Patent Description:
Structural composites are increasingly popular alternatives to traditional construction materials. Engineered wood/cellulosic (EWC) products, a type of structural composite, are typically manufactured by binding strands of wood or vegetable fiber with an adhesive under pressure. Sawmill scraps and wood that is structurally weak in its natural state can be used to make EWC products that are lighter and/or stronger than natural wood. Such products can be manufactured in a variety of sizes and configurations tailored to the end use. Some EWC products, such as glue laminated timber (glulam) and cross-laminated timber (CLT), may be used in place of natural lumber and steel.

EWC products may reduce demand for large logs from older-growth trees and provide opportunities to use smaller trees more efficiently. However, in some cases these benefits may be offset by higher manufacturing costs and the potential environmental impacts of manufacturing processes.

<CIT> discloses a continuous press for pressing mats into pressing boards in which the press has steel press belts continuously rotated in press upper and lower parts. A press framework has press frames arranged in series in a press longitudinal direction. A press cylinder works on an upper press plate or a lower press plate, and is supported on the press frames. The press frames are formed as a one-piece manufactured metal cast part and a closed frame in a window construction with a frame window. The press frames are made of spheroidal graphite cast iron and provided with a cast-voltage optimized thickening part. The press cylinder is designed as a hydraulic cylinder. <CIT> also discloses a frame module in accordance with the preamble of claim <NUM>.

<CIT> discloses a press table adapted for mounting in a press (<NUM>) and for mounting a pressing tool, including a pressing unit (<NUM>) comprising a first actuator with a displaceable first pressing cylinder for actuating the pressing tool with a first pressing force, wherein the pressing unit includes a second actuator with a through-going displaceable second pressing cylinder for actuating the pressing tool with a second pressing force, wherein the first and second actuators are arranged in continuation of each other with the first and second pressing cylinders aligned such that the pressing cylinders can actuate the pressing tool with a resulting pressing force consisting of the sum of the first pressing force and the second pressing force, and a press as well as use of a press table in a press.

<CIT> discloses a press action machine having a body which supports an operative element and means mounting the operative element for simple linear reciprocatory movement, the body itself being in the form of a curvilinear loop such as a circle or ellipse, and the arrangement of the operative element being such that the direction of its linear reciprocatory motion is parallel with a diameter of the body.

<CIT> discloses a press frame module for a press, which comprises a front plate and a rear plate, each having a rectangular plate opening with opposing first and second sides and opposing third and fourth sides. Spacer elements are arranged between the plates, such that the plates are parallely arranged with aligned plate openings between which a press chamber is formed. A press platen, which is arranged in a xy-plane, is displaceable in the press chamber along the first and second opening sides in a z direction beween a stationary lower platen and a stationary upper platen. Press forces are transferred via the upper and lower stationary platens to the front and rear plates and the spacer elements. A cage structure comprises the spacer elements in form of connecting bars, connecting the front and rear plates, and guide rails, attached to the first and second side openings for guiding the displaceable press platen. Stability is essentially maintained in a yz-plane by the connecting bars, in a xy-plane by platens and in a xz-plane by the guide rails, wherein x, y and z are coordinates of a three dimensional Cartesian coordinate system.

According to an aspect of the present invention, there is provided a press frame module according to any of claims <NUM> to <NUM>.

According to another aspect of the present invention, there is provided a press frame according to claim <NUM>.

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims.

Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order dependent.

The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments.

The terms "coupled" and "connected," along with their derivatives, may be used. Rather, in particular embodiments, "connected" may be used to indicate that two or more elements are in direct physical or electrical contact with each other. "Coupled" may mean that two or more elements are in direct physical or electrical contact. However, "coupled" may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

The description may use the terms "embodiment" or "embodiments," which may each refer to one or more of the same or different embodiments. Furthermore, the terms "comprising," "including," "having," and the like, as used with respect to embodiments, are synonymous.

In exemplary embodiments, a computing device may be endowed with one or more components of the disclosed apparatuses and/or systems and may be employed to perform one or more methods as disclosed herein.

Embodiments of a modular press suitable for use in the manufacture of EWC products are described herein. In various embodiments, a modular press may include one or more frame modules coupled together in series to form a press frame. Each frame module may have a generally planar body supported at opposite ends on a corresponding pair of bases, an interior edge that defines an opening, and an upper and a lower platform coupled to corresponding portions of the interior edge, respectively, such that the platforms extend through the opening generally perpendicular to the plane of the body. Collectively, the interior edge and the upper and lower platforms may define an aperture through which workpieces can be inserted for pressing. The aperture may have a middle portion that extends between the adjacent outer faces of the upper and lower platforms and end portions defined by the interior edge of the body. In various embodiments, the end portions of the aperture may be curved.

In accordance with the invention, each of the end portions is defined by a multiradial curve, such as a continuous, discontinuous, or mirror multiradial curve. As used herein, the term "multiradial curve" means any curve that includes two or more circular arcs, at least some of which have different radii, that are joined end-to- end. The term "continuous multiradial curve" means a curve that includes two or more circular arcs of different radii, joined tangentially without reversal of curvature. The term "discontinuous multiradial curve" means a curve that includes two or more circular arcs, at least some of which have different radii, and at least some of which are joined non-tangentially (i.e., joined at some point that is not along a common tangent). The term "mirror multiradial curve" means a multiradial curve that is symmetrical about a plane.

A platen assembly may be coupled with some or all of the frame modules. The platen assembly may include a platen disposed within the aperture and a first actuator system operable to move the platen vertically between a raised position and an intermediate, or pre-engagement, position. The platen assembly may further include a second actuator system with actuators disposed between the platen and the upper platform. The second actuator system may be operable to force the platen downwardly from the intermediate position to an engagement position to thereby press a workpiece between the platen and the lower platform.

In various embodiments, a modular press may include a transport system that is selectively operable to move workpieces into, and through, the aperture. Optionally, the transport system may include a plurality of driven conveyor rolls disposed between the lower platforms of adjacent frame modules and a third actuator system selectively actuable to raise and lower the conveyor rolls relative to the lower platform.

