# US 2019/0376231 A1 · Folding system

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- Number: US 2019/0376231 A1
- Document ID: US20190376231A1
- Status: Published application
- Kind: A1
- Application number: 16/546,445
- Filed: 2019-08-21
- Published: 2019-12-12
- Earliest claimed: 2012-11-05
- Assignees: Miller Weldmaster Corporation
- Applicants: Miller Weldmaster Corporation
- Inventors: Brian D. Henry; Zachary J. Ralston
- Web page: https://patentgrep.com/patent/US20190376231A1

## CPC

- D06H 5/00: Seaming textile materials {(splicing webs B65H21/00; seaming felts in paper-making machines D21F7/10)}
- B29C 53/36: Bending and joining, e.g. for making hollow articles (B29C53/56 takes precedence)
- B29C 65/18: using heated tools
- B29C 65/7835: {by using stops (B29C65/7823, B29C66/92651 take precedence; tongue and groove joints B29C66/124; tenon and mortise joints B29C66/126)}
- B29C 65/7841: {Holding or clamping means for handling purposes (clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04)}
- B29C 66/022: {Mechanical pre-treatments, e.g. reshaping}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/135: {Single hemmed joints, i.e. one of the parts to be joined being hemmed in the joint area}
- B29C 66/431: {Joining the articles to themselves (B29C66/4322 and B29C66/4332 take precedence)}
- B29C 66/729: {Textile or other fibrous material made from plastics}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/8161: {said pressing elements being supported or backed-up by springs or by resilient material}
- B29C 66/8242: {Pneumatic or hydraulic drives (using fluid pressure directly acting on the parts to be joined B29C66/8266)}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B29C 66/845: {C-clamp type or sewing machine type}
- B29C 2053/362: {for making hems}
- Y10T 156/1051: by folding
- D06H: MARKING, INSPECTING, SEAMING OR SEVERING TEXTILE MATERIALS (seaming by sewing D05B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A machine and method for welding sheets of plastic material. The machine includes a housing with a lower weld bar and an upper weld bar. A vertically-oriented gap is defined in a gripper assembly pivotally mounted to the housing beneath the work surface. A sheet of material is laid over the work surface covering the lower weld bar and gap. The upper weld bar is lowered to hold the sheet in place and a pusher plate is lowered relative to the upper weld bar to push some material into the gap, thereby creating a fold in the material. After withdrawing the upper weld bar and pusher plate, the gripper assembly is pivoted through ninety degrees and lays some of the folded material over the lower weld bar. The upper weld bar is lowered to weld a portion of the folded material and thereby create a pocket in the material.

## Claims

### Claim 1

A machine for welding sheets of a plastic material, said welding machine comprising:
a housing;
a lower weld bar fixedly secured to the housing such that an upper end of the lower weld bar is flush with a work surface provided on the housing;
an upper weld bar secured to the housing a distance above the lower weld bar; wherein the upper weld bar is vertically movable up and down relative to the lower weld bar;
a vertically-oriented gap defined in the work surface proximate the lower weld bar; and
a pusher plate mounted proximate the upper weld bar; said pusher plate being selectively movable up and down relative to the upper weld bar; and wherein said pusher plate is vertically aligned with the gap and is selectively receivable in the gap.

### Claim 2 (depends on 1)

The welding machine according to claim 1, wherein the gap is selectively variable in width.

### Claim 3 (depends on 1)

The welding machine according to claim 1, further comprising a gripper assembly mounted to the housing below the work surface; and wherein the gap is defined in the gripper assembly between a front plate and a clamping plate; wherein the front plate and clamping plate are oriented parallel to each other and at right angles to the work surface; and wherein the clamping plate is movable relative to the front plate.

### Claim 4 (depends on 3)

The welding machine according to claim 3, further comprising an actuator operatively engaged with the front plate; and wherein the front plate is pivotally engaged with the work surface; and wherein the actuator is selectively operable to move the front plate between a first vertical position and a second horizontal position.

### Claim 5 (depends on 4)

The welding machine according to claim 4, further comprising a rear plate spaced from the front plate and fixedly engaged therewith, wherein a space is defined between the front plate and the rear plate; and wherein the clamping plate is located in the space.

