Abstract:
A machine for continuously manufacturing tape strips having at least at one end a portion folded through an aperture of a workpiece is provided. A tape supply section supplies tape to a tape feed unit which is adapted intermittently supply a first predetermined length of tape through an aperture of a workpiece and a second predetermined length of tape not through an aperture. Work pieces are supplied to and received by a workpiece receiving device adapted to hold the workpiece and position the aperture of the workpiece in the tape traveling path. Tape folders operate to fold a tape towards a fusing member positioned above the workpiece. Tape gripping arms further fold a tape into a fusing member. A tape cutter cuts the tape after a second predetermined length of tape is fed from a tape supply section. Tape gripping arms then operate to eject the finished strap from the machine.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the field of manufacturing preassembled tape strips. More particularly, the present invention relates to manufacturing tape strips of a predetermined length, which are at one end folded about an aperture of a workpiece. 
     2. Description of the Prior Art 
     In the manufacture and assembly of fastening products, such as tape strips, belts and straps, there is commonly a need for the attachment of additional workpieces in order to provide a finished product. These additional devices may include, for example, rings, buckles or notions which allow for the tape strips, belts or straps to be attached or connected in some fashion. 
     Currently, the preferred method of attaching these buckles or notions to, for example, a tape strip, has been through sewing. In the conventional art, a tape strip is commonly folded about a workpiece and sewn to itself to create a strap that has the workpiece at one end. The other end of the strap is either sewn into a final product or connected in a similar fashion to another workpiece such as a buckle. These straps are used as part of backpacks, bags, luggage, life vests, etc. Various methods are used in the art to partially assemble a tape strip about a connecting device. These methods involve gluing or spot welding the strap to itself once the strap is folded about the connecting device. The partially assembled straps are then sent to a final sewing stage and incorporated into a final product. 
     U.S. Pat. No. 5,795,434 discusses the problems associated with assembling these tape strips in the prior art. In particular, the prior art describes methods for producing tape strips folded about a ring. The article described is manufactured by severing a predetermined length off a continuous tape, inserting the thus obtained tape strip through the ring, and folding the tape strip through and about the ring outwardly. In order to facilitate a subsequent sewing work, a laminate portion of the folded tape strip is provisionally secured, by hand, with a thread, a staple or any other fastener to keep the tape strip in a folded form. According to the conventional technology, however, production of the tape strip folded about the ring chiefly relies on manual work and hence needs large manpower, which would be inefficient and would thus render the finished product more expensive to produce. Further, since the thread and/or staple used in temporarily securing the folded tape strip are unnecessary in a final product, such a fastener has to be removed from the folded tape strip by hand at the final stage of production. When the final product is included in articles for human use, such as trampolines, the need for the removal of staples becomes especially important. If, through human error, a staple is not removed, its inclusion in the article may easily cause injury to the consumer. 
     U.S. Pat. No. 5,795,434 solves the problem of the prior art by providing a machine and method for continuously manufacturing a tape strip folded about a ring. Tape drawer rollers are intermittently driven and a continuous tape is intermittently fed along a tape traveling path. A leading edge portion of the tape is inserted through a ring at a tape folding section. After the tape is fed a predetermined length through the ring, the tape is stopped and then the lower end portion of the tape inserted through the ring is bent about the ring by a first bending member. A cutting device then severs a predetermined length of tape strip off the continuous tape, whereupon the an upper half of the severed tape strip is bent about the ring by a second bending member, thus providing a folded tape strip having a laminate portion. Finally the folded tape strip is discharged out of a machine after part of its laminate portion is fused by a fusing device. The product which is created by this method provides a tape which is folded equally about a ring. This product is used as connection points on a trampoline. 
     However, there is still a need in the art to provide for a machine which continuously manufactures a tape strip folded about a connecting device wherein an additional length of tape extends beyond the tape which is folded about the connecting device. There is a further need for a machine capable of properly manipulating a tape strip to allow differing lengths of tape to extend beyond the tape which is folded about the connecting device. The product formed from this process can then be used in a large number of applications, such as backpacks, bags, luggage, life vests, and other uses which require tape strips attached to connecting devices. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide for an efficient method of producing a tape strip folded about a connecting device which has an additional length of tape extending beyond the tape which is folded about the connecting device. 