In some embodiments, some or all of the actuator systems may be pneumatic actuator systems. The first actuator system may include one or more air bags supported on a body/upper platform, a beam supported on the air bags, and a pair of rods disposed through opposite ends of the beam. One end of the rods may be connected to the platen, and the opposite ends of the rods may be movably coupled to the corresponding body. The second actuator system may include a plurality of pneumatic hoses (e.g., water discharge hoses) supported on the platen and arranged generally parallel to a feed path axis that extends through a center of the apertures. The third actuator system may include a plurality of air bags that can be selectively inflated and deflated to raise and lower the conveyor rolls relative to the top surfaces of the lower platforms.

Any number of frame modules may be coupled together in series with corresponding platen assembly components (and optionally, with transport assembly components) to form a modular press of a desired length for processing EWC products of various dimensions. A modular press may be designed to apply a desired pressure (e.g., <NUM> kPa or <NUM> Pa (<NUM> psi or <NUM> psi)), and/or pressures within a particular range (e.g., <NUM>-<NUM> kPa (<NUM>-<NUM> psil), <NUM>-<NUM> kPa (<NUM>-<NUM> psil), <NUM>-<NUM> kPa (<NUM>-<NUM> psil), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), or <NUM>-<NUM> kPa (<NUM>-<NUM> psi)), to a workpiece for a desired length of time.

An embodiment of a modular press <NUM> with a plurality of frame modules <NUM> is illustrated by way of example in <FIG>. In various embodiments, modular press <NUM> may include a plurality of frame modules <NUM> coupled together in series to form a press frame of a desired length. Modular press <NUM> may further include one or more platen assemblies and/or transport assemblies with corresponding actuator systems, each described further below. In some embodiments, the primary and secondary actuator systems and the conveyor actuator system are pneumatic actuator systems, as described in further detail below. In other embodiments modular press <NUM> may have hydraulic, electric, mechanical, or other types of actuators instead of, or in addition to, pneumatic actuators. Some modular presses with pneumatic actuator systems, such as the modular press illustrated in <FIG>, may be operable to press workpieces at <NUM> kPa (<NUM> psi). Others may be designed to press workpieces at another desired pressure (e.g., <NUM> kPa or <NUM> kPa (<NUM> or <NUM> psi)).

Referring now to <FIG>, a frame module <NUM> includes a body <NUM> supported at opposite ends on bases <NUM> and <NUM>, an upper platform <NUM>, and a lower platform <NUM>. Body <NUM> has opposite faces, an outer edge <NUM>, and an inner edge <NUM> that defines an opening through the body. Upper platform <NUM> and lower platform <NUM> are vertically spaced apart within the opening and coupled to the body along corresponding portions of inner edge <NUM>. Collectively, inner edge <NUM> and platforms <NUM>, <NUM> define an aperture <NUM>. In some embodiments, frame module <NUM> may also include a plurality of supports <NUM> coupled to upper/lower platform(s) <NUM>/<NUM> and body <NUM> to provide additional support (see <FIG>). Optionally, body <NUM> may also include couplers <NUM> configured for attachment to a winch, crane, or other such machinery for use to lift or move body <NUM> and/or frame module <NUM>. As shown for example in <FIG>, some frame modules <NUM> may include a conveyor roll <NUM>, as described in further detail below with regard to <FIG>.

In some embodiments frame module <NUM> may also include an abutment member <NUM> rigidly coupled to the platforms <NUM>, <NUM> and/or body <NUM> (e.g., by welds or bolts) to provide a surface against which a workpiece can be positioned and/or pushed (<FIG>). Pushing workpieces laterally against abutment member <NUM> before/during the pressing operation may help to reduce gaps within the workpiece. For example, some workpieces may have a layer of pieces (e.g., boards, strips, or the like) arranged generally parallel to the feed path axis, and the workpiece may be pushed laterally against abutment member <NUM> to press the pieces together, thereby reducing gaps between the pieces within that layer. Similarly, workpieces that include multiple layers stacked vertically onto one another may be pushed laterally against abutment member <NUM> to even-end or align the layers along one side of the workpiece, thus reducing gaps between vertically adjacent layers along that side of the workpiece.

Abutment member <NUM> may be configured to provide an abutment surface that is substantially planar and orthogonal to the platforms <NUM>, <NUM>. Alternatively, abutment member <NUM> may be configured to provide an abutment surface that defines a desired profile, such as a splined, lapped, or other interlocking profile for joining workpieces together. Thus, in some embodiments the abutment surface may define at least one ridge, notch, groove, recess, or other such feature to be formed along the side of the workpiece.

Optionally, a frame module <NUM> may be provided with an abutment member <NUM> near one end of aperture <NUM> and a horizontal actuator (e.g., an air cylinder; not shown) near the opposite end of aperture <NUM>, and the horizontal actuator may be selectively actuable to provide lateral force or "side squeeze" to force the workpiece laterally against abutment member <NUM>. In various embodiments, abutment member <NUM> may include a plate member and one or more brackets or braces that are configured to be coupled to the upper surface of upper platform <NUM> and the bottom surface of lower platform <NUM> to hold the plate member in position while avoiding interference with platen <NUM> (see e.g., <FIG>). Other embodiments may lack abutment member <NUM>.

In various embodiments, frame module <NUM> may include one or more holes <NUM> through which air/fluid conduits, electrical wiring, or other components may be inserted. The number, shape, and dimensions of holes <NUM> may vary among embodiments. Optionally, body <NUM> may lack hole(s) <NUM>.

Referring again to <FIG>, body <NUM> may be constructed from a single plate of steel or other suitable material. For example, body <NUM> may be constructed from a single plate of steel with a thickness of approximately <NUM>-<NUM> inches (<NUM> - <NUM>). In other embodiments, body <NUM> may be constructed from a plate of steel with a thickness of <NUM>-<NUM> inches (<NUM> - <NUM>). In still other embodiments, body <NUM> may be constructed from multiple plates of steel, and/or from another material, in any thickness suitable for the intended application and material used. For example, in a press designed to operate at <NUM> kPa (<NUM> pounds per square inch (psi)), body <NUM> may be <NUM> inches (<NUM>) thick, and in a press designed to operate at <NUM> kPa (<NUM> psi), body <NUM> may be <NUM> inches (<NUM>) thick. Thus, the thickness or other dimensions of body <NUM> and other components of press <NUM> may vary among embodiments.

