Abstract:
Crimping machines, including constructions thereof and methods for their manufacture and use. The crimping machines include at least a first load-bearing component that comprises a plurality of load-bearing laminates that are assembled and secured together. The first load-bearing component is installed in the crimping machine so that a crimping load of the crimping machine is imposed on the first load-bearing component during a crimping operation performed by the crimping machine.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/829,691, filed May 31, 2013, the contents of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention generally relates to crimping machines, and more particularly to their construction and methods for their manufacture and use. 
         [0003]    There are various configurations for crimping machines (“crimpers”) and methods for their manufacture. Three such configurations are referred to herein as round head-type, scissor-type, and press-type crimpers, nonlimiting representations of which are depicted in  FIGS. 1 ,  2  and  3 , respectively. These types of crimpers have found uses in crimping various hardware, including crimping operations performed to attach fittings on conduits, which as used herein refers to any hose, tube, pipe, or other type of conduit adapted to transport a fluid (liquid or gas) or protect hardware, for example, electrical wiring or other line-like articles susceptible to damage. Because crimpers are often required to apply high forces during crimping, their typical construction typically entails large, high-strength structural components. As examples, the round head-type crimper of  FIG. 1  comprises a large one-piece annular-shaped outer frame  12  that surrounds and supports crimping shoes  14  that apply the crimping force, the scissor-type crimper of  FIG. 2  comprises a large one-piece outer frame  16  and an inner cradle or block  18  that are each machined from solid steel plates and together apply the crimping force, and the press-type crimper of  FIG. 3  comprises upper and lower bases  20  and  22  that are each machined from solid steel plates and support dies (not shown) that apply the crimping force. 
         [0004]    The configurations of the outer frame  16  and inner block  18  of the scissor-type crimper of  FIG. 2  produced by machining can be better appreciated from the isolated view of these components in  FIG. 4 . The frame  16  and inner block  18  support a die carrier assembly  24  comprising die carriers  27 , and closing of the die carrier assembly  24  is the result of the inner block  18  being actuated upward by an actuator assembly  26 , causing intermediate master dies or shoes  28  to collapse toward each other for the purpose of diametrically crimping two components together, such as a fitting onto a conduit. The actuator assembly  26  is located below the block  18  and die carrier assembly  24  and is adapted to raise and lower the block  18  toward the upper end of the frame  16 . Actuation is typically with hydraulic power, such as a hydraulic cylinder, though mechanical actuation or some other means of actuation can be used. Those skilled in the art will appreciate that various other types of dies and adapters can be assembled to the die carrier assembly  24  in order to adapt the crimper for crimping different types and sizes of components. 
         [0005]    Traditional types of crimpers of the types represented in  FIGS. 1-4  may have various shortcomings. As an example, individual steel plates machined to produce the outer frame  16  and inner block  18  of the scissor-type crimper of  FIGS. 2 and 4  can be costly to purchase, and machining the plates can be difficult because of their size and weight and the awkward locations of certain machined areas on the frame  16  and block  18 , for example, side rails  30  of the outer frame  16  and flanges  32  of the inner block  18  that slidably engage each other. When machining the frame  16  and block  18  of a traditional scissor-type crimper, machining errors may cause either of these components to be unusable, which can be very costly in terms of materials and processing. Similar challenges exist for round head-type and press-type crimpers of the type shown in  FIGS. 1 and 3 . For example, the outer frame  12  of the round head-type crimper of  FIG. 1  can be difficult to manufacture, as the frame  12  must be machined to create cavities in which actuators (not shown) are disposed for actuating the crimping shoes  14 . 
         [0006]    The crimpers represented in  FIGS. 1-4  can also have operational limitations. As an example, the crimping diameter of the scissor-type crimper of  FIGS. 2 and 4  is limited by the extent to which the block  18  is able to travel within the outer frame  16 . The inner block  18  moves up and down within an interior area  34  formed by machining on opening in the steel plate used to form the outer frame  16 . Though a larger interior area  34  provides for a larger opening diameter of the die carrier assembly  24 , the size of the interior area  34  also affects the overall strength of the frame  16 , and therefore structural limitations of the frame  16  also limit the size and opening diameter of the die carrier assembly  24 . 
         [0007]    Accordingly, there is a need for crimpers capable of alleviating the above shortcomings, yet are also capable of providing reliable operation to produce commercially acceptable crimped products. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0008]    The present invention provides crimping machines, including particular constructions thereof and methods for their manufacture and use. 
         [0009]    According to one aspect of the invention, a crimping machine includes at least a first load-bearing component that comprises a plurality of load-bearing laminates that are assembled and secured together. The first load-bearing component is installed in the crimping machine so that a crimping load of the crimping machine is imposed on the first load-bearing component during a crimping operation performed by the crimping machine. 
