Method and apparatus for welding 3D bellows, and bellows

Abstract

The present invention relates to a method for welding a 3D bellows. The method includes: repeatedly laminating a unit cell material, a second adhesion-preventing film, a different unit cell material, and a first adhesion-preventing film; forming ventilation holes on the unit cell materials by pressing a hole-processing cutter on which a hole-circumference welding heater is installed onto the laminated unit cell materials and the first adhesion-preventing films, and then heating the circumference of the ventilation holes; finishing two sides of the unit cells by positioning, on two outermost surfaces of the laminated unit cell materials, a first finishing unit cell material and a second finishing unit cell material provided with an air injection port; and cutting the first finishing unit cell material, the unit cell materials, and the second finishing unit cell material and heating the periphery of the cut area by pressing a contour-processing cutter.

Claims

1. A 3D bellows including a plurality of unit cells and comprising: a first finishing unit cell material that is disposed on a side of two outermost sides of the unit cells and finishes an outermost side of the unit cells; unit cell materials that are laminated on the top of the first finishing unit cell material to fit to the number of unit cells to be manufactured and each have a ventilation hole; a second finishing unit cell material that is disposed on the other side of the outermost sides of the unit cells and finishes the other outermost side of the unit cells; an air injection hole that is formed at the second finishing unit cell material to inject/discharge air into/out of the unit cells; first adhesion-preventing films that are disposed around the ventilation holes of the unit cell materials, are disposed not in all gaps between the unit cell materials, but alternately between the unit cell materials, and prevent thermal welding of the circumferences of the ventilation holes of two unit cell materials adjacent up and down when the circumferences of the ventilation holes are heated; and second adhesion-preventing films that are disposed around the unit cell materials, are disposed not in all gaps between the unit cell materials, but alternately between the unit cell materials, where the first adhesion-preventing films are not disposed, and prevent thermal welding of the perimeters of two unit cell materials adjacent up and down when the perimeters of the unit cell materials are heated.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) FIG. 1 is a schematic cross-sectional view in which some of cell materials and films for manufacturing a 3D bellows of the present invention are separated.

(2) FIG. 2 is a schematic cross-sectional view showing a state in which the cell materials and the films of FIG. 1 are in close contact with each other.

(3) FIG. 3 is a schematic cross-sectional view showing a hole-processing cutter for forming ventilation holes.

(4) FIG. 4 is a schematic cross-sectional view showing a state in which ventilation holes are formed by a hole-processing cutter and a hole-circumference welding heater and then a hole-circumference welding portion is formed around the ventilation holes of unit cells being in contact with each other without a first adhesion-preventing film.

(5) FIG. 5 is a schematic cross-sectional view showing a state in which a first finishing unit cell material and a second finishing unit cell material are positioned on both sides of FIG. 4.

(6) FIG. 6 is a schematic cross-sectional view showing a state in which the first finishing unit cell material and the second finishing unit cell material are in close contact with each other and the contour is ready for cutting to fit to the shapes of the unit cells.

(7) FIG. 7 is a schematic cross-sectional view showing a state in which a contour welding portion is formed around the contour of the unit cell materials being in contact with each other without a second adhesion-preventing film after the periphery of unit cells is cut.

(8) FIG. 8 is a schematic perspective view showing a state in which manufacturing is finished.

(9) FIG. 9 is a schematic perspective view showing a state in which air is injected into unit cells.

(10) FIG. 10 is a cross-sectional view of FIG. 9.

(11) FIG. 11 is a schematic cross-sectional view showing another embodiment of the present invention.

(12) FIG. 12 is a schematic cross-sectional view showing a state in which the periphery of a ventilation hole is welded after the ventilation hole is formed by a hole-processing cutter.

(13) FIG. 13 is a schematic perspective view showing a state in which a plurality of unit cells is laminated.

(14) FIG. 14 is a schematic cross-sectional view showing a state in which one unit cell is filled with air.

(15) FIG. 15 is schematic plan views showing another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(16) Detailed features and advantages of the present invention will be made clearer from the following description referring to the accompanying drawings.

(17) FIG. 1 is a schematic cross-sectional view in which some of cell materials and films for manufacturing a 3D bellows of the present invention are separated, FIG. 2 is a schematic cross-sectional view showing a state in which the cell materials and the films of FIG. 1 are in close contact with each other, and FIG. 3 is a schematic cross-sectional view showing a hole-processing cutter for forming ventilation holes. FIG. 4 is a schematic cross-sectional view showing a state in which ventilation holes are formed by a hole-processing cutter and a hole-circumference welding heater and then a hole-circumference welding portion is formed around the ventilation holes of unit cells being in contact with each other without a first adhesion-preventing film, FIG. 5 is a schematic cross-sectional view showing a state in which a first finishing unit cell material and a second finishing unit cell material are positioned on both sides of FIG. 4, FIG. 6 is a schematic cross-sectional view showing a state in which the first finishing unit cell material and the second finishing unit cell material are in close contact with each other and the contour is ready for cutting to fit to the shapes of the unit cells, FIG. 7 is a schematic cross-sectional view showing a state in which a contour welding portion is formed around the contour of the unit cell materials being in contact with each other without a second adhesion-preventing film after the periphery of unit cells are cut, FIG. 8 is a schematic perspective view showing a state in which manufacturing is finished, FIG. 9 is a schematic perspective view showing a state in which air is injected into unit cells, and FIG. 10 is a cross-sectional view of FIG. 9.