Body <NUM> may be generally rectangular/ovoid and elongate, such that the width of body <NUM> is greater than the height. In some embodiments, body <NUM> may be generally rectangular with rounded corners. In various embodiments, some or all of the adjacent sides may be joined by rounded corners. Referring to <FIG>, body <NUM> may have a vertical center axis A-A and a longitudinal axis B-B that extend through the plane of body <NUM>. Optionally, body <NUM>, aperture <NUM>, and/or frame module <NUM> may be symmetrical about one or both of axes A-A and B-B. As best shown in <FIG>, feed path axis C-C may extend through aperture <NUM>, orthogonal to the plane of body <NUM>.

Body <NUM> may be substantially ovoid in some embodiments. Alternatively, body <NUM> may be generally rectangular with two or more rounded corners. The bottom edge of body <NUM> may be curved, with downward projections at opposite ends thereof, in some embodiments.

Aperture <NUM> may have any suitable shape or size. Aperture <NUM> is elongate and defined collectively by upper platform <NUM>, lower platform <NUM>, and inner edge <NUM> of body <NUM>. Aperture <NUM> is typically, but need not be, wider than upper plate <NUM> and/or lower plate <NUM>. The aperture <NUM> comprises a middle portion and two end portions. The middle portion is disposed between upper and lower platforms <NUM>, <NUM>, such that the middle portion is defined by the outer face of each of the platforms <NUM>, <NUM>. The two end portions may be disposed at opposite ends of the middle portion, such that the two end portions are defined by the inner edge <NUM> of body <NUM>, and optionally also by the ends of platforms <NUM>, <NUM> (see e.g., <FIG>).

Aperture <NUM> may be generally rectangular in some illustrative examples not falling within the scope of the claims. In embodiments of the present invention, the end portions of aperture <NUM> are curved. In various embodiments, the end portions of aperture <NUM> are curved and the outer contours of body <NUM> may be curved to distribute stress over a larger surface to thereby reduce or mitigate stress. The type, location, and degree of curvature may vary among embodiments.

In various embodiments, the end portions of aperture <NUM> are curved and corresponding portions of the outer contour of body <NUM> may be curved. For example, in some embodiments the end portions of aperture <NUM> curve outwardly, such that the aperture <NUM> is wider along its longitudinal center (e.g., along Axis B-- B of <FIG>) than in the planes of the upper and lower plates <NUM>, <NUM>. In accordance with the invention, each of the end portions of aperture <NUM> are defined by a multiradial curve. The multiradial curve may be a continuous multiradial curve or a discontinuous multiradial curve. In embodiments falling within the scope of the claims, the multiradial curve is a mirror multiradial curve.

In accordance with the invention, as illustrated for example in <FIG>, each end portion of aperture <NUM> is defined by a mirror multiradial curve with a generally horizontal plane of symmetry. The plane of symmetry is along the longitudinal centerline of the aperture <NUM> (Axis B-- B, <FIG>), equidistant between the upper and lower platforms <NUM>, <NUM>. Each mirror multiradial curve includes a first arc with a radius located above the upper platform <NUM>, a second arc with a radius located along the plane of symmetry, and a third arc with a radius located below the lower platform <NUM>, with the radii of the first and third arcs in vertical alignment. In this configuration, aperture <NUM> is widest along the plane of symmetry between the upper and lower platforms <NUM> and <NUM>, and the end portions of aperture <NUM> have a 'curved barbell' shape and a greater vertical height than the middle portion of aperture <NUM>.

The outer contour of the body <NUM> may be linear, curvilinear, or a combination of linear and curvilinear portions. For example, as shown in <FIG>, in some embodiments the outer contour of body <NUM> may be generally flat/linear along portions of the top and ends, and curved along the bottom and between the top and each of the ends. Optionally, the opposite ends and bottom of body <NUM> may define a pair of downward projections.

In various embodiments, body <NUM> may be pivotably coupled to one or both of bases <NUM>, <NUM>, such as by a corresponding pivot member <NUM>. Pivot member <NUM> may be disposed through body <NUM> (e.g., through the downward projections) and/or through the corresponding base <NUM> or <NUM>. Optionally, as best shown in <FIG>, base <NUM> may be supported on a pedestal <NUM>. Pedestal <NUM> may be configured to permit lateral movement of base <NUM> in a first direction (<FIG>, Arrow B) that lies in the plane of body <NUM>, and to restrict movement of base <NUM> in a second direction (<FIG>, Arrow A) that is perpendicular to the first direction and parallel to the feed path axis. Base <NUM> may be supported on a second pedestal <NUM>. Alternatively, base <NUM> may be supported on a base support <NUM> configured to fixedly attach base <NUM> to a floor or other underlying support surface, such as by welding and/or bolts or other fasteners. Other embodiments may lack any or all of bases <NUM>, <NUM>, pivot member <NUM>, and/or pedestal <NUM>.

Each of the upper and lower platforms <NUM>, <NUM> may include one or more plates of steel or other suitable material. In some embodiments, one or both of upper and lower platforms <NUM>, <NUM> may include two or more layers of material. For example, lower platform <NUM> may include a steel plate and one or more additional plates or layers disposed on the steel plate. Optionally, lower platform <NUM> and/or other components of modular press <NUM> may include a layer or coating of polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), Fluorinated ethylene propylene (FEP), anodized aluminium, ceramic, silicone, or other non-stick and/or low-friction material to reduce adhesion of CWE materials to the press.