     It is a further object of the present invention to improve the efficiency of production of tape strips folded about a connecting device so that production of a final product using such folded tape strips can be facilitated. 
     It is another object of the present invention to manufacture a tape strip folded about a connecting device which has an additional length of tape extending beyond the tape which is folded about the connecting device. 
     It is yet a further object of the present invention to provide an improved method of properly manipulating a tape strip to allow differing lengths of tape to extend beyond a tape which is folded about a connecting device. 
     Objects of the invention are achieved by providing a machine for continuously manufacturing tape strips having at least at one end a portion folded through an aperture of a workpiece. The machine includes a tape supply section which accommodates a supply of tape having an indeterminate length. The tape supply section supplies tape to a tape feed unit which is adapted to intermittently supply a first predetermined length of tape and a second predetermined length of tape in a two stage operation. Work pieces are supplied to and received by a workpiece receiving device adapted to hold the workpiece and position the aperture of the workpiece in the tape traveling path. First and second tape folders are oppositely positioned on each side of the workpiece receiving device. These tape folders operate to move in and out of the tape traveling path. A tape fusing member is positioned above the workpiece receiving device and the tape traveling path. The tape feed unit supplies a first predetermined length of tape through the aperture of a workpiece along the tape traveling path. The tape feed unit then supplies a second predetermined length of tape that does not go through the aperture of the workpiece. First and second tape folders then move from their position outside of the tape traveling path to a position in the tape traveling path causing the tape to fold toward the heated tape fusing member above the workpiece receiving device. 
     The foregoing is illustrative of the objects and features of the present invention and is not intended to be exhaustive or limiting of the possible advantages that can be realized or achieved. These and other objects and advantages of the present invention will be readily apparent to those skilled in the art from the following description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevated perspective view of a machine according to an embodiment of the present invention. 
     FIG. 2 is a detailed view of a workpiece supply path. 
     FIG. 3 is a detailed view of a welder and workpiece gripper assembly shown with tape folders in a retracted position. 
     FIG. 4 is a detailed view of a welder and workpiece gripper assembly shown with tape folders in a protracted position. 
     FIG. 5 is a detailed view of a tape supply section and associated tape feed unit with tape feed out of tape supply path. 
     FIG. 6 is a detailed view of a tape supply section and associated tape feed unit in with tape feed guide in the tape supply path. 
     FIG. 7 is a detailed view of a tape cutter assembly. 
     FIG. 8 is a detailed view of a tape gripper arm assembly. 
     FIG. 9 is an operational view of a workpiece gripper assembly and a workpiece supply path. 
     FIG. 10 is an operational view of a workpiece gripper assembly and a tape feed unit. 
     FIG. 11 is an additional operational view of a workpiece gripper assembly and a tape feed unit. 
     FIG. 12 is an operational view of a workpiece gripper assembly with tape folders in a protracted position. 
     FIG. 13 is an operational view of a workpiece gripper assembly and a tape gripper arm. 
     FIG. 14 is an additional operational view of a workpiece gripper assembly and a tape gripper arm. 
     FIG. 15 is an operational view of two tape gripper arms. 
     FIG. 16 is and operational view of a tape gripper arm and a cutter assembly. 
     FIG. 17 is an elevated perspective view of a completed tape strap. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, wherein like numerals refer to like components, FIG. 1 illustrates a perspective view of one embodiment of a machine for continuously producing a tape strip folded about a workpiece (not shown). The machine includes a workpiece supplier, such To as a workpiece supply path  100 ; a workpiece gripper  200  which rotates from a position for receiving a workpiece from the workpiece supply path  100  to an upright position for holding a workpiece in a working position; a tape feed transfer unit  300 , which moves from a position distant to a workpiece gripper  200  to a position near the workpiece gripper  200 ; a tape cutter  400 ; a tape gripping assembly  500 ; and a tape fusing member  600 . 
