LAMINATING DEVICE AND METHOD OF OPERATING SAME

Abstract: A device for forming a composite from a pair of parts with opposed mating surfaces has a base (1) and a support member (11) is mounted on the base. A vertically adjustable head assembly (20) for holding an upper part is located at the lower end of the support and is operatively connected to a drive motor (15) at the upper end of the support member. A vacuum generator generates a negative pressure to hold the upper part on the head member. A support (50) is located below and coaxially with the head assembly for supporting a lower part. The upper and lower parts are laterally aligned and an adhesive is spread over the opposed mating surfaces of the parts.

Description: LAMINATING DEVICE AND METHOD OF OPERATING SAME BACKGROUND OF THE INVENTION ι. Field pf The Invention The invention relates generally to a device for forming a composite by laminating two shaped parts with a curable adhesive film between the mating surfaces of the parts. The adhesive is treated by an appropriate mechanism which causes the adhesive to cure. The method provides for an even distribution of a film of the adhesive over the entire mating surfaces of the parts and for the accurate alignment of the axes of the parts prior to curing the adhesive to form the composite. 2. Description of the Prior Art The formation of a composite eyeglass lens by bonding front and rear lenses together is disclosed in United States Patent No. 5,399,227. That bonding process involves placing an adhesive on the concave surface of the front lens; pressing the convex surface of the rear lens against the adhesive on the front lens to evenly spread the adhesive throughout the gap between the two lenses and permitting the adhesive to set to bond the lenses together. This process forms a composite lens which may be trimmed to fit within an eyeglass frame and which may be further processed if desired. Apparatus for aligning and laminating the upper and lower lenses of a composite eyeglass lens is disclosed in Japanese Patent Application No. Hei 5 [1993] -24872 and in Japanese Patent Application No. Hei 6 [1994] -49600. The apparatus disclosed in these applications includes upper and lower lens retaining members. Each lens is held in its respective retaining member by a vacuum and the retaining members are moveable. The apparatus includes aligning members which move laterally relative to the vertical axes of the lens retaining members to contact the peripheral edges of the lenses to align the axes thereof. Each aligning member has a contact end to contact the peripheral edges of the lenses with a predetermined force. In operation the upper retaining member picks up the lower lens and moves laterally to place the lower lens on the lower retaining member. The lower lens is aligned with the axis of the lower retaining member by the aligning members after which the aligning members are withdrawn and the lower lens is held in place on the lower retaining member by a vacuum. A bonding agent is applied to the center of the lower lens. The upper retaining member picks up the upper lens and aligns it with the axis of the lower lens. The upper lens is then lowered until it touches the bonding agent on the lower lens after which the aligning members continue to move laterally inwardly to contact the peripheral edges of the upper and lower lenses to axially align them. The aligning members are then withdrawn and the upper retaining member is lowered and the composite lens is removed after the bonding agent sets. SUMMARY OF THE INVENTION The laminating device of the present invention is for the lamination of aligned shaped parts and includes a nest member for supporting the bottom surface of a lower part and an upper head assembly for holding the top surface of an upper part. The vertical axes of the nest member and the head assembly are aligned. Both the nest member and the head assembly are subjected to a negative pressure from independent vacuum generators to maintain a part in position in the nest member and on the contact surface of the head member of the head assembly. A puddle of adhesive is placed between the mating surfaces of the parts either manually or by an automatically controlled supply conduit. When the bottom surface of the upper part contacts the adhesive, it is spread over the entire top surface of the lower part and the bottom surface of the upper part as a thin film by capillary action. The aligned parts are held together by the adhesion of the adhesive film and are raised by the upper head assembly after the vacuum at the nest member is terminated. The vacuum at the nest member is provided on the bottom surface of the lower part to prevent premature lifting of the lower part from the nest member by the capillary forces. The lower part and the upper part are laterally adjusted to align the vertical axes of the parts when the parts are held on the head member by a plurality of pneumatic cylinders having radially adjustable contact discs in an alignment fixture. The adhesive is then evenly cured by exposure to an appropriate medium for a predetermined time to bond the parts together to form a composite. After the adhesive is cured, the vacuum at the upper head assembly is terminated and the composite is removed from the upper head for further processing. A non-transparent adhesive may be used for laminating shaped parts which are not lenses. A preferred embodiment of the invention provides an apparatus and a method for laminating shaped lenses to form a composite eyeglass lens having improved optic axis alignment and lens adhesion. It provides an improved method of mounting the upper lens of the composite lens on a holder and aligning the optical axis of the upper lens with the optical axis of the lower lens of the composite lens to assure that consistent and accurate alignment of the optical axes of the individual lens is achieved in the composite lens. It will be understood by those skilled in the art that the invention is applicable to the lamination of transparent lenses having various shapes utilizing a transparent adhesive cured by light rays. The invention is also applicable to the lamination of opaque parts with an adhesive cured by heat. A complete understanding of the invention will be obtained from the following description when taken in connection with the accompanying figures of drawings wherein like reference characters identify like parts throughout. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a side elevation of a laminating device according to the invention; Fig. 2 is a front elevation of the device shown in Fig. 1; Fig. 3 is a plan view of the light box shown in Fig. 2; Fig. 4 is a plan view of the cover plate for the light box shown in Figs. 2 and 3; Fig. 5 is an end view of the shutter shown in Fig. 2; Fig. 6 is a plan view of the alignment fixture shown in Figs. 1 and 2; Fig. 7 is a vertical section through the alignment fixture and the head assembly in the raised position with a shaped composite on the head member; Fig. 8 is a rod with a contact disc thereon for use with the alignment fixture shown in Figs. 6 and 7; Fig. 9 is a plan view of the nest member; Fig. 10 is a partial section on line X-X of Fig. 9; Fig. 11 is a bottom view of the head assembly; Fig. 12 is a section on line XII-XII of Fig. 11; Fig. 13 is a plan view of a flexible shaped ring shown in Fig. 11; Fig. 14 is a section on line XIV-XIV of Fig. 13; Fig. 15 is an end view of a shutter rail and a portion of the shutter shown in Fig. 5; Fig. 16 is a pneumatic control circuit for the laminating device shown in Figs. 1 and 2; and Fig. 17 is a schematic electric circuit for controlling the operation of the elements in the pneumatic circuit in accordance with the desired cycling schedule. DESCRIPTION OF THE PREFERRED EMBODIMENTS With reference to Figs. 1 and 2 of the drawings, the laminating device has an elongated base 1 having a raised central portion 2 and a pair of substantially parallel outer members 3 spaced from the central portion 2. A vertical column 5 extends upwardly from one end of the central portion 2 of the base 1. A substantially horizontal cross member 6 extends at a right angle from the upper end of the column 5. A corner support plate or gusset 7 extends between the upper surface of the raised central portion 2 of the base 1 and the rear of the column 5. The central portion 2, the outer members 3, the column 5 and the member 6 are aluminum extrusions although other constructs may be used for these elements if desired. A mounting plate 10 for a vertical cylinder 11 is fixed to the distal end of the cross member 6 and is substantially parallel to the vertical column 5. The mounting plate 10 is formed with a plurality of spaced holes which receive bolts 12 for collars 13 which hold the cylinder 11 on the mounting plate. A drive motor 15 is mounted on the upper end of the cylinder 11 to rotate a shaft 21 in the cylinder which is connected to a head assembly 20 to raise and lower the head assembly relative to the cylinder. The head assembly is described in detail hereinafter. The cylinder 11 may be a Model ETS 50 electric cylinder manufactured by the Automation Actuator Division of Parker Motion & Control located in Wadsworth, Ohio. It will be understood by those skilled in the art that a fluid cylinder can also be used to raise and lower the head assembly 20. An alignment fixture 30 is located above the base 1 and is supported by spaced support posts 31 which extend upwardly from the upper surfaces of the outer members 3. The alignment fixture 30 includes a substantially horizontal cylindrical table 32 having a circular opening 33 in its center to permit the movement of the head assembly 20 with the composite supported thereon. The details and the operation of the alignment assembly are explained in detail hereinafter in connection with Figs. 6 and 7 of the drawings. In one embodiment of the invention, an elongated light box 40 is supported on the raised central portion 2 of the base 1 as shown in Fig. 2 of the drawings. As shown in Fig. 3 of the drawings, the light box is a U-shaped rectangular box having a bottom member 41 attached to the upper surface of the raised central portion 2 of the base 1; upstanding side walls 42 and upstanding end walls 43. A cover plate 44 is fixed to the upper edges of the side walls 42 and the end walls 43. The cover plate is shown in Fig. 4 of the drawings and has an opening 46 formed therein and a rearward extension 47. The light box 40 contains four 18-inch bulbs 45 which emit light rays to evenly cure the entire adhesive film between the mating surfaces of the parts of the composite. The bulbs are selected so that the light rays emitted therefrom are in the portion of the electromagnetic spectrum which will evenly cure the adhesive to laminate the front and rear parts into a composite. Thus, the selection of the bulbs in the light box is dictated to a large extent by the composition of the specific adhesive which is used. During curing the laminated parts are held on the contact surface S of the head member 27 of the head assembly 20 in the manner described hereinafter. In order to ensure an even distribution of the light rays over the entire lower surface of the lower part during curing, the vertical axis of the opening 46 in the cover plate 44 of the light box 40 is vertically aligned with the vertical axes of the upper and lower parts. The operation of the light box is explained in detail hereinafter. A lower nest member 50 is shown in detail in Figs. 9 and 10 of the drawings and is adjustably supported on the upper surface of the top wall 82 of the shutter 81 of the shutter assembly 80. The nest member 50 has a cylindrical base 51 having an upper annular rim 52 and a central concave upper surface portion 53 within the rim to receive the convex bottom surface of the lower part of a composite. A central axial vacuum passage 54 is formed in the base of the nest member 50. The passage 54 is connected to a radial bore 55 having a connector 56 at its outer end for connection to a conduit 128 which is connected to a vacuum generator 127 as shown in Figs. 16 and 17 of the drawings. A flexible magnetic sheet 57 is attached to the lower surface of the base 51 of the nest member 50. The magnetic sheet permits infinite adjustment of the nest member 50 on the upper surface of the steel top wall 82 of the shutter assembly 80 to facilitate the vertical alignment of the axis of the nest member with the vertical axis of the head assembly 20. Figs. 11 and 12 of the drawings show the head assembly 20 which consists of a T-shaped member having a hollow shank 22 and a base 23 integral with the lower end of the shank. The shank 22 is formed with an axial bore 24 having internal threads 24 ' at the