Couplers <NUM> may be, or may include, one or more through-holes through body <NUM>. In some embodiments, a coupler <NUM> may include a projection in the outer periphery of body <NUM> and a through-hole through the projection. In other embodiments, couplers <NUM> may include other features integral to body <NUM>, such as grooves, projections, textured surfaces, or other such features. Alternatively, couplers <NUM> may include ring bolts or other fasteners attached to body <NUM> by welding, threaded connections, or in any suitable manner.

Multiple frame modules <NUM> may be coupled together in series to form a press frame of a desired length. The upper platforms <NUM> may collectively form an upper platform assembly, and the lower platforms <NUM> may collectively form a lower platform assembly. A platen assembly may be coupled with some or all of the frame modules <NUM>, as described below.

<FIG> and <FIG> illustrate views of a platen assembly and components thereof for a modular press, in accordance with various embodiments.

Referring first to <FIG>, a platen assembly <NUM> may include a platen <NUM> and a beam <NUM> rigidly coupled together by rods <NUM>, which may be movably coupled to frame module <NUM> by retaining members <NUM>. Platen assembly <NUM> may further include actuators <NUM> and <NUM>, and corresponding supports <NUM> and <NUM>, respectively.

Platen <NUM> may be disposed below, and generally parallel to, upper platform <NUM>, and may extend generally parallel to the feed path axis through some or all of the apertures <NUM> of frame modules <NUM>. Platen <NUM> may be connected to a first end of rods <NUM>, which may extend upwardly through corresponding portions of beam <NUM> to retaining members <NUM>, which may be coupled to frame module <NUM> (e.g., affixed to body <NUM>). The second ends of rods <NUM> may be slideable within retaining members <NUM>. Beam <NUM> may be rigidly coupled to rods <NUM>, and thus to platen <NUM>, such that the beam, rods, and platen are vertically moveable as a single unit.

Actuators <NUM> may be coupled at opposite ends to beam <NUM> and corresponding supports <NUM>. Supports <NUM> may be supported on upper platform <NUM> and/or rigidly coupled to body <NUM>. Actuators <NUM> may be selectively extended or expanded to force beam <NUM> vertically upward, away from supports <NUM>, to thereby lift platen <NUM> toward upper platform <NUM> and into a raised position. Actuators <NUM> may also be retractable and/or deflatable to thereby lower platen toward lower platform <NUM> and into an intermediate position, in which the platen is near or in contact with a workpiece on lower platform <NUM>.

Actuators <NUM> may be disposed below upper platform <NUM> on supports <NUM>, which may in turn be supported on an upper surface of platen <NUM>. Actuators <NUM> may be selectively extendable or expandable to force platen <NUM> downwardly from the intermediate position to an engagement position, in which platen <NUM> is pressing against an upper surface of a workpiece on lower platform <NUM>. Actuators <NUM> may also be selectively retractable and/or deflatable to thereby allow platen <NUM> to return to the intermediate position.

Actuators <NUM> and <NUM> may be pneumatic, hydraulic, electric, mechanical, or any other suitable type of actuator, alone or in any combination. Examples of such actuators include, but are not limited to, air cylinders, pneumatic cylinders, electric motor ball screws, planetary screws, springs, and eccentric wheels.

In some embodiments, as illustrated by way of example in <FIG>, actuators <NUM> may include airbags and actuators <NUM> may include pneumatic hoses. Water discharge hoses of the type used in mining/fracking operations may be suitable for use as the pneumatic hoses. For example, an actuator <NUM> may include a length of hose <NUM> (e.g., a length of water discharge hose) sealed at opposite ends by clamps <NUM>. In some embodiments, clamps <NUM> may include a pair of plates coupled together by screws, bolts, outer bands, or the like, with the end of the hose between them. A port <NUM> may be provided at one or both of the ends to provide passage(s) through clamp <NUM> for airflow into and out of the hose <NUM>. Alternatively, the ends of the hose <NUM> may be completely sealed (e.g., by clamps <NUM> or other means), and port <NUM> may be provided in any suitable location along hose <NUM>. Ports <NUM> may optionally include valves that are selectively operable to block and unblock the ports. In various embodiments port <NUM> may include a valve fitting such as a valve stem or any other type of partially or fully self-contained valve. In a particular example, the ends of the hose <NUM> are completely sealed (e.g., by clamps or other means), and a valve-stem like fitting is disposed through a wall of the hose proximal to the clamps.

In some embodiments supports <NUM> may be channel members formed from sheets of steel or other suitable material(s) (<FIG>). The channel members may be disposed on platen <NUM>, and actuators <NUM> may be disposed within corresponding ones of the channel members. The channel members and actuators <NUM> may be oriented generally parallel to the feed path axis and extend through the apertures <NUM> of multiple frame modules <NUM>. Alternatively, other embodiments may have channel members and actuators <NUM> that are oriented transverse to the feed path axis.

In operation, a press cycle may begin with actuators <NUM> extended, expanded, or inflated, such that platen <NUM> is in the raised position (<FIG>). A workpiece may be placed or conveyed into the apertures <NUM> to rest on lower platform <NUM>. Actuators <NUM> may be actuated (e.g., retracted or deflated) to move platen <NUM> vertically downward toward lower platform <NUM> and into the intermediate position, in which platen <NUM> may be near or in contact with an upper surface of the workpiece. (Actuators <NUM> may be actuated before, during, or after placement of the workpiece onto lower platform <NUM>. ) With the workpiece positioned on lower platform <NUM> and platen <NUM> in the intermediate position, actuators <NUM> may be extended, expanded, or inflated to press platen <NUM> downwardly from the intermediate position to an engaging position (<FIG>), in which platen <NUM> is pressing downwardly against the workpiece (<FIG>). The pressure may be maintained for a desired length of time. Actuators <NUM> may be retracted or deflated to allow platen <NUM> to return to the intermediate position, and actuators <NUM> may be extended, expanded, or inflated to raise platen <NUM> to the raised position, completing the press cycle. In various embodiments, actuators <NUM> may be retracted/deflated before actuators <NUM> are expanded/extended/inflated. Alternatively, actuators <NUM> and <NUM> may be actuated simultaneously.