     FIGS. 2 and 3 illustrate a workpiece supply path  100  and a workpiece gripper  200 , in further detail. Workpiece supply path  100  includes a workpiece track  102 , which provides for the delivery of only one workpiece, such as a buckle (not shown), at a time. Buckles originate from an automated workpiece supply  104  or are fed manually onto the workpiece track  102 . Buckles may then move down the workpiece track  102  and stop at a position above an upper stopper  106 . The upper stopper  106  includes an upper actuator  108  and an upper gate  110 . The upper actuator  108  moves the upper gate  110  from a closed position to an open position. When the upper gate  110  is open, buckles can move past the upper stopper  106 . Buckles, or similar workpieces, may then move down the workpiece track  102  past the upper stopper  106  and stop at a lower stopper  114 . The lower stopper  114  includes a lower actuator  116  and a lower gate  118 . The lower actuator  116  moves the lower gate  118  from a closed position to an open position. When the lower gate  118  is open, a predetermined number of workpieces, such as buckles can move past the lower stopper  114 . The distance between the lower stopper  114  and the upper stopper  106  is preferably equal to the length of the predetermined number of workpieces utilized. 
     The lower stopper  114  and the upper stopper  106  open and close in an alternating fashion, thereby allowing the insertion of a predetermined number of workpieces per opening and closing cycle. The workpiece travels along the workpiece track  102  and stops at the upper stopper  106 . The upper gate  110  then opens, allowing workpieces to travel past the upper stopper  106  and stop at the lower stopper  114 . The upper gate  110  then closes, stopping any additional workpieces from passing the upper stopper  106 . Now, at least one workpiece, such as a buckle, rests between the upper stopper  106  and the lower stopper  114 . The lower stopper  114  then actuates and raises the lower gate  118  allowing at least one workpiece into the workpiece gripper  200 . The lower stopper  114  then actuates and lowers the lower gate  118 . 
     Referring now to FIGS. 2,  3  and  4 , a tape fusing member  600  remains at a position above the workpiece gripper  200 . The workpiece gripper  200  includes a rotator section  202  and a workpiece receiver  204 . The workpiece receiver  204  then holds the workpiece for further manipulation. The rotator section  202  moves the workpiece receiver  204  from a position at an end of the workpiece supply path  100  in line with the workpiece track  102 , as further illustrated in FIG.  9 . Therefore, when the lower stopper  114  allows the workpiece to pass, the workpiece slides into the workpiece receiver  204 . The rotator section  202  then rotates the workpiece receiver  204  and the workpiece to a vertical position. The workpiece gripper  200  also includes a first tape folder  206 , a second tape folder  208  and actuators  210 . The actuators  210  move the first tape folder  206  and the second tape folder  208  from a retracted position, as illustrated in FIG. 3, to a protracted position as illustrated in FIG.  4 . The first tape folder  206  includes a first tape folder slot  212 . The second tape folder  208  also includes a second tape folder slot  214 . During operation, the first tape folder  206  and the second tape folder  208  are in a protracted position, the tape fusing member  600  moves to a lowered position directly above the workpiece and directly between the first tape folder slot  206  and the second tape folder slot  208 . FIGS. 4,  12  and  13  further illustrate the tape fusing member  600  in its lowered position. The tape fusing member  600  includes an actuator  602 , a heating element  604  and an upper support structure  606 . The actuator  602  moves the heating element  604  from a position above the workpiece gripper  200  to a position directly between the first tape folder slot  206  and the second tape folder slot  208 . 
     Referring now to FIGS. 2,  3 ,  4  and  5 , a tape feed transfer unit  300  is shown. The tape feed transfer unit  300  includes a base  302 , which allows the tape feed transfer unit  300  to move from a position distant to the workpiece gripper  200 , as illustrated in FIG. 11 to a position near the workpiece gripper  200 , as illustrated in FIG.  10 . The tape feed transfer unit  300  also includes feed rollers  304 , a tape feed guide  306  and a tape feed guide actuator  308 . When the tape feed transfer unit  300  is in a position near the workpiece gripper  200  and while the workpiece gripper  200  holds a workpiece, the feed rollers  304  feed a predetermined length of tape along a tape traveling path  310  and through an aperture  112   a  of a workpiece  112 , as illustrated in FIG.  10 . Once a predetermined length of tape  800  extends through the aperture  112   a,  the tape feed transfer unit  300  moves to a position distant from the workpiece gripper  200 . The tape feed guide actuator  308  moves the tape feed guide  306  to a lowered position in the tape traveling path  310 . The feed rollers  304  then feed an additional predetermined length of tape  800  which collects in the opening between the tape feed transfer unit  300  and the workpiece gripper  200 . The tape  800  comes from a tape supply section  314 . The tape supply section  314  is well known in the art and can take various forms. 