         [0010]    According to another aspect of the invention, a method is provided that includes producing at least a first load-bearing component by assembling and securing together a plurality of load-bearing laminates. The first load-bearing component is installed in a crimping machine, and a crimping operation is performed with the crimping machine by applying a crimping load that is imposed on the first load-bearing component. 
         [0011]    A technical effect of the invention is the ability to provide a crimping machine that is less expensive than traditional methods requiring the purchase and machining of large plates. Relative complex features can be more readily machined in relative thin load-bearing laminates, and machining errors resulting in scrappage of a laminate are less costly as compared to machining errors that necessitate scrappage of a much larger plate. For embodiments of scissor-type crimpers that include an outer frame and inner block, each of these components can be manufactured as a load-bearing component that includes spacer laminates between or among the load-bearing laminates. In addition, the load-bearing and spacer laminates within the outer frame and inner block can be interdigitated or otherwise arranged in a manner that enables the crimper to have increased opening and closing distances as compared to a traditional scissor-type crimper having an interior area of the same dimensions. 
         [0012]    Other aspects and advantages of this invention will be better appreciated from the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIGS. 1 ,  2 , and  3  schematically represent examples of round head-type, scissor-type, and press-type crimpers known in the art. 
           [0014]      FIG. 4  schematically represents an outer frame and inner block of the scissor-type crimper of  FIG. 2 . 
           [0015]      FIGS. 5 and 6  are perspective views schematically representing opposite sides of an inner block subassembly assembled with an outer frame subassembly for use in construction of, respectively, a laminate inner block and a laminate outer frame of a scissor-type crimper. 
           [0016]      FIG. 7  is a perspective view schematically representing a laminate outer frame constructed of a plurality of outer frame subassemblies of the type represented in  FIGS. 5 and 6 , and  FIG. 8  is an exploded view of the outer frame of  FIG. 7 . 
           [0017]      FIG. 9  is a perspective view schematically representing a laminate inner block constructed of a plurality of inner block subassemblies of the type represented in  FIGS. 5 and 6 , and  FIG. 10  is an exploded view of the inner block of  FIG. 9 . 
           [0018]      FIG. 11  is a perspective view schematically representing the laminate inner block of  FIG. 9  assembled and integrated with the laminate outer frame of  FIG. 7  to yield a block and frame assembly, and  FIG. 12  is an exploded view of the assembly of  FIG. 11 . 
           [0019]      FIG. 13  is a perspective view schematically representing the block and frame assembly of  FIG. 11  further assembled with additional components to yield a scissor-type crimper. 
           [0020]      FIG. 14  is a perspective view showing a press-type crimper comprising laminate bases that are each constructed of a plurality of load-bearing laminates, and  FIG. 15  is an exploded view of the laminate bases of  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    The present invention provides various types of crimping machines (crimpers) that can be manufactured to have at least one component that is an assembly of individual sheets, plates or plies (hereinafter, laminates) that are assembled and secured together to form a laminate assembly. The invention will be primarily discussed hereinafter in reference to a scissor-type crimper, such as of the type shown in  FIGS. 2 and 4 . However, it will be appreciated that the teachings of the invention are more generally applicable to various types of crimpers, such as, but not limed to, the round head-type and press-type crimpers of  FIGS. 1 and 3 . The following discussion will focus primarily on certain aspects of crimpers that differ from the crimpers of  FIGS. 1 through 4 , and other aspects not discussed in any detail may be, in terms of structure, function, materials, etc., essentially as was described for the crimpers of  FIGS. 1 through 4 . To facilitate the description of disclosed embodiments of the invention provided below, relative terms, including but not limited to, “vertical,” “horizontal,” “lateral,” “front,” “rear,” “side,” “forward,” “rearward,” “upper,” “lower,” “above,” “below,” “right,” “left,” etc., may be used in reference to the orientation of the various views in  FIGS. 5 through 15 , and therefore are relative terms and should not be otherwise interpreted as limitations to the construction, installation, operation or use of a crimper. 
         [0022]      FIG. 13  schematically represents a scissor-type crimper  40  comprising an outer frame  46  and inner cradle or block  48  assembled with the frame  46  and adapted to cooperate with the frame  46  to apply a crimping force therebetween. As such, the frame  46  and block  48  are both load-bearing components of the crimper  40 . The frame  46  and block  48  yield a block and frame assembly  50  ( FIG. 11 ), which is shown in  FIG. 13  as further assembled with additional components to yield the scissor-type crimper  40 . In particular, the frame  46  and block  48  support a die carrier assembly  42 , and closing of the die carrier assembly  42  is the result of the block  48  being actuated by an actuator assembly  44 , causing intermediate master dies or shoes of the die carrier assembly  42  to collapse toward each other for the purpose of diametrically crimping two components together, such as a fitting onto a conduit. The actuator assembly  42  can be of any suitable type, including but not limited to a hydraulic cylinder or a mechanical actuator. The crimper  40  is not limited to the type of die carrier assembly  42  depicted in  FIG. 13 , and various types of dies and adapters can be assembled to the die carrier assembly  42  in order to adapt the crimper  40  for crimping different types and sizes of components. 