In some embodiments, modular press <NUM> and/or components thereof may be dimensioned and/or configured to accommodate a stack of two or more workpieces. For example, as shown in <FIG>, a divider <NUM> may be placed onto the upper surface of a workpiece <NUM> and another workpiece <NUM> may be placed onto divider <NUM> to thereby form a stack of workpieces. The stack may be inserted into the modular press and pressed in the same or similar manner as a single workpiece. Optionally, divider <NUM> may include one or more sheets, layers, and/or coating of a non-stick or low-friction material such as PTFE, PFA, FEP, anodized aluminium, ceramic, silicone, or other material to reduce adhesion of the workpieces to one another. Processing multiple workpieces in a single press cycle may allow better operational efficiency and/or profitability than processing workpieces singly in separate cycles.

Similarly, a modular press may be used to press either one full-length, full-width workpiece or multiple smaller workpieces in a single press cycle. For example, a modular press may be used to press two full-length, half-width workpieces placed side by side within the press, or two half-length, full-width workpieces placed end to end within the press, or four half-length, half-width workpieces, or other such combinations. Optionally one or more end spacers, side spacers, or some combination thereof may be placed within the press near the smaller workpiece(s) to help distribute the pressing force along the smaller workpiece(s). For example, a modular press may be used to press two full-length, one-third-width workpieces placed side by side within the press with a one-third-width spacer between them or along one side. Likewise, a modular press may be used to press two one-third-length, full-width workpieces placed end to end within the press with a one-third-length spacer between them. Many other combinations of workpieces and spacers are possible and will be readily apparent to those skilled in the art. Again, one or more dividers such as non-stick sheets or coatings may be used between/on workpieces to reduce adhesion of the workpieces to the press and/or to one another.

Optionally, bodies <NUM> and/or apertures <NUM> may be manufactured in sizes and shapes that are tailored to the dimensions of desired products. For example, if the desired products are <NUM> inches thick and <NUM> inches thick, bodies <NUM> and/or apertures <NUM> may be configured for use to press workpieces that are <NUM> inches thick, <NUM> inches thick, <NUM>. <NUM> inches thick, etc. In other words, bodies <NUM> and/or apertures <NUM> may be dimensioned to accommodate some multiple of a desired product dimension. In some embodiments, one or more dividers <NUM> may be placed onto or under a workpiece, or between workpieces, to reach a desired thickness for pressing. The length, width, thickness, and composition of dividers <NUM> may vary among embodiments.

Alternatively, the platen assembly may include a spacer <NUM> that can be removably coupled with platen <NUM>. <FIG> illustrate schematic views of another embodiment of a frame module <NUM> with a platen assembly <NUM> that includes a removable spacer <NUM>, in accordance with various embodiments. As illustrated, in some embodiments the aperture of frame module <NUM> may be substantially rectangular with rounded/curved corners, and/or actuators <NUM> may be mounted to the upper platform (<FIG>). Spacer <NUM> may have couplers <NUM>, such as holes, ring bolts, tabs, or other such features (<FIG>) configured to allow spacer <NUM> to be removably attached to platen <NUM> (<FIG>). In some embodiments, multiple spacers <NUM> of different thicknesses may be provided for use to press workpieces of different thicknesses. Optionally, spacers <NUM> may also be configured to be removably coupled to one another to collectively form a spacer of desired dimensions.

Actuators <NUM> and/or <NUM> may be operable to move platen <NUM> among several defined vertical positions and to maintain platen <NUM> in any of those positions for a desired length of time. Alternatively, actuators <NUM> and/or <NUM> may be operable to move platen <NUM> to, and maintain platen <NUM> in, virtually any vertical position within a range. The range may include a maximum vertical height (e.g., with actuators <NUM> fully extended/expanded/inflated and actuators <NUM> fully retracted/deflated), a minimum vertical height (e.g., with actuators <NUM> fully extended/expanded/inflated and actuators <NUM> fully retracted/deflated), and all possible vertical heights between the maximum and the minimum vertical heights.

Referring now to <FIG>, multiple frame modules <NUM> may be coupled together in axial alignment along the feed path axis to form a press frame <NUM>. Platen assembly <NUM> may be coupled with press frame <NUM>. In this Figure, some components are removed or cut away to show various details.

In various embodiments, platen <NUM>, actuators <NUM>, and/or supports <NUM> may be dimensioned for a press frame of a corresponding length. For example, platen <NUM> may include a single sheet of steel, or some other suitable material, that extends through all of the apertures <NUM> of the press frame <NUM>.

In various embodiments, some or all of platen <NUM>, actuators <NUM>, and/or supports <NUM> may be modular. Press frame <NUM> may have two or more sections, each of which includes two or more consecutive frame modules <NUM>, and platen <NUM> may be dimensioned to extend through the apertures <NUM> of the frame modules of one section. Thus, each of the sections may have a corresponding platen <NUM>. For example, press frame <NUM> may include four consecutive sections, each with four frame modules <NUM>, and each section may include a platen <NUM> dimensioned to extend through the four frame modules <NUM> of that section. Alternatively, platen <NUM> may be dimensioned to extend through two, three, five, six, or more than six frame modules <NUM>. Similarly, platen <NUM> may be dimensioned to extend across some fraction (e.g., one half, one third, one fourth) of the width of the middle portion of aperture <NUM>, and multiple platens <NUM> may be arranged side-by-side. Optionally, actuators <NUM> and/or supports <NUM> may be configured to match the dimensions of the corresponding platen(s) <NUM> on which they are supported. For instance, a modular press with four sections of four frame modules per section may include actuators <NUM> and supports <NUM> dimensioned to extend through, or substantially through, one section (four frame modules <NUM>). This may allow the modular press to be lengthened or shortened to suit the end user's needs. Combinations are also possible, such as modular platens with full-length actuators/supports (e.g., for more convenient shipping/handling) or full-length platens with modular actuators/supports (e.g., for more convenient replacement or repair of those components, and/or to allow the press to continue operation if one or a few actuators is damaged).