     FIG. 6 illustrates the tape feed transfer unit  300 . The actuator  308  extends and moves the tape feed guide  306  in the tape traveling path  310 . Once the tape feed guide  306  is in the tape traveling path  310 , a predetermined length of tape  800  feeds from the feed roller  304  into the opening between the tape feed transfer unit  300  and the workpiece gripper  200 . 
     FIG. 7 illustrates a cutting device assembly  400 . The cutting device assembly  400  includes a lower cutting device  402 , which may be a blade or cutting block, and an upper cutting device  404 , which may also be a blade or cutting block. The upper cutting device  402  includes a heating element  406  and maintains a temperature high enough to melt a tape or other fastening material. The cutting device assembly  400  may be used to sever a length of material, such as tape. When the tape feed transfer unit  300 , as illustrated in FIGS. 3,  4 ,  5  and  6 , is in a position distant to the workpiece gripper  200 , it is lined up for predetermined cutting with the upper cutting device  404  and the lower cutting device  402 . Once the tape feed transfer unit  300  feeds a predetermined length of tape into the opening between the tape feed transfer unit  300  and the workpiece gripper  200 , the upper cutting device  404  and the lower cutting device  402  lower and raise, respectively, to meet, cut and melt tape  800 . 
     FIG. 8 shows a tape gripping assembly  500 . The tape gripping assembly  500  includes a rotary base  502 , a first tape gripper arm  504  and a second tape gripper arm  506 . The rotary base  502  allows the tape gripping assembly  500  to rotate along arrow  500   a  between a first position for working with the tape  800  and a second position for ejecting a completed workpiece (not shown). The first tape gripper arm  504  moves along two dimensions as shown by  504   a  and  504   b.  The second tape gripper arm  506  moves along one dimension as shown by  506   a.  The first tape gripper arm  504  includes opposed members  508  and  510  for gripping a portion of tape near the tape feed transfer unit  300 , as illustrated in FIGS. 5 and 6, and the tape cutter  400 , as illustrated in FIG.  7 . The second tape gripper arm  506  includes opposed members  512  and  514  for gripping a portion of tape above the workpiece, and the workpiece gripper  200 , as illustrated in FIGS. 3 and 4. When the tape gripping assembly  500  is in a first position, the second tape gripper arm  506  extends along a longitudinal direction  506   a  and opposing members  512  and  514  grip a portion of tape near the tape feed transfer unit  300  and the tape cutter  400 . At the same time, the first tape gripper arm  504  extends along a longitudinal direction  504   a  and opposing members  508  and  510  grip a portion of tape above the workpiece and the workpiece gripper  200 . However, the first tape gripper arm  504  and opposing members  508  and  510  operate in conjunction with the first tape folder  206  and the second tape folder  208  as further illustrated in FIGS. 11 and 13. The first tape folder  206  and the second tape folder  208  protract to fold a tape  800 , as illustrated in FIG.  12 . 
     As further illustrated in FIG. 13, the first tape gripper arm  504  extends, and opposing members  508  and  510  grip a portion of tape  800 . At that time, the tape fusing member  600  is located directly between the first tape folder  206  and the second tape folder  208 . The opposing members  508  and  510  press the tape  800  into the heating element  604  of the tape fusing member  600 . The opposing members  508  and  510  then release the tape  800  and the first tape folder  206  and the second tape folder  208  retract. At this point, the first tape folder  206  and the second tape folder  208  are in a retracted position. The first tape gripper arm  504  can then extend upward along longitudinal direction  504   a  and raise the tape  800  and workpiece  112  out of the workpiece gripper  200 . The second tape gripper arm  506  extends along longitudinal direction  506   a  and opposing members  512  and  514 , grip a portion of tape  800  near the tape feed transfer unit  300  and the tape cutting device  400 . At this time, the cutting device  400  operates to cut a portion of tape  800  near the tape feed transfer unit  300 . The tape gripping assembly  500  then turns and ejects the completed workpiece  900 , as illustrated in FIG. 17, from the machine. 