upper end to receive the externally threaded end of the threaded shaft 21 in the cylinder 11. A radial bore 25 is connected with the lower end of the axial bore 24 and a pneumatic connector 26 is located in the outer end of the radial bore 25 for connection with the conduit 125 which is connected to a vacuum generator 123 as shown in Figs. 16 and 17 of the drawings. A head member 27 having a flat rear surface and a central coaxial vacuum chamber 28 is attached to the lower surface of the base 23 by a layer of a Dow-Corning silicone rubber. The head member 27 has a central axial passage 29 which is aligned with the axis of the axial bore 24 and a plurality of outwardly located radially spaced vertical passages 29' surround axial passage 29. The passages 29 and 29' extend between the vacuum chamber 28 and the contact surface S of the head member. A flexible ring member R having an opening with a peripheral shape substantially the same as the peripheral shape of the upper lens to be supported is attached to the contact surfaces of the head member 27 by an appropriate adhesive. The flexible ring member R is made of a rubber or a thin flexible plastic material and is positioned on the contact surface S of the head member 27 so that when a part which has an edge with the same shape as the peripheral shape of the opening in the ring member R is located within the opening in the ring member on the contact surface of the head member 27, the axis of the part is aligned with the axis of the axial bore 24 of the head assembly 20. This assures that the axes of the upper part and the lower part will be properly aligned because the upper part and the lower part have their peripheral edges aligned before the adhesive is cured to form the upper and lower parts of the composite. Such alignment ensures that the axis of the composite is the aligned axes of the upper and lower parts. The contact surface S of the head member 27 interfaces with the upper concave surface of the upper part which is firmly secured thereto by means of a vacuum. The curvature of the contact surface S of the head assembly 20 is substantially the same as the curvature of the concave surface of the upper part. The vacuum is provided at the contact surface S through the pneumatic connector 26; the radial bore 25; the axial bore 24; the vacuum chamber 28 and the passages 29 and 29' which are connected to the vacuum generator 123 by conduit 125 as shown in Figs. 16 and 17 of the drawings. The flexible ring member R on the contact surface of the head member 27 ensures the proper positioning of the shaped upper part on the surface of the head member with the axis aligned with the axis of the axial bore 24. The alignment fixture 30 shown in Figs. 6 and 7 of the drawings consists of the circular table 32 having the central opening 33 formed therein to receive the head assembly 20 and a composite supported thereon. A plurality of radially spaced substantially horizontal alignment assemblies 60 are mounted on the upper surface of the table 32 by spaced L-shaped mounting brackets 61 and 62 which are attached to the table by screws 63. As shown in Fig. 6 of the drawings, the alignment assemblies are radially spaced 60° around the circumference of the table 32 so that six assemblies are provided. Each alignment assembly has a horizontal pneumatic cylinder 69 mounted by the brackets 61 and 62. A reciprocal piston rod 65 extends through each pneumatic cylinder 69 and a threaded lock ring 66 is on the external end of the rod. With reference to Fig. 8 of the drawings, a Mylar edge contact disc 67 is carried on the inner end of a mounting rod 64 which is affixed to the inner end of the piston rod 65 by an internally threaded socket 68. The surfaces of the contact discs are adapted to gently contact the shaped edges of the upper and lower parts as shown in Fig. 7 of the drawings to laterally move the parts before the adhesive is cured so that a laminated composite is formed with the axes of the parts vertically aligned. As will be understood by those skilled in the art the pneumatic cylinders 69 shown in Figs. 6 and 7 of the drawings can be replaced by radially spaced vertical pneumatic cylinders in the nest member 50 having upwardly extending aligning pins with inwardly beveled contact surfaces to contact the edges of the two parts to move them laterally into axial alignment. Another arrangement for aligning the axes of the parts is an electric or pneumatic vibrator 150 which may be attached to the lower end of the cylinder 11 adjacent to the head assembly 20. The vibrator imparts a vibratory motion to the head assembly to align parts which are supported thereon. Manual vibration may also be utilized on the lower end of cylinder 11 for alignment purposes although the frequency is inconsistent. With reference to Figs. 5 and 15 of the drawings, a shutter assembly 80 for opening and closing the opening 46 in the cover plate 44 of the light box 40 includes a U-shaped shutter 81 having a plurality of rollers 88 which travel along horizontal steel rods 91 which are supported on horizontal rails 90 attached to the outer surfaces of the side walls 42 of the light box 40 in the manner shown in Figs. 2 and 15 of the drawings. The shutter assembly 80 is made of steel and consists of the inverted U-shaped shutter 81 having a top wall 82 and spaced side walls 83 extending downwardly therefrom. A vertical cross plate 87 extends upwardly from the upper surface of the top wall 82 of the U-shaped shutter and a hole 89 is drilled in the horizontal center of the plate to receive the distal end of a piston rod 95 of pneumatic shutter cylinder 96 which is mounted on the rearward extension 47 of the cover plate 44 of the light box 40. With additional reference to Fig. 5 of the drawings, the U-shaped shutter 81 has a bearing block 85 located at each of the four upper interior corners and a bearing block 86 located at each of the four lower interior ends of the side members 83. Each bearing block has a roller 88 rotatably mounted thereon which rides along a round steel rod 91 attached to a rail 90 attached to the exterior surface of a side wall 42 of the light box 40 by clamp members 92, as shown in Fig. 15 of the drawings. The pneumatic shutter cylinder 96 moves the shutter 81 along the rods 91 relative to the light box 40. When the pneumatic cylinder 96 retracts the rod 95, the composite lens which