji rf ^^. A < ^ A.- > .A ^ Aa ^ .¿ .AA ^^ .. «A .. ^^. Tl | .a! F | ^ | i i tlrilülnl i Figure 6 is a top plan view of the mat of the Figure 5; Figure 7 is a schematic side elevational view in partial cross section showing a second embodiment of a continuous platform cutting apparatus that can be used to practice the invention; Figure 8 is a partial schematic side elevational view in partial cross section showing a modification to the second embodiment of the Figure 7; and Figure 9 is a partial schematic side elevational view in partial cross section showing a third embodiment of a continuous platform cutting apparatus that can be used to practice the invention.

DESCRIPTION OF THE PREFERRED MODALITIES Referring first to the apparatus as shown in Figures 1-3, a continuous platform profiling cutting apparatus for compressible or cellulosic polymeric materials 10 is supported on a first mounting structure 12 and on a second construction structure. assembly 22. A shaft 14 is mounted to rotate in the first mounting structure 12, preferably with bearings. A motor 16 drives the shaft 14. A control roller 18 is mounted fcittáfc? a¡fcjfi) ¡¡¡ílf,? * l? ¡. & it¿ já¡e, on the shaft 14. The outer surface of the drive roller 18 can be covered or coated with a resistive sliding material, such as urethane. The projections or gear teeth 20 are provided around the outer end or peripheral end surfaces of the first drive roller 18. Alternatively, separate gears with appropriate gear teeth can be provided at each end of the first drive roller 18. The shaft 24 is mounted to rotate in the second mounting structure 22, preferably using the bearings. A first follower roller 28 is mounted on the shaft 24. The outer surface of the first follower roller 28 can be covered or coated with a resistive sliding material, such as urethane. A patterned platform, such as a continuous patterned belt 32, has a patterned front surface 34 and an opposing surface 38. The belt 32 is mounted around the drive roller 18 and the first follower roller 28. The belt front surface 34 defines the cavities 36, which can be of simple or complex shapes, simple geometric patterns, complex, symmetric and repetitive or asymmetric and non-repetitive. The rectangular cavities 36 and circular cavities 37 are shown by way of example in Figure 1. The cavities can be as discussed in detail later. * The coupling grooved sections 39 on the outer edges of the opposite surface of the belt 38 engage or fit with the protrusions or gear teeth 20 provided on the drive roller 18. When the servo motor 16 drives the shaft 14 , which in turn rotates the control roller 18, the continuous belt 32 travels around the control roller 18 and the first follower roller 28. The coupled grooved sections 39 and the projections 20 and the frictional coupling between the contact surfaces of the belt with rollers, keep the belt centered and aligned with the rollers as it travels a path around the rollers. First the tension roller 40 is mounted for rotation on the shaft 42, which is supported by a portion 44 of the mounting structure 12. First, the tension roller 40 is placed at a point between the control roller 18 and the first follower roller 28 for stabilizing the movement of the continuous belt 32. The compression roller 46 is provided at a point between the control roller 18 and the first follower roller 28. The compression roller 46 is mounted to rotate about the axis 48. The axle 48 is held in a 1 i MMÜifi- »» - < ™ ** »u» ^ ldtta - ,. ». Fi < i?. ** »» -'- ^ * ^ * »t? tá iait 3U support cavity within a support 52. The tension adjustment means 54, such as a fluid cylinder or spring or a series of springs, it can act on the support 52 to adjust the applied compression force. The outer surface 47 of the compression roller 46 makes contact with the opposite surface 38 of the belt 32 in which the fluted portions 39 are provided. The outer surface 47 of the compression roller 46 can be covered or coated with a resistive sliding material, as urethane. As best shown in Figure 2, the surface 47 of the compression roller 46 does not extend the outer periphery of the roller as much as possible, leaving a cavity where the grooved portions 39 extend so that the surface 47 of the roller 46 contacts the the surface 38 of the belt 32. The greater sliding resistance results when the amount of surface engagement between the belts 32 and the compression surface 47 of the roller is increased. The compression roller 56 with the external compression surface 60 is mounted for rotation on the shaft 58. The shaft 58 is supported within the support 62. An engine 57 drives the shaft 58. The roller 56 is separated from the compression roller 46. , leaving a space or passage through which the continuous belt 32 travels between the compression surfaces of the rollers. The arrow 64 in Figure 2 indicates the force applied against the support 62 to the driving roller 56 towards the roller 6 / Referring to Figure 3, the blade 76 is held within the cover 74. The blade 76 should have a Sharp point that is sharp enough to cut cellulosic polymeric materials, such as polyurethane foams. Because the construction of the sheet 76 is known and understood by those skilled in the art of cutting cellulosic polymeric materials, such as polyurethane foams, it will not be described in