Blank forming device

Abstract

1. A profiled press plate for forming a blank from two or more layers of sheet-like material in a platen press, comprising: a profiled press plate including a first profiled portion on a surface thereof, the first profiled portion configured to compress the two or more layers of sheet-like material to form a seal about at least a portion of a periphery of the blank; the plate portion further comprising a second profiled portion on a surface thereof, the second profiled portion located inwardly of the first profiled portion and configured to compress the two or more layers of sheet-like material to form a fold line; the profiled press plate including one or more inlets in fluid communication with a source of fluid and one or more outlets in fluid communication with the one or more inlets via fluid flow paths in the first profiled portion and / or the second profiled portion, wherein flow of fluid through the fluid flow paths is configured to change a temperature of the first profiled portion and / or the second profiled portion.

Description

[Technical field]

[0001] The present invention relates to a blank forming apparatus, and more particularly to an apparatus for forming a blank using a platen press. [Background technology]

[0002] Presses having multiple moving platens are commonly used for converting sheet-like materials such as rubber, plastics, paper, wood products, etc. In some types of platen presses, the platens are heated during the converting cycle.

[0003] In platen presses used to manufacture laminate materials consisting of multiple layers, the heating of the layers with the heated platens can cause air or other gases trapped between the layers (or within the layers, if a foam material is used) to expand. This can cause bubbles to form in the surface layers of the laminate material, which are not only unsightly but can also compromise the performance and durability of the laminate material.

[0004] In some manufacturing processes, materials that have been formed using a platen press (e.g., laminate materials) need to be moved between different types of presses. For example, some materials may move from a heated platen press to a cooled platen press, or to another manufacturing process. Currently, there are inefficiencies in moving materials into and out of platen presses (especially multi-stage presses), which increases manufacturing costs and time.

[0005] It would therefore be advantageous to provide an apparatus for a platen press that can reduce or eliminate bubble formation in the laminate material. Additionally, it would be advantageous to provide an apparatus for a platen press that improves the efficiency with which material is transferred to, from, or between platen presses (such as multi-stage presses) to reduce manufacturing costs and / or time.

[0006] It should be expressly understood that where a prior art document is referenced, the act of referring to it is not an admission in Australia or any other country that that document forms part of the public general knowledge in the art. Summary of the Invention [Problem to be solved by the invention]

[0007] Embodiments of the present invention provide methods and apparatus for forming blanks that may at least partially address one or more of the problems or deficiencies discussed above, or may provide the public with a useful or commercial option. [Means for solving the problem]

[0008]

[0010] With the above in mind, in a first aspect the invention broadly relates to a profiled press plate for forming a blank from two or more layers of sheet-like material in a platen press, the profiled press plate comprising a plate portion having a first profiled portion on a surface thereof, the first profiled portion configured to compress the two or more layers of sheet-like material to form a seal about at least a portion of a periphery of the blank, the plate portion further having a second profiled portion on a surface thereof, the second profiled portion being located inwardly of the first profiled portion and configured to compress the two or more layers of sheet-like material to form a fold line, the profiled press plate comprising one or more inlets in fluid communication with a source of fluid and one or more outlets in fluid communication with the one or more inlets via fluid flow paths in the first and / or second profiled portions, wherein flow of fluid through the fluid flow paths is configured to change the temperature and / or pressure of the first and / or second profiled portions.

[0009] The profiled press plate may be of any suitable type. However, in a preferred embodiment of the present invention, the profiled press plate may be heated via a pressure platen or other heat source. It should be understood that platen heating is conventional and requires no further explanation.

[0010] The profiled press plate may be of any suitable size and shape. Typically, however, the profiled press plate is substantially rectangular. It will be appreciated that the size of the profiled press plate will depend on the size of the blank being produced, and the thickness and width of the contact surface of the profiled press plate may vary depending on the nature of the blank being produced.

[0011] The profiled press plate may be made from any suitable material. Preferably, however, the platen is at least partially made from a metal or combination of metals. In a preferred embodiment of the invention, the profiled press plate may be at least partially made from aluminum.

[0012] In a preferred embodiment of the invention, the profiled press plate may include a substantially planar surface from which a first profiled portion and a second profiled portion extend. Preferably, the first profiled portion and the second profiled portion extend outwardly from the planar surface of the platen. In one embodiment of the invention, the first profiled portion and / or the second profiled portion may extend at a substantially perpendicular angle from the substantially planar surface.