### Claim 6 (depends on 5)

The welding machine according to claim 5, wherein the actuator pivots the rear plate, the front plate, and the clamping plate in unison.

### Claim 7 (depends on 3)

The welding machine according to claim 3, further comprising one or more first actuators engaged with the clamping plate, said one or more actuators being operable to move the clamping plate one of toward the front plate and away from the front plate and thereby change a width of the gap.

### Claim 8 (depends on 1)

The welding machine according to claim 1, further comprising an upper beam provided on the housing; wherein the upper weld bar is located in the upper beam and wherein the welding machine further comprises a translation mechanism operatively engaging the pusher plate to the upper beam, wherein the translation mechanism selectively raises and lowers the pusher plate relative to the upper beam.

### Claim 9 (depends on 1)

The welding machine according to claim 1, further comprising a fabric position stop provided on the work surface, said fabric position stop being selectively horizontally movable across the work surface toward and away from the lower weld bar.

### Claim 10

A method of forming a fold or a pocket in a sheet of plastic material, said method comprising:
defining a gap in a work surface;
placing a sheet of plastic material over an opening to the gap, wherein the opening is defined in the work surface;
moving a pusher plate into contact with a region of the sheet of plastic material that extends over the opening;
moving the pusher plate inwardly into the gap; and
creating a fold in the sheet of plastic material as the pusher plate moves inwardly into the gap.

### Claim 11 (depends on 10)

The method as according to claim 10, wherein:
the defining of the gap comprises defining a vertically-oriented gap in the work surface; and
the providing of the pusher plate comprises providing a vertically-oriented pusher plate that is aligned with the vertically-oriented gap.

### Claim 12 (depends on 10)

The method as according to claim 10, wherein the defining of the gap comprises:
providing a front plate having a front surface and a rear surface that are oriented at right angles to the work surface;
providing a clamping plate having a front surface and a rear surface that are oriented at right angles to the work surface; and the gap is defined between the rear surface of the front plate and the front surface of the clamping plate; and wherein the method further comprises:
inserting the pusher plate between the front surface of the clamping plate and the rear surface of the front plate.

### Claim 13 (depends on 12)

The method as according to claim 12, further comprising:
inserting the pusher plate into the gap when the gap is set at a first width;
withdrawing the pusher plate from the gap when the fold has been created in the sheet of plastic material; and
reducing the first width of the gap to a second width; and
clamping the fold between the front plate and the clamping plate.

### Claim 14 (depends on 13)

The method as according to claim 13, wherein the reducing of the first width of the gap includes:
activating one or more actuators engaged with the clamping plate; and
moving the clamping plate toward the front plate.

### Claim 15 (depends on 14)

The method as according to claim 14, wherein the moving of the clamping plate toward the front plate includes keeping the clamping plate parallel to the front plate.

### Claim 16 (depends on 13)

The method as according to claim 13, further comprising:
rotating the clamping plate, the front plate, and the fold in the sheet of plastic material from a vertical orientation to a horizontal orientation.

### Claim 17 (depends on 16)

The method as according to claim 16, further comprising:
placing a portion of the fold that extends outwardly from the gap onto an upper surface of the sheet of plastic material and over a lower weld bar;
moving an upper weld bar into contact with the portion of the fold; and
heat-welding the portion of the fold to the upper surface of the sheet of plastic material.

### Claim 18 (depends on 12)

The method as according to claim 12, further comprising:
determining a depth of the pusher plate into the gap relative to an axis of rotation of the front plate; and
selecting the depth of the pusher plate so that when rotation of the front plate occurs, a portion of the fold extends outwardly beyond an end wall of the front plate.

### Claim 19 (depends on 10)

The method as according to claim 10, further comprising:
abutting an edge of the sheet of plastic material on the work surface against a face of a fabric position stop prior to moving the pusher plate into the gap.

### Claim 20 (depends on 19)

The method as according to claim 19, further comprising:
adjusting a location of the fabric position stop on the work surface prior to abutting the edge of the sheet of plastic material against the end face.