Abstract:
An adjustable foam insertion machine capable of inserting foam spacers of a user desired length into channels of cabinetry frames or other types of channels. The apparatus has a frame, a foam material feed, a foam material cutter assembly, a foam material holder, a foam material inserter, and a controller which controls and coordinates the operation of the aforesaid. The apparatus utilizes rolls of foam material, cuts them to a user desired length of foam spacer, and inserts the foam spacers pursuant to a user input. The apparatus is capable of quick, safe, and repeated foam spacer insertion without the requirement of a user feeding or utilizing pre-cut spacers or inserts.

Description:
This application claims priority of U.S. Provisional Patent Application No. 61/206,421, filed Feb. 2, 2009, entitled Adjustable Foam Insertion Machine. 
    
    
     BACKGROUND OF THE INVENTION 
     The art of the present invention relates to cabinetry construction equipment in general and more particularly to an apparatus and method of use which automates the time and labor intensive task of installing foam rubber expansion spacers into cabinet door frames prior to assembly. 
     Cabinet and other types of frames often have one or more slots or channels within an inside periphery into which the cabinet panels and other portions of the frame fit, seat, and/or mate. The slot or channel typically has a “U” shape with sidewalls and a bottom wall. When the frame is assembled from individual frame pieces, the separation of the channel bottom walls, i.e. base of the “U” shape, from frame top to bottom and from frame side to side is generally slightly greater than the cabinet panel top to bottom and side to side dimensions respectively, thereby creating a gap when the frame is assembled with a panel. This gap allows or compensates for thermal and humidity expansion and contraction and tolerance variations. In order to minimize any movement or noise of the assembled cabinet and panel, one or more short strips or inserts of foam rubber are placed within and around the frame channel prior to assembly of the frame and panel. The short strips or inserts of foam rubber compress when the frame and panel is fully assembled and ensure a positive hold of the panel and further provide for component expansion and contraction without cabinet deformation. 
     The foam rubber insert material is generally supplied in bulk rolls and requires precise cutting to form the strip inserts for the channels. Prior art devices generally require precut inserts which seriously increase assembly time and cost. For informational purposes only, a common width for said bulk material is approximately one inch in width and ¼ inch in thickness with a plurality of other sizes available. The present art adjustable foam insertion machine automates the process of foam rubber insertion by precisely cutting and inserting the foam rubber from multiple rolls. Unlike the prior art, the present art utilizes multiple rolls (preferably up to five) of foam rubber in a horizontal position and uses a roller or guide mechanism to vertically locate the foam rubber prior to cutting and inserting. The prior art machines utilize a single roll which is vertically positioned on the machine. 
     The preferred embodiment of the present art utilizes a step motor which feeds the foam rubber which is thereafter cut and inserted into the cabinetry component. The present art allows an adjustable length foam rubber material cut. The present art machine also allows customization of the cut length at the individual cabinetry shop in order to compensate for tolerances and/or other factors such as changes in humidity. 
     In the preferred embodiment, the present art utilizes pneumatic actuators, i.e. air cylinders, to cut, hold, and insert the individual foam rubber pieces. A bottom pneumatic actuator holds the bulk foam rubber material in place during the cutting process, a top pneumatic actuator cuts the foam rubber to a manufacturer desired length, and a middle pneumatic actuator inserts the cut foam rubber into the slot or channel. The present art provides a faster cycle time than the prior art as the cut foam rubber insert is formed each time the machine is cycled. The precut operation allows the foam rubber to be inserted immediately upon activation of the machine by an operator. Unlike the prior art, the present art provides quick and easy adjustability of the foam rubber insert material size. 
     Accordingly, it is an object of the present invention to provide an adjustable foam insertion machine and method of use which is capable of delivering and inserting a repeatable and programmed length of foam material within a channel of a frame. 
     Another object of the present invention is to provide an adjustable foam insertion machine and method of use which does not require manual foam insertion by an operator. 
     Another object of the present invention is to provide an adjustable foam insertion machine and method of use which is capable of quickly and economically inserting one or more lengths of foam material with a minimum of operator interface. 
     SUMMARY OF THE INVENTION 
     To accomplish the foregoing and other objects of this invention there is provided an adjustable foam insertion machine and method of use. The apparatus allows a user to automatically cut foam spacers from a bulk roll of foam material and insert said spacers into a channel of a cabinetry frame in a single operation. The apparatus allows a user to quickly and repeatedly insert foam spacers into a frame without the requirement of precutting the spacers. 