[0013] The first profiled portion may be of any suitable shape. As previously described, the first profiled portion is configured to compress two or more layers of sheet-like material to form a pre-compressed region therebetween about at least a portion of the periphery of the blank. The first profiled portion may be located at or near the periphery of the substantially planar surface of the platen. As an alternative, the first profiled portion may be spaced inwardly from the periphery of the substantially planar surface of the platen along at least a portion of its length.

[0014] In some embodiments of the invention, the blank may be provided in the form of a regular polygon. In those embodiments, the shape of the first profile portion may also be in the form of a regular polygon. However, as an alternative, the periphery of the blank may be in the form of an irregular polygon. Thus, in this embodiment, the shape of the first profile portion may also be in the form of an irregular polygon. Thus, a portion of the first profile portion may be oriented differently than other portions of the first profile portion. Furthermore, a portion of the first profile portion may be spaced a different distance from the periphery of the substantially planar surface of the platen than other portions of the first profile portion.

[0015] In a preferred embodiment of the invention, the first profile portion may extend about substantially the entire periphery of the blank, thus forming a pre-compression about substantially the entire periphery of the blank.

[0016] The first profile portion may comprise one or more first profile members associated with each other to form the first profile portion in the shape of the periphery of the blank. It should be understood that any suitable number of first profile members may be provided, and the number of first profile members and their orientation relative to each other may be determined by the desired shape of the periphery of the blank to be manufactured.

[0017] In embodiments of the invention in which two or more first profile members are provided, the first profile members may be associated with one another using any suitable technique. For example, the first profile portion may be formed as a unitary structure. In other embodiments, the two or more first profile members may be formed separately from one another and configured to be fixedly or removably connected to one another. In a preferred embodiment, the two or more first profile members may be configured to be fixedly connected to one another, such as by welding.

[0018] The first profile portion may be connected to the substantially planar surface of the platen using any suitable technique. For example, the first profile portion may be integrally formed with the substantially planar surface of the platen. In other embodiments, the first profile portion may be fabricated separately from the substantially planar surface of the platen and configured to be fixedly or removably connected thereto. The first profile portion may be connected to the platen using any suitable technique, such as using one or more mechanical fasteners, adhesives, or welding or similar processes.

[0019] It should be appreciated that at least a portion of the first profiled portion may be spaced inwardly from a perimeter of the substantially planar surface of the platen. In this embodiment, the sheet of material may have an area greater than an area of ​​the blank formed by the platen such that the perimeter of the blank is spaced inwardly from the perimeter of the sheet of material. In such a situation, it is contemplated that the blank formed by the platen may be cut, punched, or otherwise removed from the sheet of material.

[0020] In some embodiments of the invention, the first profiled portion may extend outwardly from the substantially planar surface of the platen the same distance as the second profiled portion. In other embodiments, the first profiled portion may extend outwardly from the substantially planar surface of the platen a greater distance than the second profiled portion. In this embodiment, when the platen engages the sheet-like material to form the blank, the first profiled portion engages the sheet-like material before the second profiled portion, thereby allowing additional compression of the sheet-like material (and thus improved formation of the pre-compressed region) by the first profiled portion.

[0021] In embodiments of the invention in which the platen is heated, it is believed that the formation of a pre-compressed region by the first profile portion adjacent at least a portion of the blank may be achieved by a combination of the pressure applied by the first profile portion to the sheet material and the relatively high temperature of the first profile portion.

[0022] The second profile portion may be of any suitable size, shape, or configuration. As previously discussed, the second profile portion is configured to compress two or more layers of sheet-like material to form fold lines. Thus, the second profile portion may comprise one or more second profile members configured to form fold lines at desired locations on the sheet-like material. It should be understood that any suitable number of second profile members may be provided, with the quantity of the second profile members and their orientation relative to one another being determined by the number and locations of fold lines to be formed in the sheet-like material.

[0023] In embodiments of the invention in which two or more second profile members are provided, the second profile members may be associated with one another using any suitable technique. For example, the second profile portions may be formed as a unitary structure. In other embodiments, the two or more second profile members may be formed separately from one another and configured to be fixedly or removably connected to one another. In a preferred embodiment, the two or more second profile members may be configured to be fixedly connected to one another, such as by welding.