Alternatively, platen <NUM>, supports <NUM>, and/or actuators <NUM> may be constructed/dimensioned to extend through all of the apertures <NUM> of the press frame <NUM>.

In either case, in some embodiments the actuator(s) <NUM> of one platen <NUM> may be controllable independently of the actuator(s) <NUM> of another platen <NUM>, such that fewer than all of the platens <NUM> are used to press a workpiece in a particular press cycle. For example, two modular presses (e.g., two modular presses <NUM>), each with a corresponding actuator system, may be positioned end-to-end to form a longer modular press with an upstream section and a downstream section that are controllable independently of one another. As another example, a modular press may have two platens <NUM> positioned on opposite sides of the feed path axis, each with corresponding actuators <NUM> that extend through all of the apertures of the press frame, and the actuator(s) of one platen may be controllable independently of the actuator(s) of the other platen. Again, two such presses (each with two independently controlled platens) may be positioned end-to-end to form a longer modular press with two upstream sections and two downstream sections that are independently controllable. These examples are provided merely by way of illustration, and other combinations are also possible. Thus, in some embodiments full-length and/or full-width workpieces may be pressed by actuating all of the actuators <NUM>, and shorter/narrower workpieces may be pressed by actuating only some of the actuators <NUM>. In other embodiments, actuators <NUM> may be controlled collectively rather than independently, and workpieces of less than the full length/width may be pressed by using spacers of appropriate dimensions positioned along one or both ends/sides of the workpieces to offset the difference.

Referring again to <FIG>, in various embodiments frame modules <NUM> may be provided with a through-hole 166a dimensioned to accommodate air/fluid conduits, electrical wiring, or the like. In some embodiments, through-hole 166a may be located above upper platform <NUM> along a vertical centerline of the corresponding frame module <NUM>. Frame modules <NUM> may be coupled together by connectors <NUM>, such as steel beams, plates, or other rigid and durable material. Optionally, connectors <NUM> may be hollow structures with an interior void, and may be coupled at opposite ends to adjacent frame modules <NUM> such that the interior voids and holes 166a are in axial alignment. This configuration may provide structural stability as well as a passage through press frame <NUM> for the conduits, wiring, etc..

In a particular embodiment, actuators <NUM> and <NUM> may be pneumatic actuators, and air may be supplied to them via corresponding air conduits that extend through the press frame <NUM>. Referring now to 11A-B, conduits <NUM> and <NUM> may be disposed within the through-holes 166a and connectors <NUM>. Conduit <NUM> may be operatively coupled with actuators <NUM>, and conduit <NUM> may be operatively coupled with actuators <NUM>. Conduits <NUM> and <NUM> may be operatively coupled to a source of pressurized air, as described further below. Conduit <NUM> may extend from the outer face of the first frame module <NUM> to the opposite outer face of the last frame module <NUM>. At one or both ends, conduit <NUM> may be connected to a series of additional conduits <NUM>, <NUM>, <NUM>. Conduit <NUM> may extend laterally along the outer face of the frame module, and may be connected to conduit <NUM> by conduit <NUM>. Each conduit <NUM> may be connected at opposite ends to conduit <NUM> and a corresponding one of the actuators <NUM>. Collectively, conduits <NUM>, <NUM>, <NUM>, and <NUM> may be operatively connected to the source of pressurized air, and may form a passage through which air can be introduced into, and/or removed from, actuators <NUM>.

Conduits <NUM>, <NUM>, <NUM>, and <NUM>, and/or other conduits in any suitable number and arrangement, may be provided at only one end of modular press <NUM>. Alternatively, such conduits may be provided at both ends of modular press <NUM>, and/or at predetermined increments along the length of modular press <NUM> (e.g., every four frame modules), and each group of conduits may be coupled to the same or different source of pressurized air. This may allow actuators <NUM> to be filled with air from both ends of the actuators simultaneously, which may in turn provide faster inflation and deflation of the actuators. Optionally, valves <NUM> may be provided between and/or along any of the conduits to control airflow.

Similarly, conduit <NUM> may be coupled at one or both of its opposite ends to the source(s) of pressurized air via other conduits (not shown) in the same or similar manner. Additional conduits may operatively connect conduit <NUM> to actuators <NUM>. Referring now to <FIG>, which shows a side elevational view of press frame <NUM>, frame modules <NUM> may be grouped into sections generally as discussed above. Each section may include a corresponding platen assembly <NUM> with actuators <NUM>. In the illustrated embodiment, each section has four frame modules <NUM>. However, in other embodiments, a section have two, three, five, six, or more than six frame modules <NUM>.

In some embodiments, actuators <NUM> may be coupled to the end-most frame modules <NUM> of each section. Other arrangements are also possible, and in other embodiments actuators <NUM> may be coupled to the inner-most frame modules of each section, to each of the frame modules, to every second frame module, or arranged in any other suitable manner. Regardless, each actuator <NUM> may be operatively coupled with conduit <NUM>. For example, conduit <NUM> may be provided with connectors <NUM> at locations that correspond to the locations of actuators <NUM> (<FIG>; see also <FIG>, with support <NUM> removed to reveal a connector <NUM>, and <FIG>, showing a sectional view taken along lines A-A of <FIG>). Connectors <NUM> may have nozzles <NUM> (see <FIG>, taken along lines B-B of <FIG>), and additional conduits may connect each nozzle <NUM> to a corresponding actuator <NUM>.

Optionally, conduits <NUM> and <NUM> may be coupled to corresponding outlets of a single source of pressurized air <NUM> (<FIG>). Each of the outlets may be controllable independently of the others. For example, conduits <NUM> and <NUM> may be coupled to corresponding first and second outlets, respectively, of the source of pressurized air <NUM>. The outlets may be controlled such that when air is being supplied to conduit <NUM>, airflow to conduit <NUM> is blocked, and vice versa. Alternatively, the outlets may be controlled based on pressure to provide desired airflow to each conduit simultaneously.