detail. The blade 76 is positioned adjacent the compression rollers 46, 56 so that the sharp tip of the blade is adjacent or just beyond the point at which the outer surfaces 47, 60 of the compression rollers 46, 56 act to its greater degree to compress the material that is located between the rollers (that is to say the predetermined step). The blade 76 is also placed between the compression surface 60 of the compression roller 56 and the patterned front surface 34 of the continuous belt 32 such that the blade tip is close to it to make tangential contact with the front surface 34. The blade 76 should be positioned so that it does not cut the compression surface 60 of the roller 56 or the patterned front surface 34 of the belt 32. The blade 76 should not interfere with the rotation of the rollers 46, 56 or the movement of the »Ti, j.j. ^ .. ¡»*« .. A ^ .. ^ .- a, .. ^ aÉaaJ > ^ giÜ > . belt 32. The orientation of the blade can be adjusted to move the pint of the blade closer or farther from the transfer junction point between the roller 46 and the roller 56. In a mode as best shown in FIGS.

Figures 2 and 3, a plate 80 of cellulosic material, such as polyurethane foam, is fed between the compression surface 60 of the compression roller 56 and the patterned front surface 34 of the continuous belt 32, the plate 80 is compressed by the rollers 46, 56. When the plate 80 travels at the predetermined transfer junction or gap or space between the rollers 46, 56, portions of the compressed plate material are retained within the cavities 36 defined within the front surface 34 of the strap 32. The blade 76 cuts transversely portions of the plate 80 just as the plate 80 emerges from between the compression rolls 46, 56. As shown in Figure 3, the cuts in the plate 80 are made in the regions corresponding to the regions where the plate material has been compressed within the cavities 36 defined in the front surface 34 of the belt 32. portion of the material that was held within a cavity in the belt is cut from the plate before the compressed cellulosic material can return to its state without M ÉH "Mh, -dfcfc; compress as emerges from the compression rollers. The portions of the non-compressed plate surface in the cavities or voids in the front surface 34 of the belt 32 may or may not be cut, depending on the position of the sheet 76. After the plate is cut as it emerges from the rolls, the cut portions 88 are removed as waste, leaving a resultant shaped cellulosic material 90. The resulting product 90 has cavities 92 corresponding substantially in shape to the cavities 36 provided in the front patterned surface 34 of the continuous belt 32. The plates of cellulosic material can thus be provided with the profiled surfaces with a continuous arrangement of patterns, symmetrical or asymmetrical, simple or complex, or repetitive or non-repetitive. For example, alternatively the cut portion 88 may be a product of separate shaped cellulosic material 90. Preferably, only portions of the plate that have been compressed in the cavities are cut, resulting in less waste to remove from the plate surface. as it emerges from the cutting apparatus. In contrast to the above cutting methods, the waste material does not fall and does not contaminate the apparatus, but is carried by the belt 32. The waste can then be swept or sucked off the belt as it continues to travel along of its path defined by the position of the rollers 18, 28. The long plates of cellulosic material can be continuously fed into and formed by the continuous platform cutting apparatus. The method can be used to cut multiple products continuously from a single plate of material. The cavities and / or projections formed on a single patterned platform can be arranged in separate configurations for different products. Alternatively, patterns of repetitive cavities can be formed on the modeled platform. In addition, patterned platforms of different lengths can be used to form final cutting products of different lengths. An example of a profiled cutting product 300 made according to the invention is shown in Figures 5 and 6. The profiled cutting product 300 represents a barrier or insulating base of cellulose polymer that will be installed in the interior of a motor vehicle between the surface of the floor and the carpeting. -The upper surface 310 of the base has been cut to provide complex patterns of cavities. As shown in Figure 6, the generally rectangular-shaped cavities 312 have been cut into the surface of the product 300. In addition, cavities of more complex shape, such as interconnecting cavities of generally oval shape 314 and interconnection cavities of straight edges and curved edges 316, can be cut into the cellulosic material. For the base of a motor vehicle, preferably a surface, which is referred to herein as top surface 310, is cut and the opposite surface remains uncut. The cutting surface of the base is placed adjacent to the surface of the motor vehicle in such a way that the voids and cavities in the base are coupled with the formed portions projecting from the surface of the vehicle. In this way, the base can be provided to match the contour of the interior surface of the vehicle. Once the base is installed in the vehicle, the carpet or other cover can be installed adjacent to the uncut and generally