Multi-cavity handle platen conveyor - forming application

A method of pressforming handles via a web of shapable material and a web of substrate material, the method comprising steps of:

• conveying a plate of a plate train to a pressforming position near a roller press;
• feeding the web of shapable material between the plate and the roller press;
• and
• shifting the roller press so that a plurality of protrusions of the roller press extend into a plurality of pockets of the plate thereby forming bands from the shapable material.

A system for pressforming handles via a web of shapable material and a web of substrate material, the system comprising:

• a carriage;
• a conveyor assembly mounted on the carriage, the convey assembly including:
• a first shaft rotatably supported on the carriage;
• a first sprocket attached to the first shaft to rotate therewith;
• a second shaft rotatably supported on the carriage and spaced from the first shaft;
• a second sprocket attached to the second shaft to rotate therewith;
• and
• a roller chain linking the first sprocket and the second sprocket;
• a plate train conveyably engaged with the roller chain, the plate train including a plurality of plates pivotably connected to each other, each plate including:
• a flat portion;
• and
• a plurality of pockets spaced from each other via the flat portion;
• a roller press configured to engage the web of shapable material opposite the plates of the plate train, the roller press including:
• a third shaft rotatably supported on the carriage;
• and
• a plurality of discs attached to the third shaft to rotate therewith, each disc including:
• a plurality of intermediate portions annularly spaced apart from each other;
• and
• a plurality of protrusions annularly spaced apart from each other between the intermediate portions and configured to press the shapable material into the pockets of the plates;
• a sensor positioned near the plate train for ensuring timely application of adhesive to the web of shapable material relative to the pockets;
• an idler roller configured to initiate bonding between the shapable material and the substrate material via the adhesive;
• and
• a compression roller spaced from the idler roller and configured to compress the shapable material and the substrate material to increase bond strength therebetween.