     As understood within the mechanical arts, precise cutting and feeding of a thin, flexible, and compressible foam material in order to form a narrow strip or foam spacer which is inserted into a frame channel is difficult to perform without jamming, feeding, or dimensional irregularities. The present art provides all of the aforesaid cutting, feeding, and insertion without mechanical issues expected or found within the prior art. 
     In its preferred embodiment, the apparatus comprises a frame, a controller, a work table mounted with said frame, a foam material feed, a foam material cutter assembly, a foam material holder, a foam material inserter, pneumatic valves (fed with a compressed air supply) connected with the actuators and one or more (preferably two) actuation switches. 
     The work table preferably sits atop the frame and is sized and configured at the front portion to allow the frame work piece to interface and mate with the machine (i.e. a fence) during the insertion process. One or more switches extend from a fence on the table and trigger insertion when the frame piece is positioned there against. 
     The foam material feed introduces or injects the bulk foam material into the foam material cutter assembly which performs substantially two operations when actuated. That is, the foam material cutter assembly cuts a preprogrammed length of foam and allows the foam material inserter to insert the foam spacer into the cabinetry frame. The foam material holder allows the cut foam spacer to be guided to an exiting slot whereby the inserter injects the foam spacer into a channel of the cabinetry frame. 
     For the preferred embodiment, pneumatic actuators feed, cut, and insert the foam material via the actuation of one or more pneumatic valves which are controlled by the controller. The controller is preferably any type of electronic controller or programmable logic device (as understood within the mechanical and electronic arts) which can provide time sequenced on, off, and drive signals to control the aforesaid components. The controller program operation and flow is described via the operation of the aforesaid and further described interacting mechanical components. 
     The present art apparatus is capable of storing one or more bulk rolls of foam material, feed said foam material, cut said foam material, and insert or inject said foam material, all when the user places a channeled workpiece onto the work table. All of the aforesaid is accomplished in a quick, efficient, safe, and convenient fashion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Numerous other objects, features and advantages of the invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a right front perspective view of an adjustable foam insertion machine. 
         FIG. 2  is a left front perspective view thereof. 
         FIG. 3  is a left rear perspective view thereof. 
         FIG. 4  is a right rear perspective view thereof. 
         FIG. 5  is a front plan view thereof. 
         FIG. 6  is a rear plan view thereof. 
         FIG. 7  is a left plan view thereof. 
         FIG. 8  is a right plan view thereof. 
         FIG. 9  is a top plan view thereof. 
         FIG. 10  is a bottom plan view thereof. 
         FIG. 11  is a cross sectional view taken along line  FIG. 11-FIG .  11  of  FIG. 9 . 
         FIG. 12  is a cross sectional view taken along line  FIG. 12-FIG .  12  of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION 
     The preferred embodiment of the present art adjustable foam insertion machine  10  comprises a frame  16 , a controller  74 , a work table  18  mounted with said frame  16 , a foam material feed  38 , a foam material cutter assembly  44 , a foam material holder  62 , a foam material inserter  68 , pneumatic valves  76  (fed with a compressed air supply) connected with the actuators  48 ,  66 ,  72  and one or more (preferably two) actuation switches  32 . The controller  74  is preferably an electronic box (i.e. microprocessor, microcontroller, embedded personal computer, programmable logic controller, or equivalent) which has one or more controls to feed the material  77  and allow the apparatus  10  to cycle pursuant to an input from the actuation switch(es)  32 . Alternative embodiments may utilize pneumatic, hydraulic, or mechanical controllers without departing from the scope and spirit of the present invention. 
     The work table  18  preferably sits atop the frame  16  and has a front portion  20 , a rear portion  24 , and two or more sides  26 . The work table  18  is sized and configured at the front portion  20  to allow the frame work piece  78  to interface and mate with the machine  10  during the insertion process. The one or more switches  32  extend from a fence  28  on the table  18  and trigger insertion when the frame piece  78  is positioned there against. 
     For the preferred embodiment, the foam material feed  38  comprises a stepper motor  40  interfaced with the controller  74 . The stepper motor  40  has a serrated drive wheel  42  which drives the foam material  77  into an entrance slot  50  within the foam material cutter assembly  44 . For the preferred embodiment, the drive wheel  42  compresses the foam material  77  against a raised portion  30  of the work table  18  and/or an idler wheel  31 . As the drive wheel  42  rotates, the serrations of the drive wheel  42  engage the foam material  77  and feed it towards the cutter assembly  44 . Unique to the present art is the ability of the controller  74  to control the precise rotation of the stepper motor  40 . This allows precise control and adjustability of the length of foam material  77  inserted into the cutter assembly  44  and thereby allows precise control of the foam material  77  cut length. A manufacturer can program the controller  74  for any length of foam  77  insertion (foam spacer length) desired. Also for the preferred embodiment, the entrance slot  50  of the cutter assembly  44  is offset or at a higher level than the exiting slot  58  of the cutter assembly  44 . The foam material  77  is fed into the entrance slot  50  as described, cut by the cutter  45  of the cutter assembly  44 , and exits the exiting slot  58  via the action of the foam material inserter  68 . 