smooth surface of the base. The depth of the cavities 36, 37 of the belt 32 is normally a small fraction of the depth of the corresponding cuts that will be made on the surface of the foam material 80. Due to the compression factor of the foam against the model 32 belt, a shallow depression 36, 37 on the model belt 32 provides a much deeper depression in the foam. For example, a thick 1.6 cm (5/8 inch) sheet of the compressed foam material against a depression 20 of 508 μm (20 mils) on the patterned belt, in the apparatus 10 described above, produced a depression of approximately 1.27 cm (1/2 inch) deep in the foam sheet 80. The spacing between the belt surface 34 and the surface 56 of the roller, and if the rest of the factors are equal, determines the compression factor of the foam. and therefore, the proportion of belt depth modeled to the depth of foam cut. The depth of the cut in the foam can be reduced to a given model belt cavity depth or projection height by increasing the spacing between the roller surface 56 and the belt surface 34, thus reducing the compression factor. Where the belt 32 moves at the same speed as the roller 56, the cutting product has the cavities (or projections) formed with the side walls substantially perpendicular (90 °) to the upper surface of the product. The angle of the sidewalls of the cut can be varied by moving the belt 32 at a different speed than the speed that the roller 56 moves. When varying drive speeds are used, one surface of the plate 80 will enter the predetermined pitch before the other surface. The driving speed can be continuously adjusted as the foam material plate 80 is introduced into the passage. In this way, the angles of the side wall can be the same or different in various regions of the cutting product. Referring to Figure 5A, the cavity is cut with the substantially perpendicular side walls (90 °) 340, but a cut cavity with the angled side walls 342 is shown in an imaginary trace. When the compression roll moves at a speed of surface of 7.5 meters (25 feet) per minute and the modeled platform runs at a surface velocity of 10.5 meters (35 feet) per minute, the cutting product has cavities with side walls cut at an angle of approximately 110 ° to 115 ° . However, the cutting angle is approximately 90 ° when both surfaces are moved at the same speed. For certain applications, this may be desired to cut the top and bottom surfaces of a plate of cellulosic material. If the apparatus shown in Figures 1-3 is used for this purpose, once the plate has been fed between the compression rollers and cut on one side, the plate can then be inverted and fed between the compression rollers so that can be cut profiled on the opposite surface. The continuous belt 32 is preferably formed of a flexible material such as rubber or silicone rubber or urethane. The strap 32 is thick enough to withstand the compressive forces, preferably about 0.952 cm (0.375 inches) or more, and has a durometer of about 35 or more, preferably 75 or more, preferably at least 90. Alternatively, the belt may be formed of glass fiber reinforced polyurethane or of other suitable composite materials for continuous belts with such thickness and durometer. As shown in Figure 4, instead of using a continuous belt, the modeled platform 200 can be constructed as a continuous or endless series of interconnected panels driven by chain and pinion. The series of plates 208, preferably formed of metal or other firm substrate, are mounted on the shafts 210. The shafts 210 are held for rotation within the support handles 212. The Y-shaped follower bars 214 are connected in a end to the axes 210 and the other two ends to the members 204 that hold together the links 202 of a chain. The chain links 202 are moved by the pinions (not shown), which in turn are driven by motors (not shown). The plates 208 can define one or more cavities 216, or portions of cavities 216a. The cavities can be cut through a portion or through the entire thickness of a plate. The cavities may be rectangular, circular or other geometric shape. The cavities can be cut in non-uniform, asymmetrical and non-repetitive ways. The cavities do not need to be completely contained within a single plate. Preferably, a cavity defined by a plate can complement the cavity defined by an adjacent plate to realize larger or more complex cavity shapes. When a series of plates is used as the patterned platform, the plate of cellulosic material will be pressed against the plates by a compression roller (not shown in Figure 4) so that a portion of material is compressed within the cavities in the plates. plates and is cut from the plate by a blade blade just as the cellulosic material emerges from the compression roller. A support platform 222 is provided below the plates 208 to support the plates when the compression forces are exerted on them by the compression roller. Figure 7 shows a preferred embodiment of the invention. As the reference numbers of Figure 7 refer to the same elements shown in Figures 1-3 because the apparatus 300 in Figure 7 is similar to the apparatus 10 shown in Figures 1-3. A control roller 18 is provided which travels in the direction indicated by the arrow 302. The external surface of the control roller 18 is provided with teeth 20. The apparatus also includes the follower roller 28.