is held on the contact surface S of the head member 27 by the vacuum formed therein is evenly exposed to the curing light rays emitted from the bulbs 45, which rays pass through the opening 46 in the cover plate 44 of the light box 40. The top wall 82 of the shutter 81 normally covers the opening 46 in the light box cover plate 44 to prevent exposure of the adhesive to light rays emanating from the bulbs 45 located in the light box 40. Extension of the rod 95 out of the pneumatic cylinder 96 moves the shutter 81 relative to the cover plate 44 of the light box 40 to close the opening 46. It is essential that the light rays which pass through the opening 46 in the top wall 44 of the light box 40 contact the complete surface area of the lower lens in order to evenly cure the thin film of adhesive which is evenly spread over the mating surfaces of the lenses . An uneven distribution of light rays will produce uneven curing of the adhesive which is unacceptable because it renders the composite unfit for further use. When the device is used for laminating opaque parts, an adhesive which is cured by light rays cannot be used because the light rays cannot pass through the opaque part to the adhesive film. Therefore, the light box 40 may be replaced by a heat source, such as an infrared heater which provides a temperature between ambient and 350°F. If desired, a source of heat for curing adhesives may be included in the device with the light box and the desired curing mechanism will be selected by the operator. Heat sources other than infrared may also be utilized. The resin used to laminate opaque parts can be an art recognized, thermally curable resin based adhesive of which there are many commercially available. The pneumatic circuit for operating the fluid cylinders in the laminating device is shown in Fig. 16 of the drawings. The pneumatic circuit is connected to a source 100 of pressurized plant air. The source 100 is connected to a filter 101 and pressure regulators 102 and 103 which are connected to branch conduits 107 and 108 by a T connection 104. Branch conduit 107 is connected to the inlet of a solenoid operated spring-loaded reversible valve 112 having mufflers 110 and 111. The reversible valve 112 is connected to a conduit 113 which is connected to a manifold 114. The manifold 114 has a plurality of ports which are in flow communication with the head ends of the pneumatic cylinders 69 in the alignment assemblies 60. A flow control regulator 115 is connected in the conduit between each port in the manifold 114 and the head end of each pneumatic cylinder 69. The rod end of each pneumatic cylinder 69 is connected by a conduit having a flow control regulator 117 to a manifold 118 which is connected through a conduit 119 to the reversible valve 112. The flow control regulators 115 and 117 moderate the flow of air to the cylinders 60 to cushion the operation of the cylinder. The reversible valve 112 is connected by a conduit 120 to a connection 106 for a conduit 121. Conduit 121 is connected to a conduit 116 through a connection 109 and to a vacuum generator 123. A manual control switch 122 is located in conduit 121 so that the operator can control the vacuum created by the vacuum generator 123 at the contact surface S of head member 27 on the head assembly 20. The vacuum generator includes a muffler 124. The vacuum generator 123 is connected by a conduit 125 to the connector 26 in the radial bore 25 on the head assembly 20. A second vacuum generator 127 is connected to a solenoid operated spring loaded control valve 137 by a conduit 126. The vacuum generator 127 has a muffler 129 and a conduit 128 connects the vacuum generator to the connector 56 in the radial bore 55 in the nest member 50. The control valve 137 is connected to connector 104 by a conduit 138. Pressurized air flows through the conduit 108 to a spring loaded reversible valve 130 having mufflers 131 and 132. The reversible valve 130 is connected to the head end of the pneumatic cylinder 96 in the shutter assembly 80 by a conduit 133 having a flow regulator 134 therein. The reversible valve 130 is connected to the rod end of the cylinder 96 by a conduit 136 having a flow regulator 135 therein. It will be seen that the flow of pressurized air from the source 100 controls the operation of the pneumatic alignment cylinders 69; the shutter assembly pneumatic cylinder 96; the vacuum at the contact surface S of the head member 27; and the vacuum at the concave portion 53 of the nest member 50. The sequential control of these elements and their functions in the operating cycle of the laminating device is determined by a schedule according to a controller 141 which is shown in Fig. 17 of the drawings. The controller 141 is an electronic device which issues commands to relays to control the various system functions. The controller program is stored in a non-volatile memory and cannot be accidentally erased when the controller is shut off. When the controller is powered up or is reset, the program first raises the head assembly 20 to the retracted home position shown in Fig. 1 of the drawings. As shown in Figs. 16 and 17 of the drawings, the operation of the pneumatic circuit is controlled by electric solenoids which operate the spring loaded valves. The solenoids are electrically connected to individual relays in a relay box 140. The relays are electrically connected to the controller 141 and to an electric power supply 143. The controller 141 also operates the drive motor 15 in the cylinder 11 and is electrically connected to a safety photocell 144 which is located below the head assembly 20 and above the alignment fixture 30. The safety photocell 144 is located adjacent to the vertical axis of travel of the head assembly 20 to prevent the head assembly from moving downwardly to pick up a lower part from the nest member 50 when the operator's hand is located between the head assembly 20 and the nest member 50. The electric circuit also includes magnetic switches at the upper and lower limits of travel of the head assembly 20 to stop the head assembly at the home position which is the start position of each laminating cycle performed by the device. The solenoids 147, 148, and 149 are respectively located in the spring loaded control valves 112, 130 and 137 to shift the valve position against the force of the spring to control the flow of air to the nest vacuum