     Again for the preferred embodiment, the cutter assembly  44  comprises a mount  46  attached with and extending from the work table  18 , a cutter housing  54  mounted therewith, a cutter  45  positioned within said housing  54 , and the top actuator  48  connected with said cutter  45 . The cutter housing  54  has a channel or opening  56  within which the cutter  45  is slidably engaged and advanced or retracted by said top actuator  48 . For the preferred embodiment, the mount  46  has the foam material  77  entrance slot  50  and the cutter housing  54  has the exiting slot  58 . The exiting slot  58  aligns with an inserter slot  60  within the mount  46 . An inserter tongue  70  interfaces or slidably fits with the inserter slot  60  and is connected with the middle actuator  72  near a rearmost base of the inserter tongue  70 . The inserter tongue  70 , when actuated by the middle actuator  72 , forces the recently cut foam material  77  through the exiting slot  58  and into the channel  79  of the frame work piece  78 . The middle actuator  72  is preferably mounted with the work table  18  but may also be mounted in a plurality of other fashions. 
     The foam material holder  62  comprises a holder tongue  64  which is also movably positioned within said channel  56  of the cutter housing  54 . The holder tongue  64  is connected with and actuated or moved with said bottom actuator  66 . The holder tongue  64  advances substantially flush with a bottom wall  52  of the entrance slot  50  prior to the cutter  45  advancing toward the foam material  77 . When the cutter  45  advances toward the holder tongue  64 , it pinches the foam material  77  there between and cuts the foam material  77 . The cutter  45  and holder tongue  64  are then positioned whereby the cut foam material  77  is aligned with the exiting slot  58  whereby the inserter tongue  70  may perform insertion. 
     As described, the preferred embodiment utilizes pneumatic actuators. The pneumatic valves  76  direct compressed air into or vent the actuators connected therewith via tubing or lines. The valves  76  are controlled by the controller  74  pursuant to an operators input. As understood within the arts, appropriate electrical connections are made between the valves  76  and the controller  74 . 
     A roll holder  34  attached with said frame  16  holds a roll of bulk foam material  77 . The bulk foam material  77  is fed through one or more roller guides  36 , under the serrations of the drive wheel  42  and atop the raised portion  30  of the table  18 , and into the entrance slot  50 . For the preferred embodiment, the front portion  20  of the work table  18  is adjustable in height for different sizes or types of work pieces  78 . One or more height adjusters  22  are provided which allow the front portion  20  of the work table  18  to move substantially perpendicular relative to the plane of the exiting slot  58 . 
     In operation an operator places a roll of bulk foam material  77  onto the roll holder  34 , feeds the material  77  through the guides  36 , under the drive wheel  42  of the feed, and into the entrance slot  50  of the cutting assembly  44 . The controller  74  is programmed for a specific feed length and operation begins. The operator places a frame work piece  78  with a slot or channel  79  against the fence  28  which compresses the actuation switches  32 . The cutter  45  in conjunction with the holder tongue  64  cuts a pre-programmed length of the foam material  77 , aligns the foam material  77  with the exiting slot  58 , and the inserter  68  forces the cut material  77  into the slot or channel  79  of the frame work piece  78 . The foam material  77  is then fed by the feed and another insertion operation may begin. 
     The art of the present invention may be manufactured from a plurality of materials including but not limited to metals and alloys thereof, plastics, composites, or ceramics without departing from the scope and spirit herein intended. The apparatus may further be manufactured via molding, machining, casting, forging, pressing, laminating, carving, or utilization of stereo-lithographic or electro-dynamic milling or other techniques which are appropriate for the material utilized. For the preferred embodiment, the frame  16  is manufactured from a steel material and the work table  18  is manufactured from an aluminum material. 
     Although described for enablement purposes, the lengths, widths, and other dimensional attributes may depart significantly from those specified. The shape, size, location, component numbers and mounting methods utilized for the components described may take a plurality of forms as recognized within pertinent arts without departing from the scope and spirit of the present invention. 
     Having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the invention and its method of use without departing from the spirit herein identified. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described. Rather, it is intended that the scope of this invention be determined by the appended claims and their equivalents.