A belt 32 has a patterned surface 34 with one or more cavities 36 and has an opposing surface 38. The projections or engagement teeth 39 are tested on the opposite surface 38 of the belt. The teeth 39 engage the teeth 20 provided on the drive roller 18. As the belt travels along a path around the drive roller 18 and the follower roller 28, it also makes contact with the outer surfaces of the first and second. tension rolls 40, 40 '. A compression roller 56 mounted on an axis 58 is provided with an external surface 60. In this apparatus 300, the compression roller 56 is positioned near the external surface of the control roller 18 to define a predetermined pitch between the outer surface 60. and the roller 18. The position of the roller 56 is adjustable, such that the outer surface 60 of the roller may be closer or further away from the outer surface of the control roller 18 to change the pitch. The belt 32 travels between the outer surface 60 of the compression roller 56 and the outer surface of the control roller 18. A plate of compressible material 80 is fed in the passage between the patterned surface 34 of the belt 32 and the outer surface 60 of the belt. compression roller 56. The passage is fixed at a distance which causes the compressible material to be compressed between the outer surface 60 of the compression roller 56 and the patterned surface 34 of the belt 32. The portions of the compressible material are forced into the cavities 36 formed on the patterned surface 34 of the belt 32. A blade 76 held within the blade cover 74 is positioned just downstream of the passage. As the compressible material 80 passes through the passage, the plate portions 80 retained within the cavity 36 are cut by the blade 76. The cutting plate emerges with a cutting surface profiled with cavities. The cut portions 88 are separated from the plate 80 and are carried by the belt 32 to be removed, either by falling off the belt, by removing them manually or by vacuuming. The apparatus in Figure 8 shows a modification to the apparatus of Figure 7. In order to more easily compress the plate 80 of compressible material between the compression roller 56 and the movable patterned continuous belt 32, the tension rollers 304 and 306 are provided, and a follower roller 308. A belt 310 travels in a circuit defined by the compression roller 56 and the follower roller 308 and the tension rollers 304, 306. A tapered passage is defined between the belt 308 and the belt 32. The passage is wider between the follower roller 308 and the belt 32 and progressively narrows or closes between the tension roller 306 and belt 32 and between tension roller 304 and belt 32. As plate 80 passes between belt 32 and belt 308 and through the progressively tapering passage, the compressible material is compressed to a greater degree, up to maximum compression at the predetermined pitch between the compression roller 56 and the belt 32. Figure 9 shows a belt 32 'modified to include the raised projections 320 projecting from the patterned surface 34'. Some cutting products are formed by cutting a canvas or thin layer of the surface along the total length of the plate 80. With the projections 320 provided on the belt 32 ', cutting products can be formed without cutting the material where the portions of the plate passing through the predetermined passage are supported on one side of the sheet 76 by the projections 320. The apparatus and methods according to this invention may be used to make shaped cutting products for a variety of end uses. In addition to the carpeting systems of motor vehicles, the profile cut products can be developed for other uses in vehicle interiors, such as main coatings, side panels and boards. Profiled cutting products can also be used for mattresses, * * * * * * 1í É 'i »mattress cushions, cushions, furniture cushions, filters, sports equipment, footwear components and packaging The above list is intended to be representative and not exhaustive as to all Possible Applications for the Invention While the preferred embodiments of the invention have been described and illustrated herein, various changes, substitutions and modifications to the embodiments described will therefore be apparent to those skilled in the art without departing from the scope and spirit of the invention. the invention.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention. i ^ ???????????????