generator 127, the aligning cylinders 69 and the shutter cylinder 96. The head vacuum generator 123 is controlled by the manual switch 122 which is located in the line between the plant air source 100 and the head vacuum generator 123. The various solenoids and relays are purchased items which are well-known to those skilled in the art and form no part of the present invention. The control diagram shown in Fig. 17 of the drawings also includes an electric or pneumatic vibrator 150 which is connected to a relay in the relay box 140. The vibrator 150 is mechanically attached to the outside of the cylinder 11 adjacent to the lower end. When one of electric current or air is supplied to the vibrator 150, it causes the head assembly 20 and the parts which are held on the contact surface S of the head member 27 to vibrate to assist in the alignment of the axes of the parts. The vibrator may replace the alignment fixture 30 under circumstances dictated by the viscosity of the film of adhesive on the mating surfaces of the parts. A manual vibration may also be applied to the head assembly 20 to assist in aligning the parts although manual alignment does not provide the consistent frequency of vibration which is created by the vibrator 150. When the device is to be used to laminate opaque parts the light box 40 will be replaced by a radiant heater which is electrically connected to the controller 141 through a relay in relay box 140. The pneumatic cylinders and valves are manufactured by FESTO located in Hauppauge, New York; the power cylinder, the vibrator and the controller are manufactured by Parker Motion & Control located in Wadsworth, Ohio,- and the shutter assembly is manufactured by Item Products, Inc. located in Houston, Texas. In operation, the lamination process for a composite lens is initiated by placing a lower lens in the lower nest member 50. The lens is held in position by a vacuum created by the vacuum generator 127 and a puddle of an adhesive material is placed on the upper surface of the lower lens. The adhesive material which is used in the device for the fabrication of laminated electrochromic lenses has the dual function of an ion conducting electrode and an adhesive. A suitable adhesive material that may be used is disclosed in United States Patent No. 5,327,281, granted July 5, 1994. This adhesive is utilized in the manufacture of laminated eyeglasses because the lenses are transparent. The vacuum in the nest member 50 is controlled by the spring loaded valve 137 and the solenoid 147 and the vacuum at the contact surface S of the head member 27 is created by the vacuum generator 123 and is controlled by the operator using the manual switch 122. The head assembly 20 is lowered by the drive motor 15 to position the bottom convex surface of the upper part a small predetermined distance from the top concave surface of the lower part and delays in this position for approximately 10 seconds. When the upper and lower lenses are properly vertically positioned, the concentricity of the spherical mating surfaces establishes a uniform gap or a finite distance between the mating surfaces. The uniform gap or finite distance is necessary to avoid optical distortion and the approximate 10 second delay permits the adhesive to spread evenly throughout the entire uniform gap by capillary action. The lenses adhere to each other because of the adhesion created by the film of adhesive between the lenses. The vacuum on the nest member 50 is released and the head member 27 is retracted in cylinder 11 by drive motor 15 to raise the composite attached thereto. The upward movement is interrupted with the composite located in the lateral plane which includes the centers of the contact discs 67 on the pneumatic cylinders 69. The operation of the cylinders 69 in the alignment fixture 30 shown in Figs. 6 and 7 of the drawings is controlled by the spring loaded control valve 130 and the solenoid 149 and the piston rods 65 extend from the pneumatic cylinders 69 until the surfaces of the discs 67 contact the peripheral edges of the lenses to laterally align the lenses. The extension distance of each piston rod 65 from its pneumatic cylinders 69 is preset in accordance with the peripheral shape of the lenses so that all of the contact discs 67 simultaneously gently touch the peripheral edges of both lenses as is best shown in Fig. 7 of the drawings to align the optical axes of the lenses. After the lenses are aligned, the contact discs 67 are withdrawn by the piston rods 65 of the cylinders 69. The drive motor 15 raises the head assembly to a predetermined height and the composite is vibrated by the vibrator 150 or manually to guarantee proper alignment of the center lines of the lenses. The movement of the shutter rod 95 to move the shutter 81 and the nest member 50 to open the opening 46 in the cover plate 44 to expose the composite and the film of adhesive to the light rays from the bulbs 45 in the light box 40 is controlled by the solenoid 148. The composite is exposed to the light rays for a minimum period of 3 minutes to cure the adhesive and retain the mated lenses together as a laminated composite. When the adhesive is cured, the shutter assembly piston rod 95 is extended from the pneumatic cylinder 96 to close the opening 46 in the light box cover plate 44. The vacuum is released from the head assembly by the operator using the manual switch 122 and the composite is manually removed from the head assembly. The method of operating the laminating device is initiated by placing a part in the nest member 50 and a part on the head member 27 and holding each part in place by a vacuum. A puddle of the adhesive is applied to the concave top of the lower lens in the nest member 50 and the cycle start button is depressed to instruct the controller to begin issuing commands to the device. The first command lowers the upper lens until the bottom surface of the upper lens is a predetermined distance above the top surface of the lower lens and delays for approximately 10 seconds. A uniform gap or finite distance is established between the mating surfaces of the lenses, and the adhesive spreads on the surfaces of the lenses by capillary action to form a thin film which evenly fills the entire gap. The next command releases the vacuum in the nest member 50 and instructs the drive motor 15 to retract the head member 27 to raise the composite