[0024] The second profile portion may be connected to the substantially planar surface of the platen using any suitable technique. For example, the second profile portion may be integrally formed with the substantially planar surface of the platen. In other embodiments, the second profile portion may be made separately from the substantially planar surface of the platen and configured to be fixedly or removably connected thereto. The second profile portion may be connected to the platen using any suitable technique, such as using one or more mechanical fasteners, adhesives, or welding or a similar process.

[0025] In other embodiments of the invention, the second profile part may be connected to the first profile part. The second profile part may be integrally formed with the first profile part or may be formed separately therefrom and configured to be fixedly or removably connected thereto using any suitable technique (e.g., by one or more mechanical fasteners, adhesives, or welding, or a similar process). It is therefore contemplated that at least a portion of the second profile part may be arranged to abut against the first profile part.

[0026] In a preferred embodiment, the first and second profile members may be configured to be fixedly connected to one another by cutting a profile from, for example, a sheet of material. This profile, sometimes referred to as a "profiled press plate", may be attached to the platen as a separate unit.

[0027] As mentioned above, the second profiled portion is located inside the first profiled portion, meaning that the second profiled portion is located closer to the center of the substantially planar surface of the platen than the first profiled portion. In this way, the first profiled portion is configured to define a periphery of the blank and the second profiled portion is configured to form a fold line inside the periphery of the blank of sheet-like material.

[0028] In embodiments of the invention in which the platen is heated, it is believed that the formation of fold lines by the second profile portion may be achieved by a combination of pressure applied to the sheet material by the second profile portion and heat transferred by the relatively high temperature of the second profile portion.

[0029] As previously mentioned, the profiled press plate includes one or more inlets in fluid communication with a source of fluid. The inlet or inlets may be in any suitable form, and the exact nature of the inlet or inlets is not critical to the invention. The source of fluid may be in any suitable form, such as a reservoir, bottle (including gas cylinder), tank, blower, etc. The inlet or inlets may be provided in the first profile section, the second section, or both.

[0030] The fluid may be a liquid or a gas, however, in a preferred embodiment of the invention, the liquid may be a gas. Any suitable gas may be used, however, in a preferred embodiment of the invention, the gas may be air. In a specific embodiment of the invention, the gas may be compressed air.

[0031] The fluid flow passages of the first and / or second profile portions may be in any suitable form. In some embodiments of the invention, the fluid flow passages may extend through all portions of the first and / or second profile portions. In other embodiments, the fluid flow passages may extend through only a portion of the first and / or only a portion of the second profile portions.

[0032] Preferably, the fluid flow path may be formed inside the first profile portion and / or the second profile portion. In this embodiment of the invention, it is considered that at least a part of the first profile member forming the first profile portion and / or the one or more second profile members forming the second profile portion may be substantially hollow. In this embodiment, the hollow interior of the first profile member and / or the one or more second profile members may form the fluid flow path.

[0033] The fluid flow path may be substantially linear from the inlet(s) to the outlet(s). Alternatively, the fluid flow path may have a tortuous path. In some embodiments of the invention, the fluid flow path may include one or more closure members therein. In this embodiment, it is contemplated that the closure member(s) may be opened or closed to allow or prevent fluid flow therethrough. Thus, it is contemplated that the length and path of the fluid flow path may be altered depending on the desired outcome. The closure member(s) may be of any suitable form and may include one or more gates, valves, and the like.

[0034] The outlet(s) may be of any suitable form, and the exact nature of the outlet(s) is not critical to the invention. The outlet(s) may be located in the first profile portion, the second profile portion, or both. In some embodiments of the invention, the fluid exiting the first profile portion and / or the second profile portion through the outlet(s) may be captured in a container (such as a vessel, tank, bottle, etc.). In these embodiments, the fluid may be captured for reuse, repurposing, or disposal. In other embodiments, the fluid may be released to the atmosphere through the outlet(s).

[0035] In a preferred embodiment, the fluid may be contained in the first and / or second profile portions using one or more sealing members. Any suitable sealing member may be used, including, but not limited to, one or more backing plates and / or seals.