Claims

CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A method for forming a cellulosic polymeric material by cutting portions of a surface of the material, characterized in that it comprises: establishing a predetermined pitch between a compression roller and a cooperating surface; interposing at the predetermined pitch between the compression roller and the cooperating surface a movable continuous patterned platform defining at least one cavity; continuously feeding a plate of cellulosic polymeric material through the passage between the compression roller and the cooperating surface and compressing the plate while a surface of the plate is adjacent to the movable continuous patterned platform in such a way that at least one cavity is substantially filled by a portion of the cellulosic polymeric material when the plate is compressed as it passes through the passage between the compression roller and the cooperant surface; and cutting transversely from the plate at least a fraction of the portion of the received cellulosic material within the cavity of the patterned platform with a sheet, as the plate emerges from the passage between the compression roll and the engaging surface,. 2. The method according to claim 1, characterized in that the cooperating surface is a control roll. 3. The method according to claim 1, characterized in that the patterned platform is a continuous flexible belt. 4. The method of compliance with the claim 1, characterized in that the polymeric cellulosic material is passed through a step that progressively narrows before being compressed in the predetermined step. The method according to claim 4, characterized in that the progressively tapered passage is formed between a belt and the platform, wherein the belt travels along a path defined by a series of tension rollers spaced apart from the platform at variable distances. 6. The method of compliance with the claim 5, characterized in that the belt is driven by the compression roller. The method according to claim 1, characterized in that the compression roller and the moving continuous patterned platform are driven, and wherein the compression roller moves at a surface speed different from the speed at which the roller moves. mobile continuous modeled platform. 8. A method for forming a cellulosic polymeric material by cutting portions of a surface of the material, characterized in that it comprises: establishing a predetermined pitch between a compression roller and a cooperating surface; interposing in the passage between the compression roller and the cooperating surface a continuous patterned platform having an external surface from which at least one projection extends; feeding a plate of polymeric cellulosic material through the passage between the compression roller and the cooperating surface and compressing the plate while a surface of the plate is adjacent to the movable continuous patterned platform in such a way that at least one projection acts on a portion of the polymeric cellulosic material when the plate is compressed as it passes through the passage between the compression roller and the cooperant surface; and transversely cutting the cellulosic material of the plate with a sheet as the plate emerges from the passage between the compression roller and the cooperating surface, without cut the portion of the cellulosic polymeric material worked by the projection. The method according to claim 8, characterized in that the cooperating surface is a control roller. The method according to claim 8, characterized in that the patterned platform is a continuous flexible belt. 11. The method according to claim 10, characterized in that at least one outer surface of the flexible belt defines a plurality of projections. The method according to claim 8, characterized in that the patterned platform is formed of a series of panels. The method according to claim 8, characterized in that the compression roller and the continuous patterned platform are driven and wherein the compression roller is moved to have a surface velocity different from the surface velocity of the continuous patterned platform. . The method according to claim 8, characterized in that the continuous patterned platform further defines at least one cavity. 15. An apparatus for forming a plate of polymeric cellulosic material by cutting and removing portions of the material from an outer surface of the plate, characterized in that it comprises: a compression roller and a cooperating surface, the compression roller rotates on an axis and has its surface outer spaced apart from the cooperating surface to define a predetermined pitch therebetween such that the roller exerts a compressive force against the plate of the cellulosic polymeric material as the plate passes through the passage between the compression roller and the engaging surface; a continuous driven patterned platform having an external surface interposed in the predetermined passage between the compression roller and the cooperating surface and movable relative thereto, the outer surface of the patterned platform defines at least one cavity for receiving a portion of the polymeric cellulosic material when a region of the plate passes through the passage and is compressed between the compression roller and the cooperating surface; and a sheet for cutting the cellulosic polymeric material as the plate emerges from the predetermined passage between the compression roller and the cooperating surface, the sheet is placed in closely adjacent relation - '* - iiá? ^ J? ^ ?. -.... «- *, .. tafc ^^^ atiiiAil.ti '^ j ^ fa | a *? To > substantially tangential to the outer surface of the patterned platform to cut a portion of the received cellulosic material into the cavity of the patterned platform of the plate. 