which is held thereon by the vacuum upwardly into the same lateral plane as the centers of the contact discs 67 in the alignment fixture 30. The pneumatic cylinders 69 are actuated by the controller 141, the solenoid 149 and the spring loaded control valve 112 to move the Mylar contact discs 67 inwardly toward the peripheral edges of the lenses on the contact surface S of the head assembly 20 by extending each of the piston rods 65 a preset distance from the cylinders 69. The faces of the Mylar discs 67 contact the peripheral edges of both lenses in accordance with a preset pattern to properly align the lenses. The length of travel of the piston rods 65 is set so that the contact surfaces of the discs 67 gently touch the peripheries of the lenses to align the optical axes of the lenses. After a slight pause, the piston rods 65 retract and the drive motor 15 raises the head assembly and the parts on the head member to a predetermined height. The controller 141, the solenoid 148 and the control valve 137 actuate the shutter cylinder which retracts the rod 95 to move the shutter 81 and the nest member 50 which is supported thereon to open the opening 46 in the cover plate 44 of the light box 40 to expose the suspended lenses to the curing rays of the bulbs 45 for the desired period of time. When the adhesive between the lenses is cured, the controller instructs the piston 96 to close the opening 46 in the cover plate 44. The vacuum is manually shut off by the switch 122, and the cured composite lens is removed from the contact surface S of the head member 27 by the operator for further processing. It will be understood by those skilled in the art that the terms "upper part" , "upper lens" , "lower part" , and "lower lens" are used herein for convenience only. The device laminates both opaque parts and clear lenses. While different embodiments of the invention are described in detail herein, it will be understood by those skilled in the art that additional modifications and alternatives to the described embodiments can be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments shown in the drawings are illustrative only and are not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.

Claims: CLAIMS : 1. A laminating device for forming a composite from an upper part and a lower part having opposed mating surfaces, said device having a base, a substantially vertical support member extending upwardly from said base, a drive means mounted at the upper end of said support member and a vertically moveable head assembly at the lower end of said support member, connecting means for connecting said drive means to said vertically moveable head assembly for moving said head assembly relative to said support member, said head assembly including a head member for supporting an upper part, means operatively connected with said head member for holding an upper part on said head member, support means coaxial with and below said head member for supporting a lower part, means operatively connected with said support means for holding a lower part on said support means, an adhesive on the opposed mating surfaces of upper and lower parts, means for laterally aligning a lower part and an upper part, and means located below said head assembly for providing a curing medium to the aligned upper and lower parts to evenly cure the adhesive film on the opposed mating surfaces of the upper part and the lower part to bond the upper part and the lower part to form a composite. 2. A laminating device as set forth in claim 1, wherein said upper part and said lower part are transparent lenses, said adhesive is clear and said composite is a transparent lens for use in an eyeglass. 3. A laminating device as set forth in claim 2, wherein said means for providing a curing mechanism is a light box mounted on said base below said head assembly, said light box including an interior and a cover plate with an opening formed therein, a light source located in said interior of said light box, and shutter means for opening and closing said opening in said cover plate of said light box to control the passage of light rays emitted from said light source in said interior of said light box, wherein said shutter means includes an adjustable shutter for controlling the time the light rays pass through said opening in said cover plate of said light box. 4. A laminating device as set forth in claim 1, wherein said means for laterally aligning an upper part and a lower part includes a substantially horizontal table with a central opening formed therein mounted on said base and having an upper surface, a plurality of angularly spaced alignment assemblies mounted on said upper surface of said table, each of said alignment assemblies including a reciprocal contact disc for contacting the peripheral edges of the parts to move the parts laterally into axial alignment, and means for reciprocating each of said contact discs between an extended contact position and a retracted position, whereby each of said reciprocal contact discs is in contact with the peripheral edges of the upper and lower parts when said contact discs are in the extended contact position. 5. A laminating device as set forth in claim 4, wherein said means for reciprocating each of said contact discs includes a pneumatic cylinder having a rod end and a head end, means for mounting each of said pneumatic cylinders on said upper surface of said table, a piston rod extending from said rod end of each of said pneumatic cylinders and each of said contact discs mounted on the distal end of one of said piston rods, whereby extension of said piston rods from said pneumatic cylinders moves said contact discs laterally into contact with the peripheral edges of the parts and retraction of said piston rods into said pneumatic cylinders moves said contact discs laterally away from the peripheral edges of the parts. 