[0036] In a preferred embodiment of the invention, the fluid flowing through the fluid flow passages is at a relatively low temperature compared to the temperature of the profiled press plate. Furthermore, the flow rate of the fluid into and out of the profiled press plate may be controlled. In this way, the fluid may be used to cool the portion of the first and / or second profiled section in which the fluid flow passages are located. Furthermore, it is believed that the flow of fluid through the fluid flow passages may create additional pressure on the sheet-like material during the formation of the blank. It is believed that the supply of fluid at a pressure above atmospheric pressure to the fluid flow passages may inhibit the formation of air bubbles in the sheet-like material during the formation of the blank. The backing sheet may be attached to the profiled press plate using a gasket material to form an airtight seal as the profiled press plate presses the sheet-like material (such as a laminated foam sheet) during the press compression cycle. It is believed that the attachment of the gasket material to the profiled press plate may form one or more sealed areas in the sheet-like material, the one or more sealed areas being delimited by at least a portion of the first and / or second profiled sections. Preferably, the sheet-like material may be pressurized and / or cooled by the fluid. More specifically, one or more regions of the sheet material bounded by the first and / or second profile sections (such as, but not limited to, one or more sealed portions) may be pressurized and / or cooled by a fluid. Preferably, each of the first and second profile sections is pressurized by a flow of fluid through an inlet. It is believed that generating a relatively high pressure (particularly a pressure greater than atmospheric pressure) in the sealed area or areas may help reduce or eliminate the formation of air bubbles in the sheet material in the sealed area or areas.

[0037] In a preferred embodiment of the invention, the inclusion of a low thermal conductivity material (such as made from polyoxybenzyl methylene glycol anhydride (commonly known as Bakelite) or similar) between the profiles that is secured to the backing plate of the profiled press plate may provide a heat shield to the material being processed and may help the fluid flowing through the fluid flow passages to remain relatively cool compared to the temperature of the heated platens. It is believed that the combination of heat shielding and fluid cooling may further reduce or eliminate the formation of air bubbles in the sheet material between the profiled sections.

[0038] Preferably, the selective cooling of the first and / or second profile portions and / or the additional pressure (i.e. pressure above atmospheric pressure) generated by the fluid (particularly if the fluid is a pressurized fluid) may result in reduced delamination of the layers of sheet-like material within the blank as well as reduced formation of air bubbles on the surface of the formed blank. Thus, the present invention provides significant advantages.

[0039] In a second aspect, the invention broadly relates to a transport mechanism for a platen press comprising a first connecting member pivotally coupled to a first platen at a first end and at an opposing second end to a base member, a second connecting member pivotally coupled to the second platen at the first end and at an opposing second end to the base member, and a transport member associated with and movable relative to the base member, the transport member further associated with a material transport member configured to transport one or more sheet-like materials thereon, movement of the transport member relative to the base member moving the material transport member between an engaged state in which the material transport member is substantially located between the first and second platens and a released state in which the material transport member is moved away from the first and second platens.

[0040] The platen press may be of any suitable form. Preferably, however, the platen press comprises a first platen and a second platen that are brought into proximity to form the product. Examples of this include multi-stage presses comprising multiple platens. It is contemplated that the product is made from one or more sheets of material conveyed by a material conveying member. In these embodiments, it is contemplated that the first and second platens (and further platens, if present) may, in use, apply heat and / or pressure to the one or more sheets of material to form the product.

[0041] In some embodiments of the invention, the first and second platens may be conventional, while in other embodiments the first and / or second platen may be or include the profiled press plate of the first aspect of the invention.

[0042] The first connecting member may be of any suitable form. However, preferably, the first connecting member may be of a type that allows the first connecting member to pivot relative to the first platen. In a preferred embodiment of the invention, the first connecting member may also be pivotally connected to the base member. In some embodiments of the invention, the first connecting member may comprise a pivot joint or a ball joint. More preferably, however, the first connecting member may comprise a rod end bearing (also called a Heim joint or rose joint). In some embodiments, these may be connected by a jack screw. More specifically, the first connecting member may comprise a rod end bearing connected to the first platen and a shaft extending from the rod end bearing to the base member, which may further support a shaft associated with the linear bearing carriage.

[0043] The second connecting member may be of any suitable form. However, preferably, the second connecting member may be of a type that allows the second connecting member to pivot relative to the first platen. In a preferred embodiment of the invention, the second connecting member may also be pivotally connected to the base member. In some embodiments of the invention, the second connecting member may comprise a pivot joint or a ball joint. More preferably, however, the second connecting member may comprise a rod end bearing (also called a Heim joint or rose joint). In some embodiments, these may be connected by a jack screw. More specifically, the second connecting member may comprise a rod end bearing connected to the second platen and a shaft extending from the rod end bearing to the base member, which may further support a shaft associated with the linear bearing carriage.