16. The apparatus according to claim 15, characterized in that the cooperating surface is a control roller. 17. The apparatus according to claim 15, characterized in that the patterned platform is a continuous flexible belt. 18. The apparatus according to claim 15, characterized in that a motor drives the control roller and this causes the platform to travel at a speed synchronized with the speed at which the external surface of the control roller moves. The apparatus according to claim 15, characterized in that a motor drives the control roller and this causes the platform to travel at a speed different from the speed at which the outer surface of the compression roller moves. The apparatus according to claim 15, characterized in that it comprises: at least one follower roller; and a belt that travels in a circuit defined by the compression roller and the follower roller and interposed between the compression roller and the outer surface of the patterned platform, and wherein the follower roller is placed upstream of the predetermined step for: compressing the plate of cellulosic polymeric material between the belt and the movable patterned platform before entering the predetermined step . The apparatus according to claim 20, characterized in that the belt is driven by a control roller defining a cooperating surface, and wherein the belt travels along a path defined by a series of tension rollers spaced apart of the platform at varying distances. 22. An apparatus for forming a continuously fed plate of cellulosic polymeric material by cutting and removing portions of the material from an outer surface of the plate, characterized in that it comprises: a compression roller and a cooperating surface, the compression roller rotates on an axis and has its outer surface spaced apart from the cooperating surface to define a predetermined pitch therebetween such that the roller exerts a compressive force against the plate of polymeric cellulosic material as the plate is continuously fed through the plate. predetermined pitch between the compression roller and the engaging surface; a continuous shaped patterned platform having an external surface interposed in the passage between the compression roller and the cooperating surface and movable relative thereto, the outer surface of the patterned platform has at least one projection extending therefrom to act on a portion of the cellulosic polymeric material when the plate is compressed as it passes through the predetermined passage between the compression roller and the cooperating surface; and a sheet for cutting the cellulosic polymeric material as the plate emerges from the predetermined passage between the compression roller and the cooperating surface, the sheet placed in closely adjacent relation substantially tangential to the outer surface of the patterned platform to cut a portion of the cellulosic material of the plate without substantially cutting the portion of the cellulosic material worked by the projection. 23. The apparatus according to claim 22, characterized in that the patterned platform is a continuous belt. 24. The apparatus according to claim 23, characterized in that a plurality of Projections extend from the outer surface of the continuous belt. 25. The apparatus according to claim 22, characterized in that a motor drives the control roller and this causes the platform to travel at a speed synchronized with the speed at which the external surface of the control roller moves. 26. The apparatus according to claim 22, characterized in that a motor drives the control roller and this causes the platform to travel at a speed different from the speed at which the external surface of the compression roller moves. RESOLUTION OF THE INVENTION An apparatus and method is described for forming a plate of cellulosic or compressible polymeric material (80), such as polyurethane foam, which cuts portions of the material from a surface of the plate. A movable patterned platform (32), preferably a continuous belt or a series of interconnected panels, is interposed at a predetermined pitch formed between a compression roller (56) and a control roller (18) and defines at least one cavity (36). ) or at least one projection (320) or a combination of cavities and projections. When the plate is compressed between the compression roller and the platform, a portion of material fills the cavity or cavities in the movable platform. At least a portion of the compressed material within the cavity (s) is then cut from the surface of the plate by a sheet (76) just as the plate emerges from between the compression roller and the platform, leaving a profiled cutting surface with sliced portions corresponding in pattern and shape to the cavity (s) provided in the mobile patterned platform. Alternatively, a portion of the material is forced from the sheet (76) by the projection (320) so that a portion of the compressed material is not cut by the