     General Machine Operation 
     In one embodiment of the present invention and illustrated by FIG. 9, a workpiece  112  travels along a workpiece supply path  100  along a workpiece track  102 . Workpiece  112  can be automatically fed to the workpiece track  102  by a workpiece supply  104  or manually by an operator. The workpiece  112  first reaches an upper stopper  106  and stops. The upper stopper  106  then allows the workpiece  112  to pass, then shuts again. The workpiece  112  stops at a lower stopper  114  and rests between the lower stopper  114  and the upper stopper  106 . The lower stopper  114  then opens and allows the workpiece  112  to slide into the workpiece receiver  204  of the workpiece gripper  200 . 
     As illustrated in FIGS. 9 and 10, a rotator section  202  of the workpiece gripper  200  rotates so that the workpiece  112 , now in the workpiece receiver  204  is vertical. The tape feed transfer unit  300  moves to a position near the workpiece gripper  200 . This facilitates the transfer of tape  800  through the workpiece aperture  112   a . Feed rollers  304  feed a predetermined amount of tape  800  through an aperture  112   a  of the workpiece  112  along a tape traveling path  310 . The amount of tape  800  fed through the aperture  112   a  depends on how much folded tape  800  is required and how far the tape feed transfer unit  300  will move away from the workpiece gripper  200 . As illustrated in FIG. 11, the tape feed transfer unit  300  then moves away from the workpiece gripper  200 . A tape feed guide actuator  308  forces the tape feed guide  306  into the tape traveling path  310 . This forces tape  800  to point in a downward direction. Feed rollers  304  then feed an additional predetermined length of tape  800  which collects in an opening between the tape feed transfer unit  300  and the workpiece gripper  200 . This will provide for an additional length of tape  800  which will extend away from the workpiece  112 . The tape cutter  400  will then sever the tape  800  as illustrated in FIG.  16 . 
     As illustrated in FIGS. 11 and 12, before the tape feed transfer unit  300  feeds an additional predetermined length of tape  800 , the first tape folder  206  and the second tape folder  208  move to the protracted position, forcing the tape  800  to fold about the workpiece  112 . As illustrated in FIG. 12, the tape fusing member  600  lowers a heating element  604  to a point directly above the workpiece  112 . The first tape gripper arm  504  extends and opposing members  508  and  510  grip a portion of tape  800  through the first tape folder  206  and the second tape folder  208 . At that time, the heating element  604  is located directly between the first tape folder slot  212  and the second tape folder slot  214 . Opposing members  508  and  510  then press the tape  800  into the heating element  604  of the tape fusing member  600 . Opposing members  508  and  510  then release the tape  800  and the first tape folder  206  and the second tape folder  208  retract. Opposing members  508  and  510  then grip a portion of the tape  800  above the workpiece  112 . At this point, the first tape folder  206  and the second tape folder  208  are in a retracted position. This is illustrated in FIG.  14 . 
     As illustrated in FIGS. 15 and 16, the first tape gripper arm  504  now has a welded portion of tape  800  and can then extend upward along arrow  504   b  and raise the tape  800  and the workpiece  112  out of the workpiece receiver  204 . The second tape gripper arm  506  may then extend along arrow  506   a  and opposing members  512  and  514  grip a portion of the tape  800  near the tape cutter  400 . 
     Now, the second tape gripper arm  506  holds a portion of the tape  800  near the tape cutter  400 . The tape gripping assembly  500  then rotates and ejects the completed workpiece  900  from the machine. 
     The completed strap  900  is shown in FIG.  17 . The completed strap  900  includes a predetermined length of tape  800 , part of which is folded and spot-welded  802  about an aperture  112   a  of the workpiece  112 . These completed workpieces  900  can now be used in completing a final product such as backpacks, bags, luggage, life vests, etc. 
     Although the present invention has been described in detail with particular reference to preferred embodiments thereof, it should be understood that the invention is capable of other different embodiments, and its details are capable of modifications in various obvious respects. As is readily apparent to those skilled in the art, variations and modifications can be affected while remaining within the spirit and scope of the invention. Accordingly, the foregoing disclosure, description, and figures are for illustrative purposes only, and do not in any way limit the invention, which is defined only by the following claims.