[0044] It is contemplated that the first and second connecting members may pivot simultaneously. Preferably, the first and second connecting members may pivot simultaneously in opposite directions. Preferably, when the first and second connecting members pivot in a first opposite direction, the first and second platen members may abut or at least be relatively close to each other. When the first and second connecting members pivot in a second opposite direction, the first and second platen members may move away from each other.

[0045] In a preferred embodiment of the invention, the first connecting member may also be pivotally connected to the base member. In some embodiments of the invention, the first connecting member may comprise a pivot joint or a ball joint. More preferably, however, the first connecting member may comprise a rod end bearing (also known as a Heim joint or a rose joint). More specifically, the first connecting member may comprise a rod end bearing connected to the first platen and an adjustable linkage (preferably a left and right jack screw) extending from the rod end bearing to the second connecting member and supporting the linear bearing carriage via the base member. The linear bearing carriage may support a shaft that may be connected and supported by another set of first and second connecting members and associated bearing carriage members as previously described. For example, the first and second sets of rod end bearing connections in the base member may connect to a bearing block supporting a horizontal shaft with an end mounting plate connected to a support bracket, or a portion thereof, that is connected to the material transfer plate via a bearing channel. The support brackets may be fitted with additional horizontal bearing blocks for supporting the drive shafts etc., and additional vertical bearing blocks on either end of the transfer plate to maintain lateral positioning relative to the pressure platen and attached profiling press platen. The drive shaft or shafts may be provided with a circular gear such as a pinion at their ends which may engage a drive rack, allowing the material transfer plate to extend fully outwardly on either side of the platen press under control using any suitable technique.

[0046] The transfer member may be of any suitable form and may be associated with the base member in any suitable manner. For example, the transfer member may move telescopically relative to the base member. Similarly, the transfer member may be configured for pivotal, hinged or rotational movement relative to the base member.

[0047] More preferably, however, the transfer member may be configured for sliding or ratcheting movement relative to the base member.Preferably, the transfer member may move substantially linearly between the engaged and released states.

[0048] In embodiments of the invention in which the transfer member moves substantially linearly relative to the base member, it is contemplated that the transfer member may comprise one or more bearing channels and one or more bearing carriages. In these embodiments, the base member may comprise the bearing channel and the transfer member may pass at least partially through the base member. In certain embodiments of the invention, the base member may comprise a bearing channel through which the bearing carriages may exit from either end thereof. In this embodiment, the transfer member may have a substantially square cross-sectional shape.

[0049] In a preferred embodiment, movement of the transfer member to the engaged state may actuate movement of the first and second platens towards one another, and similarly, movement of the transfer member to the released state may actuate movement of the first and second platens away from one another.

[0050] Movement of the transfer member may actuate movement of the underlying and upper platens in any suitable manner (particularly in a multi-stage press), for example, the transfer member may include one or more actuating members that interact with a bearing channel, a bearing carriage, and / or a rack and pinion drive.

[0051] The material transport member may be of any suitable form. However, as discussed above, the material transport member is configured to transport one or more sheets of material thereon. It is contemplated that when the material transport member is in use, the one or more sheets of material may be used to form a product in a platen press. In use, it is contemplated that a first platen and a second platen may be brought into contact with opposing surfaces of the material transport member, thereby compressing the one or more sheets of material therebetween to form a product.

[0052] In preferred embodiments of the invention, the material transport member may be provided in the form of a plate-like member having opposing first and second substantially planar surfaces. In some embodiments of the invention, one or more sheets of material may be transported to each of the first and second surfaces of the material transport member. In this manner, two products may be formed simultaneously with the platen press in use. A first product is formed between the first platen and the first surface of the material transport member, and a second product is formed between the second platen and the second surface of the material transport member.

[0053] The sheet or sheets of material may be retained on the material transport member as it moves from the released state to the used state (and vice versa) using any suitable technique, for example, one or more mechanical fasteners (clips, pins, etc.) may be provided to retain each sheet of sheet-like material on the material transport member.

[0054] In some embodiments of the invention, the first and / or second surface of the material conveying member may include one or more openings therein. In this embodiment, the suction force through the one or more openings may be obtained using any suitable technique. For example, it is contemplated that the material conveying member may be associated with one or more suction devices configured to draw air into the material conveying member through the one or more openings, thereby creating a suction force that holds the sheet or sheets of material in contact with the material conveying member. Any suitable suction device may be used, such as a pump, a vacuum generator, or the like.