         [0023]    As evident from  FIGS. 11 through 13 , the outer frame  46  and inner block  48  of the block and frame assembly  50  are each an assembly of individual laminates, and as such may be referred to as a laminate outer frame  46  and a laminate inner block  48 . As represented in  FIGS. 7 and 8 , the outer frame  46  is preferably constructed of a plurality of outer frame subassemblies  52  and, as represented in  FIGS. 9 and 10 , the inner block  48  is preferably constructed of a plurality of inner block subassemblies  54 .  FIGS. 5 and 6  represent a single inner block subassembly  54  assembled with a single outer frame subassembly  52 . As evident from  FIGS. 5 and 6 , each subassembly  52  and  54  is made up of multiple individual laminates  56  and  58  having different functions. The laminates  56  will be referred to herein as load-bearing laminates  56  that are configured to contact or otherwise apply the crimping force to the die carrier assembly  42  and therefore bear the crimping load during a crimping process. The other laminates  58  will be referred to herein as spacer laminates  58  whose function is to appropriately and reliably position and space the load-bearing laminates  56  relative to each other. 
         [0024]    In the embodiment of  FIGS. 5 and 6 , the load-bearing laminate  56  of the inner block subassembly  54  entirely defines the outermost perimeter  60  of the subassembly  54 , and is essentially continuous within this perimeter  60 , whereas a spacer laminate  58  defines, at most, only portions of the perimeter  60  and is not continuous throughout the extent surrounded by the perimeter  60 . Instead, the spacer laminate  58  lies entirely within the perimeter  60  of the block subassembly  54  defined by the load-bearing laminate  56 , is entirely superimposed by the load- bearing laminate  56  of the subassembly  54 , and is set back (recessed) from at least a portion of the perimeter  60  to define a gap  76  between two immediately-adjacent load-bearing laminates  56  ( FIG. 9 ). Similarly, the load-bearing laminate  56  of the outer frame subassembly  52  entirely defines innermost and outermost perimeters  61  and  62  of the subassembly  52 , and is essentially continuous between these perimeters  61  and  62 , whereas multiple spacer laminates  58  define, at most, only portions of the perimeters  61  and  62  and are not continuous therebetween. Instead, the multiple spacer laminates  58  lie entirely within the perimeters  61  and  62  of the outer frame subassembly  52  defined by the load-bearing laminate  56 , defining an arrangement of spacer laminates  58  that are entirely superimposed by the load-bearing laminate  56  of the subassembly  52 , with portions of the spacer laminates  58  being set back (recessed) from at least a portion of each perimeter  61  and  62  to define gaps  74  ( FIG. 7 ) between two immediately-adjacent load-bearing laminates  56 . 
         [0025]    As a result of the arrangements of the load-bearing and spacer laminates  56  and  58  described above, surfaces  64  of the load-bearing laminate  56  of the outer frame subassembly  52  remain exposed by its corresponding spacer laminates  58 , and surfaces  66  of the load-bearing laminate  56  of the inner block subassembly  54  remain exposed by its spacer laminate  58 . At least portions of these surfaces  64  and  66  are adapted to contact each other during movement of the inner block  48  within an interior area  68  of the outer frame  46  defined by its innermost perimeter  61 . From  FIGS. 5 through 12  and the completed block and frame assembly  50  of  FIGS. 11 and 13 , it can be appreciated that the spacer laminates  58  are interleaved with the load-bearing laminates  56 , such that portions of the exposed surfaces  64  and  66  are disposed on frame and block flanges  70  and  72 , respectively ( FIG. 5 ), of adjacent pairs of load-bearing laminates  56 , and the aforementioned gaps  74  and  76  are defined between the flanges  70  and  72  ( FIGS. 7 and 9 ). By placing the flanges  70  of the frame  46  within the gaps  76  of the block  48  and placing the flanges  72  of the block  48  within the gaps  74  of the frame  46 , thus preferably interdigitating the frame and block flanges  70  and  72 , the block  48  is slidably secured to the frame  46 . In effect, the frame flanges  70  functionally perform the role of the traditional side rails  30  and the block flanges  72  functionally perform the role of the traditional flanges  32  of  FIGS. 2 and 4 . As evident from  FIGS. 11 and 13 , crimping forces are applied in a direction parallel to the plane of each load-bearing laminate  56 . Because the load-bearing laminates  56  define the perimeters  60 ,  61  and  62  of the outer frame  46  and inner block  48 , the crimping load imposed on a load-bearing laminate  56  is parallel to the plane of the laminate  56  and, at most, may be distributed between load-bearing laminates  56  through contact with shared spacer laminates  58 . 