As shown in <FIG>, in various embodiments some or all of the frame modules <NUM> may include abutment members <NUM> rigidly coupled to the platforms <NUM>, <NUM> and/or body <NUM>. For example, in some embodiments abutment members <NUM> may be provided in an alternating fashion (e.g., every second, third, or fourth frame module <NUM>). In other embodiments, some frame modules may have an abutment member <NUM>, and other frame modules may have actuators <NUM>. In still other embodiments, some frame modules may have both an abutment member <NUM> and actuators <NUM>, or neither. Some embodiments may lack abutment members <NUM>.

Some modular presses may include a transport system/assembly. <FIG> shows a side elevational view of one such embodiment, with components of transport assembly enclosed in broken lines, enlarged in <FIG>.

Referring now to <FIG>, a conduit <NUM> may be disposed through holes 166b (see <FIG>) on each of the opposite sides of the press frame <NUM>. Conduit <NUM> may be coupled to actuators <NUM> and to the source of pressurized air <NUM>. While actuators <NUM> are shown as air bags in the illustrated embodiment, other embodiments may have other types of actuators instead of, or in addition to, air bags, and corresponding types of conduits (or no conduits). Examples of other actuators include, but are not limited to, air cylinders, pneumatic cylinders, electric motor ball screws, planetary screws, springs, and eccentric wheels.

As shown in <FIG>, consecutive frame modules <NUM> may have corresponding lower platforms <NUM>, and the frame modules may be arranged such that each lower platform <NUM> is spaced apart from the next by a gap. Conveyor rolls <NUM> may be disposed within some or all of the gaps between the lower platforms <NUM>. Optionally, a conveyor roll may be positioned upstream of the first lower platform <NUM>, downstream of the last lower platform <NUM>, or both.

Actuators <NUM> may be connected to a bottom portion of corresponding brackets <NUM>, which may extend upwardly above actuators <NUM>. The upper portion of brackets <NUM> may be coupled at opposite ends to a conveyor roll <NUM> and a support <NUM>. Each bracket <NUM> may be pivotably coupled to the corresponding support <NUM>, such as by a pivot member <NUM>. Thus, each conveyor roll <NUM> may be coupled at its opposite ends to a pair of brackets <NUM> and a pair of actuators <NUM>. Optionally, in embodiments with conveyor rolls upstream of the first lower platform <NUM> and/or downstream of the last lower platform <NUM>, the brackets for the first or last conveyor roll may be pivotably coupled to the same support <NUM> as the next conveyor roll, but in the opposite orientation, such that they pivot in the opposite rotational direction around the corresponding pivot members <NUM>.

Actuators <NUM> may be actuable to reposition conveyor rolls <NUM> between a resting position (<FIG>), in which an upper surface of the conveyor rolls is below an upper surface of lower platform <NUM>, and a transport position (<FIG>), in which the upper surface of the conveyor rolls is elevated above the upper surface of lower platform <NUM>.

In some embodiments, some of the conveyor rolls <NUM> may be coupled together in groups and driven and/or moved vertically as a unit. For example, conveyor rolls <NUM> may be coupled together in groups of two (or more) by corresponding roll frames <NUM> (<FIG>). Each of the opposite ends of roll frame <NUM> may be pivotably coupled to a corresponding one of the brackets <NUM>, such that actuation of the corresponding actuators <NUM> raises and lowers the roll frame <NUM> and its conveyor rolls <NUM> as a single unit. In some embodiments brackets <NUM> may be provided with a projection <NUM>, such as a pin or bolt, configured to support the roll frame <NUM>. In any case, conveyor rolls <NUM> may be linked together by belt(s) or chain(s) driven by a common drive, or conveyor rolls <NUM> may be driven electrically, hydraulically, pneumatically, or in any other suitable manner, either individually or collectively.

In various embodiments, actuators <NUM>, <NUM>, and <NUM> may be pneumatic actuators such as airbags or air hoses, and corresponding conduits <NUM>, <NUM>, and <NUM> may be coupled to corresponding outlets of a source of pressurized air, which may include pressure regulator/compensator mechanisms configured to control airflow into, and air pressure within, the actuators. An example of such a device is shown in <FIG>.

In operation, actuators <NUM> may be extended, expanded, or inflated to raise the conveyor rolls to the transport position. The conveyor rolls may be driven in the direction of workpiece flow to convey a workpiece thereon into the modular press. Once the workpiece has been conveyed the desired distance into the modular press, the rotation of the conveyor rolls may be stopped, and actuators <NUM> may be retracted or deflated to lower the conveyor rolls to the resting position to deposit the workpiece onto the lower platform <NUM> (see <FIG>). The platen assembly <NUM> may be operated as described above to press the workpiece for the desired length of time. The platen may be moved vertically upward away from the workpiece, and the actuators <NUM> may be extended, expanded, or inflated again to raise the workpiece above lower platform <NUM> (see <FIG>). The conveyor rolls may be driven again in the same or opposite rotational direction to convey the workpiece out of the modular press.

<FIG> illustrate an alternative embodiment of a modular press and transport assembly, in accordance with various embodiments. As shown, in some embodiments rollers <NUM> may be mounted on lateral beams <NUM> and/or axial beams <NUM>. Optionally, lateral beams <NUM> and axial beams <NUM> may be coupled together to form a single sub-frame or several modular sub-frames. In any case, actuators <NUM> may be disposed beneath the beams <NUM>/<NUM> on supports <NUM>. Actuators <NUM> may be actuable to raise and lower the beams <NUM>/<NUM> to thereby raise and lower the conveyor rolls <NUM>.

In various embodiments, a modular press may have a first set of actuators operable to exert force against the platen relative to the press frame, and a second set of actuators operable to exert force against the platen relative to the upper platform. The modular press may be operated generally as follows.

One or more workpieces may be moved into the opening of the press with the platen (e.g., platen <NUM>) in the raised position. In some embodiments, the workpiece(s) may be deposited onto conveyor rolls (e.g., conveyor rolls <NUM>), and the conveyor rolls may be rotated until the workpiece is in the desired position within the modular press. With the workpiece in position, the conveyor rolls may be stopped and lowered to deposit the workpiece onto the lower platform (e.g., platform <NUM>). In a particular embodiment, the conveyor rolls may be raised and lowered by operating a third set of actuators that are operable to exert force against the conveyor rolls relative to the press frame or underlying floor. Optionally, the third set of actuators may be a set of pneumatic actuators such as air bags (e.g., actuators <NUM>). In some embodiments, the workpiece(s) may also be pushed laterally against an abutment member generally as described above.