[0055] It is contemplated that in the released state, one or more sheets of material may be placed on the material transport member. The material transport member is then moved to an engaged state in which the material transport member is located between the first and second platens (preferably substantially centered between the first and second platens) and pressure is applied by the first and / or second platens to the one or more sheets of material located on the first and / or second sides of the material transport member to form a product. Once the product has been formed, the material transport member may be returned to the released state.

[0056] In some embodiments, a single material transport member may be associated with the platen press, in which embodiment it is contemplated that the product or products formed in the platen press may be removed from the material transport member in a released state and a new sheet of sheet-like material may be placed on the material transport member before the material transport member is returned to use.

[0057] It is contemplated that in some embodiments of the invention, a multiple platen press may be provided in a stacked configuration (such as a multi-stage press). In this embodiment, one or more additional platens may be disposed on either side of the first and / or second platen. In this embodiment, each platen in the stack (except for the platens at the outer ends of the stack) may be double-sided. It is contemplated that a material transport member may be moved into service between each adjacent platen so that multiple products may be formed simultaneously.

[0058] In some embodiments, the first connecting member, the second connecting member, the base member, and the transfer member may be associated with each material transport member associated with the stack. In other embodiments, the first connecting member, the second connecting member, the base member, and the transfer member may be associated with a portion of the platens in the stack. In further embodiments, the first connecting member, the second connecting member, the base member, and the transfer member may be associated with a set of platens in the stack.

[0059] In a third aspect, the invention relates to a material transport member for use in a platen press, the material transport member comprising a first substantially planar surface and an opposing second substantially planar surface, each of the first and second substantially planar surfaces configured to transport one or more sheet-like materials thereon, the material transport member comprising one or more openings in each of the first and second substantially planar surfaces, and a suction force configured to be applied to the material transport member, the suction force being configured to draw air into the material transport member through the one or more openings such that the one or more sheet-like materials are retained on the first and second substantially planar surfaces.

[0060] It is contemplated that in some embodiments, the first substantially planar surface and / or the second substantially planar surface of the material conveying member may be configured to convey sheets of composite materials, such as aluminum, silicone rubber, and PTFE tape, to improve pre-compression and fold line performance.

[0061] It is contemplated that in some embodiments of the present invention, an aluminum profile may be attached over the silicone rubber to limit heat loss from the heated profiled press plate to the material handling members.

[0062] In another embodiment of the present invention, it is contemplated that an additional heat source (such as, but not limited to, an impulse heating band) may be attached to the aluminum profile to facilitate higher levels of pre-compression and shorter cycle times.

[0063] In a fourth aspect, the invention relates to a blank formed using the profiled press plate of the first aspect.

[0064] Any feature described herein may be combined in any combination with one or more other features described herein within the scope of the present invention.

[0065] The reference to prior art in this specification is not, and should not be construed as, an acknowledgment or in any way an indication that the prior art forms part of the common general knowledge. [Brief description of the drawings]

[0066] Preferred features, embodiments and variations of the present invention may be understood from the following detailed description, which provides sufficient information for those skilled in the art to practice the invention. The detailed description should not be construed as limiting the scope of the foregoing summary in any manner. In the detailed description, reference is made to several drawings, in which: [Figure 1] FIG. 2 is a detailed view of a blank formed by a prior art process. [Diagram 2] 1 illustrates a profiled press plate according to one embodiment of the present invention. [Diagram 3] FIG. 2 is a detailed view of a profiled press plate according to one embodiment of the present invention. [Figure 4] 1 illustrates a blank formed using a profiled press plate according to one embodiment of the present invention. [Diagram 5] 1 illustrates a profiled press plate according to one embodiment of the present invention. [Figure 6] 1 illustrates a material transport member according to one embodiment of the present invention. [Figure 7] 1 illustrates a transport mechanism for a platen press according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] 1 is a detailed view of a sheet of material 1 formed by a prior art process. In this view, it may be seen that air bubbles 2 may form near the pre-compressed areas 3 of the sheet of material 1. These air bubbles 2 are not only unsightly, but may also reduce the useful life and / or performance of products formed from the sheet of material 1.