         [0026]    As represented in  FIGS. 7 through 13 , fasteners  78  can be used to secure multiple outer frame subassemblies  52  together to form the outer frame  46  and to secure multiple inner block subassemblies  54  together to form the inner block  48 . However, it should be understood that the frame  46  and block  48  could be held together by other means. 
         [0027]    As should be evident from  FIG. 13 , the above-described combinations of load-bearing laminates  56  and spacer laminates  58  used to manufacture the load-bearing outer frame  46  and inner block  48  enable the crimper  40  to have a similar appearance and to essentially function in the same manner as the scissor-type crimper represented in  FIG. 2 . A laminate construction can be employed to construct other types of crimpers. For example,  FIGS. 14 and 15  represent a press-type crimper  80  having load-bearing bases  82  and  84  with a laminate construction. The bases  82  and  84  are not required to be assembled in an interdigitated manner, in which case the spacer laminates  58  of the prior embodiment can be omitted, such that each base  82  and  84  is shown as entirely constructed of load-bearing laminates  56 . Because crimping forces are applied in a direction normal to the plane of each base  82  and  84 , the laminates  56  primarily promote the ability of the bases  82  and  84  to resist flexing out of their respective planes. 
         [0028]    Crimpers manufactured from laminates  56  and (optionally)  58  as described above benefit from the ability to more readily handle and machine the thinner laminates  56  and  58  as compared to a solid plate of a size equivalent to a laminate component (e.g., outer frame  46  or inner block  48 ) constructed of the laminates  56  and  58 . The material for the laminates  56  and  58  can also be less expensive to purchase than an equivalent-sized solid plate. The construction from interleaved laminates  56  and  58  also facilitates machining various features that are more difficult with an equivalent-sized solid plate, for example, the side rails  30  of the outer frame  16  and the flanges  32  of the inner block  18  of the conventional scissor-type crimper of  FIGS. 2 and 4 . 
         [0029]    A round head-style crimper ( FIG. 1 ) can also benefit from being manufactured from laminates  56  and/or  58 , as the material costs, machining, and assembly of the laminates  56  and  58  to produce the annular-shaped outer frame  12  can be less extensive than the conventional approach of producing the frame  12  by casting and machining. 
         [0030]    Crimpers manufactured from laminates  56  and  58  as described above also benefit from the ability to reduce the costs associated with errors during manufacturing. For example, if an error occurs during the machining of a spacer or load-bearing laminate  56  and  58 , only a small subcomponent (e.g., the laminate  56  or  58 ) of the intended component (e.g., frame  46  or block  48 ) need be scrapped or remanufactured, avoiding the cost incurred to scrap and replace an entire equivalent-sized solid plate. 
         [0031]    In terms of operation, crimpers manufactured from laminates  56  and  58  as described above also benefit from the interdigitated frame and block flanges  70  and  72  replacing the side rails  30  and flanges  32  of the conventional scissor-type crimper of  FIGS. 2 and 4 . Because the flanges  70  and  72  of the load-bearing laminates  56  of the frame  46  and block  48  are able to slide within the gaps  74  and  76  between the flanges  70 / 72  of the other, the crimper  40  can have a greater opening and closing distance when compared to a traditional scissor-type crimper of the same dimensions, for example, the same interior area  68  within the inner perimeter  61  of the outer frame  46 . This aspect is significant because it can reduce overall size, weight, and cost of material and/or allow a larger crimping die open diameter as compared to a traditional scissor-type crimper. 
         [0032]    A variation of the techniques described above could be to manufacture either but not both of the frame  46  and block  48  from the laminates  56  and  58 . It should be further noted that, aside from the desire to interdigitate to some extent the load-bearing laminates  56  of the frame  46  and block  48 , there are no set number, thicknesses, materials, or arrangements required of the laminates  56  and  58 , other that what would be prescribed by conventional engineering principles. Furthermore, it is foreseeable that additional components could be incorporated into a laminate component (for example, the frame  46  and/or block  48 ) within the scope of the invention, including but not limited to laminates that might not be described as spacer or load-bearing laminates as these terms are used herein. 
         [0033]    In view of the above, while the invention has been described in terms of particular embodiments, it is apparent that other forms could be adopted by one skilled in the art. Therefore, the scope of the invention is to be limited only by the following claims.