6. A laminating device as set forth in claim 3 , wherein said shutter means includes a plurality of rollers mounted on said adjustable shutter, rails attached to said light box for receiving said rollers and reciprocating means mounted on said light box connected to said adjustable shutter for reciprocating said adjustable shutter relative to said light box to open and close said opening in said cover plate of said light box to control the passage of light rays from said interior of said light box through said opening in said cover plate of said light box. 7. A laminating device as set forth in claim 6, wherein said reciprocating means mounted on said light box to move said adjustable shutter relative to said light box is a pneumatic cylinder and a laterally moveable piston rod extending from said pneumatic cylinder, said laterally moving piston rod having a distal end connected to said adjustable shutter, whereby retraction of said piston rod into said cylinder moves said adjustable shutter to open said opening in said cover plate of said light box to permit the passage of light rays from said light box through said opening in said cover plate of said light box and extension of said piston rod out of said cylinder moves said adjustable shutter to close said light box to interrupt the passage of light rays from said light box. 8. A laminating device as set forth in claim 1, wherein said head assembly includes a shank having a hollow axial bore with an internal thread extending along at least a portion thereof and a base at the lower end of said shank, a head member attached to said base, said head member having a convex lower contact surface and a vacuum chamber formed therein in operative communication with said hollow axial bore, and a plurality of passages formed in said head member extending from said vacuum chamber to said lower contact surface of said head member, whereby said connecting means is threaded to said internal threads in said shank to connect said drive means to said head assembly. 9. A laminating device as set forth in claim 8, including a flexible ring member affixed to said lower contact surface of said head member, said flexible ring member having a shaped opening formed therein to position a part having a periphery with the same shape as said shaped opening in said flexible ring member on said lower contact surface of said head member to properly position the part with the axis of the part axially aligned with the axis of said hollow axial bore. 10. A laminating device as set forth in claim 8, wherein said head assembly includes a radial bore in flow communication with said hollow axial bore in said shank and a connector in said radial bore for connecting said radial bore to a vacuum generator conduit . 11. A laminating device as set forth in claim 5, including a pneumatic control system having a source of pressurized air, a reversible spring loaded valve in flow communication with said source, a first manifold in flow communication with said head ends of said plurality of pneumatic cylinders and a second manifold in flow communication with said rod ends of said pneumatic cylinders, said reversible spring loaded valve controls the flow of air from said source to said first and second manifolds, whereby air supplied to said head ends of said pneumatic cylinders from said first manifold extends said contact discs laterally to contact the peripheral edges of the parts and air supplied to said rod ends of said pneumatic cylinders from said second manifold moves said contact discs away from the peripheral edges of the parts. 12. A laminating device as set forth in claim 5, including a pneumatic control system having a source of pressurized air, a first reversible spring loaded valve in flow communication with said source, a first manifold in flow communication with said head ends of said plurality of pneumatic cylinders and a second manifold in flow communication with said rod ends of said plurality of pneumatic cylinders wherein said first reversible spring loaded valve controls the flow of air from said source to said first and second manifolds, a second reversible spring loaded valve in flow communication with a separate pneumatic cylinder, a first vacuum generator in flow communication with said head member, a second vacuum generator in flow communication with said support means, an electric control circuit including actuating means for controlling said first and second reversible spring loaded valves and said second vacuum generator, and a manual valve for controlling said first vacuum generator. 13. A laminating device as set forth in claim 2, wherein said means for providing a curing mechanism is a light box mounted on said base below said head assembly, said light box including a cover plate having an opening formed therein, a light source in said light box and adjustable shutter means for controlling the passage of light rays from said light box through said opening in said cover plate of said light box, said shutter means including a reciprocal shutter and means for reciprocating said shutter relative to said light box to open and close said opening in said cover plate of said light box, whereby light rays pass from said light box through said opening in said cover plate of said light box when said shutter is retracted to expose said opening in said cover plate and passage of light through said opening is interrupted when said shutter is extended over said opening in said cover plate. 14. A laminating device as set forth in claim 13, wherein said means for reciprocating said shutter is a pneumatic shutter cylinder having a head end, a rod end and a piston rod, a pneumatic control system having a source of air under pressure in flow communication with said head end and said rod end of said shutter cylinder, and a reversible spring loaded valve in flow communication with said head end and said rod end of said shutter cylinder and said source of air, whereby air supplied to said rod end of said shutter cylinder when said reversible spring loaded valve is in a first position retracts said shutter to expose said opening in said cover plate of said light box and air supplied to said head end of said shutter cylinder when said reversible spring loaded valve is in a second position extends said cylinder to close said opening in said cover plate of said light box. 15. A laminating device as set forth in claim 1, wherein said head assembly includes a shank portion having a hollow axial bore extending therethrough, a base at the lower end of said shank portion, a head member attached to said base and having a convex outer contact surface, a vacuum chamber formed in said head member in flow communication with said hollow axial bore in said shank portion and a plurality of passages formed in said head member extending from said vacuum chamber to said outer contact surface of said head member, and means for connecting said hollow axial bore to a vacuum generator, whereby a vacuum can be drawn at said contact surface of said head member to hold a part on said head member. 