The upper platen may be moved downwardly into the intermediate position by retracting/deflating the first set of actuators (e.g., actuators <NUM>). The upper platen may be moved to the intermediate position before, during, or after placement of the workpiece(s) onto lower platform <NUM>. In some embodiments, the first set of actuators is a set of pneumatic actuators operatively coupled with a source of pressurized air. Optionally, these pneumatic actuators may be air bags, and may be inflated/deflated from either end of the press or from both ends simultaneously.

The second set of actuators (e.g., actuators <NUM>) may be extended or inflated to move the platen downwardly, from the intermediate position to the engaging position, into engagement with the workpiece. The second set of actuators may be controlled to maintain the desired pressure (e.g., <NUM> psi, <NUM> psi, etc.) against the workpiece for the desired length of time. The desired length of time may be determined based on factors such as workpiece dimensions, wood/fiber type, adhesive type (e.g., cold set adhesives), temperature, humidity, desired product, and the like. In some embodiments, the second set of actuators is a set of pneumatic actuators, and the air pressure may be monitored and adjusted either manually or automatically during this portion of the press cycle to maintain or adjust the desired downward force. In some embodiments, the second set of actuators may be pneumatic actuators. Optionally, these pneumatic actuators may be air hoses, and the hoses may be inflated from one end or from both ends simultaneously.

When the desired length of time has elapsed, the second set of actuators may be retracted or deflated to return the platen to the intermediate position. The first set of actuators may be extended or inflated to return the platen <NUM> to the raised position. The workpiece(s) may be moved out of the modular press once the platen is returned to the raised position, or while the platen is being returned to the raised position. In embodiments with conveyor rolls, the workpiece(s) may be moved out of the modular press by raising the conveyor rolls to lift the workpiece(s) above the lower platform and rotating the conveyor rolls until the workpiece has exited the press.

In various embodiments, a modular press may be constructed generally as follows. A plurality of generally planar bodies (e.g., bodies <NUM>) may be formed, each with a corresponding aperture (e.g., aperture <NUM>) that extends through opposite faces of the planar body. The bodies and/or apertures may have one or more curved portions. The bodies may be provided with corresponding upper and lower platforms coupled to the bodies along the upper and lower portions, respectively, of the apertures to form frame modules (e.g., frame modules <NUM>). The bodies/frame modules may be coupled together in axial alignment to form a press frame, such that the apertures collectively define a feed path extending through the bodies. (Upper/lower platforms may be coupled to the bodies before or after the bodies are coupled to one another. ) A platen may be movably coupled with the upper platform and the frame modules, such that the platen is coplanar with the feed path and the upper and lower platforms. A first actuator system may be coupled with the platen and the upper platform to selectively reposition the platen vertically relative to the bodies. A second actuator system may be coupled with the platen and the frame modules to selectively reposition the platen vertically relative to the upper platform. Optionally, a plurality of conveyor rolls may be coupled with the frame modules and disposed between adjacent ones of the lower platforms, and a third actuator system may be coupled with the conveyor rolls to selectively raise and lower the conveyor rolls. Some or all of the actuator systems may be coupled with a source of pressurized air or other pressurized fluid.

A modular press may be modified generally as follows. To extend the modular press, one or more additional frame modules may be coupled with the modular press, such that the existing press and additional frame module(s) are in axial alignment. Again, the upper and lower platforms may be coupled to the body(ies) before or after coupling the body(ies) to the existing press. A platen may be coupled to the additional frame module(s). The platen may be provided in addition to, or place of, an existing platen of the modular press. One or more of the existing actuator systems of the modular press may be extended by coupling additional actuators with the added frame module(s) and the existing actuator system. Alternatively, an existing actuator system that includes hoses (e.g., actuators <NUM>) may be extended by replacing some or all of the existing hoses with longer hoses. Likewise, a modular press may be reduced in length by uncoupling one or more frame modules and corresponding components (e.g., corresponding actuators and/or conveyor rolls) from the modular press, and removing or replacing the platen with another of appropriate size. In some embodiments, modifying the modular press may include replacing an existing actuator system with a pneumatic actuator system or other type of actuator system.

Claim 1:
A press frame module (<NUM>) comprising:
a substantially planar body (<NUM>) with opposite faces, an outer edge (<NUM>), and an inner edge (<NUM>), wherein the inner edge (<NUM>) defines an opening that extends through the body (<NUM>); and
an upper platform (<NUM>) and a lower platform (<NUM>) coupled to the inner edge (<NUM>) and extending at least partially through the opening, each of the platforms (<NUM>, <NUM>) having a corresponding outer face, wherein the outer faces are spaced apart by a gap and extend substantially perpendicular to the faces of the body (<NUM>),
wherein the platforms (<NUM>, <NUM>) and the inner edge (<NUM>) of the body (<NUM>) collectively define an elongate aperture (<NUM>) with a middle portion and two end portions, and the end portions are curved,
wherein the press frame module (<NUM>) has a first configuration in which the middle portion of the elongate aperture (<NUM>) is disposed between the outer faces of the platforms (<NUM>, <NUM>), and each of the end portions is defined by a respective portion of the inner edge that forms a multiradial curve,
characterized in that:
the multiradial curve is symmetrical about a generally horizontal plane that lies along a longitudinal centerline (B--B) of the aperture (<NUM>) equidistant between the upper and lower platforms, wherein the multiradial curve includes a first arc located above the outer face of the upper platform (<NUM>), a second arc that extends through said plane, and a third arc located below the outer face of the lower platform (<NUM>) and in vertical alignment with the first arc, such that the greatest width of the aperture (<NUM>) is along said plane and the end portions have a greater vertical height than the middle portion.