[0068] 2 illustrates a profiled press plate 10 according to one embodiment of the present invention. The profiled press plate 10 includes a plate portion 11 having a first profiled portion 12 configured to compress two or more layers of sheet-like material to form a seal about at least a portion of a peripheral edge of a blank, the plate portion 11 further including a second profiled portion 13 on a surface thereof, the second profiled portion 13 being located inwardly of the first profiled portion 12 and configured to compress two or more layers of sheet-like material to form a fold line. The profiled press plate 10 includes a plurality of inlets 14 in fluid communication with a source of fluid (not shown) and one or more outlets (not shown) in fluid communication with the one or more inlets 14 via fluid flow paths (not explicitly shown) in the first profiled portion 12 and / or the second profiled portion 13.

[0069] The profiled press plate 10 is made from aluminium. It can be seen that the first profile portion 12 extends substantially about the periphery of the plate portion 11 and the second profile portion 13 includes a plurality of second profile portion members located inwardly of the periphery of the plate portion 11 defined by the first profile portion 12.

[0070] Fluid entering the first profiled section 12 and the second profiled section 13 causes the fluid pressure in the fluid flow passages (not explicitly shown) to be greater than atmospheric pressure. In this manner, delamination of layers of sheet material (not shown) within the blank (not shown) may be reduced, as well as the formation of air bubbles on the surface of the formed blank (not shown).

[0071] 3 is a detailed view of a profiled press plate 10 according to one embodiment of the present invention. The profiled press plate 10 is the same as that shown in FIG.

[0072] In Figure 3, the first profiled portion 12 is used to form a pre-compressed region in a sheet-like material (not shown) and the second profiled portion 13 is used to form a fold line in the sheet-like material (not shown). It can be seen that the second profiled portion 13 includes a contact surface 16 which, in use, is placed in abutment with the sheet-like material (not shown). The width of the contact surface 16 may vary depending on the design of the blank being formed and the thickness of the sheet-like material used to form the blank.

[0073] In FIG. 3 the inlet 14 of the second profile section 13 is more clearly visible.

[0074] 4 shows a blank 17 formed using a profiled press plate according to one embodiment of the present invention. It can be seen that the blank 17 includes a pre-compressed area 18 near its periphery, which is formed by a first profiled portion of the profiled press plate. The blank 17 further includes a fold line 19, which is formed by a second profiled portion of the profiled press plate.

[0075] It will be noted that during the manufacture of the blank 17, no air bubbles are formed on its surface, this is due to the heat and / or the higher than atmospheric pressure of the fluid in the fluid passages of the first and / or second profiled parts of the profiled press plate.

[0076] Figure 5 illustrates a profiled press plate 10 according to one embodiment of the present invention. The profiled press plate 10 of Figure 5 is similar to that shown in Figure 2, except that a number of mounting members 20 are attached to the profiled press plate 10 of Figure 5. Thus, the profiled press plate 10 of Figure 5 is configured to be attached to a platen (not shown).

[0077] In Figure 5, a material 21 having a relatively low thermal conductivity is applied to the plate portion 11 of the profiled press plate 10. The material 21 is applied to the plate portion 11 between the members of the first profile portion 12 and the second profile portion 13. The use of the material 21 provides heat insulation to the sheet material (not shown) used to form the blank. In this embodiment of the invention, the material 21 is polyoxybenzyl methylene glycol anhydride (commonly known as Bakelite) provided in the form of a sheet material or fabric.

[0078] Figure 6 illustrates a material transport member 22 according to one embodiment of the present invention. The material transport member 22 comprises a first substantially planar surface 23 and an opposite second substantially planar surface (not expressly shown), each of the first substantially planar surface 23 and the second substantially planar surface (not expressly shown) configured to transport one or more sheets of material (not shown) thereon.

[0079] The material transport member 22 further includes openings (not shown) disposed on each of the first substantially planar surface 23 and the second substantially planar surface (not expressly shown). Suction is applied to the material transport member 22 through the one or more openings such that air is drawn into the material transport member 22 through the one or more openings (not shown) to retain one or more sheets of material on the first substantially planar surface 23 and the second substantially planar surface (not expressly shown).

[0080] In the embodiment of the invention shown in Figure 6, a base layer 24 is provided comprising a silicone sheet on a planar surface (not explicitly shown) and is configured to provide a substantially planar surface against which a sheet of material is pressed. An aluminium profile 25 is attached to a portion of the base layer 24. The profile 25 defines the periphery of the blank to be formed and is configured to provide a pressing surface against which a pre-compressed profile of a profiled press plate (such as the profiled press plate of Figure 2) can apply pressure during formation of the blank.