16. A laminating device as set forth in claim 15, including a flexible ring member affixed to said contact surface of said head member, said flexible ring member having a shaped opening to position a part having a periphery with the same shape as said shaped opening in said flexible ring member on said contact surface of said head member to position the part so that the axis of the part is aligned with the axis of said hollow axial bore. 17. A laminating device as set forth in claim 15, wherein said plurality of passages formed in said head member includes a central axial passage and a plurality of passages located radially outwardly of said central passage, whereby said passages permit the formation of a vacuum at said contact surface of said head member to hold a part on said contact surface of said head member. 18. A laminating device as set forth in claim 1, wherein said support means for supporting a lower part is a nest member, said nest member having a substantially cylindrical base with an annular rim and a concave inner contact surface, a central vacuum passage in said base extending from said inner contact surface to a radial bore formed in said base, a connector in said radial bore for connecting said radial bore to a vacuum generator conduit, whereby a vacuum can be drawn at said inner contact surface of said base to hold a part in contact with said inner contact surface of said base. 19. A laminating device as set forth in claim 18, wherein said nest member includes a surface on said base opposite said contact surface and a magnetic sheet on the surface of said base opposite said contact surface for adjustably locating said nest member on said means for providing a curing mechanism to the aligned upper and lower parts. 20. A laminating device for forming a composite from a first member and a second member having opposed mating surfaces, said device having a base, a support member on said base, a vertically moveable shaft supported by said support member having an upper end and a lower end, a drive means operatively connected to said shaft for moving said shaft relative to said support member and a head assembly connected to the lower end of said shaft, said head assembly including a contact surface for supporting a first member, means for holding a first member on said contact surface, support means below said head assembly for supporting a second member, means for holding a second member having a top surface on said support means, an adhesive on said top surface whereby said drive means lowers the first member toward the second member to spread the adhesive over the opposed surfaces of the first and second members, means for laterally aligning the first member and the second member of a composite, and means for providing a curing medium to the aligned first and second members to cure the adhesive on the opposed surfaces of the first and second members of a composite. 21. A method for laminating an upper part and a lower part, wherein said upper and lower parts have opposed complementary mating surfaces, said method comprising retaining said lower part in a position with the mating surface facing upwardly, locating said upper part coaxially with said lower part with the mating surface of said upper part facing the mating surface of said lower part, placing an adhesive on said mating surface of said lower part, lowering said upper part toward said lower part until said mating surfaces of said parts are spaced a predetermined uniform finite distance wherein said adhesive spreads over the complete mating surfaces of said parts to form an adhesive film on said parts to hold as a composite, raising said composite to an intermediate position, and exposing said adhesive film in said composite to a curing mechanism to evenly cure said adhesive to form a laminated composite. 22. A method as set forth in claim 21, wherein said adhesive spreads over the complete mating surfaces of said parts by capillary action. 23. A method as set forth in claim 21, including laterally aligning the center lines of said upper and lower parts after said adhesive film is formed on said mating surfaces of said parts. 24. A method as set forth in claim 21, wherein said curing mechanism is light rays and exposing said composite to said light rays for at least 3 minutes to evenly cure said adhesive to bond said parts. 25. A method as set forth in claim 21, wherein said lower part is positively retained in position during the spreading of said adhesive over said mating surfaces of said parts to form an adhesive film. 26. A method as set forth in claim 25, including releasing said lower part after said adhesive has spread over said mating surfaces of said parts to form an adhesive film. 27. A method as set forth in claim 21, wherein said parts are lenses for the formation of a composite eyeglass lens and said adhesive is clear. 28. A method as set forth in claim 23, including maintaining said composite in said raised position during said lateral aligning of said parts. 29. A method for laminating a first member and a second member having opposed complementary mating surfaces, said method comprising retaining said first member in a lower position, locating said second member coaxially above said first member, placing an adhesive material on the mating surface of said first member, lowering said second member toward said first member until said members are a predetermined finite distance apart wherein said adhesive spreads into a thin film on the complete areas of the mating surfaces of said first member and said second member, raising said first and second members with said adhesive film therebetween into an intermediate position, exposing said adhesive to light rays to cure said adhesive to form a laminated composite. 30. A method as set forth in claim 29, including aligning the center line of the first member with the center line of the second member. 31. A method as set forth in claim 30, wherein said aligning is accomplished by vibrating the first member and the second member.

Inventors: SMARTO JOHN E, SMARTO, JOHN, E.
Applicants: PPG INDUSTRIES INC, PPG INDUSTRIES, INC.
Application year: 1997
Main classification: B24B13
IPC codes: B29D11, C03B23, C09J5, G02C7