[0081] 7 shows a transport mechanism 30 for a platen press according to an embodiment of the invention. The transport mechanism 30 comprises a first connecting member 31 pivotally connected at a first end to a first platen 32 and at an opposite second end to a base member 33. The transport mechanism 30 further comprises a second connecting member 34 pivotally connected at a first end to a second platen 35 and at an opposite second end to the base member 33.

[0082] The transport mechanism 30 further includes a transport member 36 associated with the base member 33 and movable relative thereto, which is further associated with a material transport member 22 configured to transport one or more sheet-like materials.

[0083] In use, the transfer member 36 is configured to be movable relative to the base member 33 to move the material transport member 22 between an in-use state (shown in FIG. 7) in which the material transport member 22 is substantially positioned between the first platen 32 and the second platen 35, and a released state in which the material transport member 22 is spaced apart from the first platen 32 and the second platen 35.

[0084] In this specification and the claims (if present), the words "comprise" and its derivatives "including" and "comprising" are inclusive of the appended number but do not exclude a number of one or more.

[0085] References throughout this specification to "one embodiment" or "one embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrase "one embodiment" or "one embodiment" in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner, in one or more combinations.

[0086] In accordance with the statute, the invention has been described in terms more or less specific to structural or methodological features. Since the means described herein include preferred forms for carrying out the invention, it is to be understood that the invention is not limited to the specific forms shown or described. The invention is therefore claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. 1. A profiled press plate for forming a blank from two or more layers of sheet material in a platen press, comprising: a plate portion including a first profiled portion on a surface thereof, the first profiled portion configured to compress the two or more layers of sheet-like material to form a seal about at least a portion of a peripheral edge of the blank, the plate portion further including a second profiled portion on a surface thereof, the second profiled portion being located inwardly of the first profiled portion and configured to compress the two or more layers of sheet-like material to form a fold line; the profiled press plate including one or more inlets in fluid communication with a source of fluid and one or more outlets in fluid communication with the one or more inlets via fluid flow paths in the first profile portion and / or the second profile portion; A flow of fluid through the fluid flow path is configured to change a temperature of the first profile portion and / or the second profile portion. Profiled press plate.

2. one or more regions of the sheet material bounded by the first profiled portion and / or the second profiled portion are pressurized and / or cooled by the fluid.

2. The profiled press plate of claim 1.

3. the plate portion includes a substantially planar surface from which the first profile portion and the second profile portion extend.

3. A profiled press plate according to claim 1 or 2.

4. the first profile portion and / or the second profile portion extend from the substantially planar surface at an angle substantially perpendicular to the substantially planar surface; 4. The profiled press plate of claim 3.

5. the first profile portion is spaced inwardly from a periphery of the substantially planar surface along at least a portion of its length; 5. A profiled press plate according to claim 3 or claim 4.

6. the first profiled portion extends substantially about a periphery of the blank such that the first profiled portion forms a precompressed region about substantially the entire periphery of the blank. A profiled press plate according to any one of the preceding claims.

7. the pre-compressed zone being formed by a combination of pressure applied to the sheet material by the first profiled portion and a relatively high temperature of the first profiled portion; 7. The profiled press plate of claim 6.

8. the first profile portion includes one or more first profile members associated with one another to form the first profile portion in a shape of the periphery of the blank; 8. The profiled press plate of claim 7.

9. the first profile portion extends outwardly from the substantially planar surface of the press plate a greater distance than the second profile portion; 6. Profiled press plate according to any one of claims 3 to 5.

10. the second profile portion includes one or more second profile members configured to form fold lines in the sheet of material; A profiled press plate according to any one of the preceding claims.

11. the second profiled portion is configured to form fold lines in the sheet-like material due to a combination of pressure applied by the second profiled portion to the sheet-like material and a relatively high temperature of the second profiled portion.

11. The profiled press plate of claim 10.

12. the fluid comprises compressed air; A profiled press plate according to any one of the preceding claims.

13. the fluid flow path includes one or more closure members therein, the one or more closure members being configured to open and close to permit or prevent fluid flow therethrough; A profiled press plate according to any one of the preceding claims.

14. the fluid is contained within the first profile portion and / or the second profile portion using one or more sealing members; A profiled press plate according to any one of the preceding claims.

15. A blank formed using a profiled press plate according to any one of claims 1 to 14.

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