(18) A 3D bellows of the present invention includes a plurality of unit cells 10 that are welded to each other by two-time punching work, in which the unit cells 10 are composed of a unit cell materials 20, a first adhesion-preventing film 30, a second adhesion-preventing film 40, a first finishing unit cell material 50, and a second finishing unit cell material 60.

(19) The unit cell materials 20 are laminated on the top of the first finishing unit cell material 50 to fit to the number of the unit cells 10 to be manufactured and each have a ventilation hole 21.

(20) The first adhesion-preventing film 30 is disposed around the ventilation hole 21 of the unit cell material 20, is disposed alternately between the unit cell materials 20, and prevents the circumferences of the ventilation holes 20 of two unit cell materials 20 adjacent up and down from being thermally welded when the circumferences of the ventilation holes 21 are heated.

(21) The first adhesion-preventing film 30 is alternately disposed with a second adhesion-preventing film 40 to be described below between the unit cell materials 20, as shown in FIG. 1, when the second adhesion-preventing film 40 is disposed between the first and second unit cell materials 20 from the bottom, the first adhesion-preventing film 30 is disposed between the second and the fourth unit cell materials 20, and in this way, the first adhesion-preventing film 30 and the second adhesion-preventing film 40 are alternately disposed between the unit cell materials 20 to fit to the number of the unit cell materials 20.

(22) The second adhesion-preventing film 40 is disposed around the unit cell material 20, is disposed alternately between the unit cell materials 20 where the first adhesion-preventing film 30 is not disposed, not in all gaps between the unit cell materials 20, and prevents the contours of two unit cell materials 20 adjacent up and down from being thermally welded when the contours of the unit cell materials 20 are heated.

(23) The second adhesion-preventing film 40 is alternately disposed with the first adhesion-preventing film 30 between the unit cell materials 20, as shown in FIG. 1, when the second adhesion-preventing film 40 is disposed between the first and second unit cell materials 20 from the bottom, the first adhesion-preventing film 30 is disposed between the second and the fourth unit cell materials 20, and in this way, the first adhesion-preventing film 30 and the second adhesion-preventing film 40 are alternately disposed between the unit cell materials 20 to fit to the number of the unit cell materials 20.

(24) The first finishing unit cell material 50 is disposed on a side of both outermost sides of the unit cells 10 and finishes an outermost side of the unit cells 10.

(25) The second finishing unit cell material 60 is disposed on the other side of both outermost sides of the unit cells 10 and finishes the other outermost side of the unit cells 10. Accordingly, both outermost sides of the unit cells are finished by the first finishing unit cell material 50 and the second finishing unit cell material 60, so the spaces between the unit cells 10 are sealed.

(26) An air injection hole 61 is formed at the second finishing unit cell material 60 and air is injected/discharged into/out of the unit cells 10.

(27) The unit cells 10 for a 3D bellows of the present invention are manufactured by a 3D bellow welding device. The 3D bellow welding device includes a hole-processing cutter 70, a hole-circumference welding heater 80, a contour-processing cutter 90, and a contour welding heater 100.

(28) The hole-processing cutter 70 forms ventilation holes 21 through the unit cell materials 20 and the first adhesion-preventing films 30 by punching the portion where two unit cell materials 20, the first adhesion-preventing film 30, and other two unit cell material 20 are laminated.

(29) The hole-circumference welding heater 80 is disposed on the hole-processing cutter 70 to heat the hole-processing cutter 70 and welds the peripheries of the ventilation holes of the two adjacent unit cell materials 20 that is not blocked by the first adhesion-preventing film 30 by transmitting heat to the circumferences of the ventilation holes 21 punched by the hole-processing cutter 70.

(30) FIG. 4 is a schematic cross-sectional view showing a state in which ventilation holes 21 are formed by the hole-processing cutter 70 and the hole-circumference welding heater 80 and then hole-circumference welding portions 11 are formed around the ventilation holes 21.

(31) When the unit cell materials 20 and the first adhesion-preventing film 30 are punched by the hole-processing cutter 70, the ventilation holes 21 are formed in them. After the hole-processing cutter 70 punches them, the hole-circumference welding heater 80 is operated and heats the circumferences of the punched ventilation holes 21, the circumferences of the ventilation holes 21 are melted.

(32) In this state, the peripheries of the ventilation holes 21 of the second and third unit cell materials 20 are blocked by the first adhesion-preventing film 30. Accordingly, even though the ventilation holes 21 are melted by the hole-circumference welding heater 80, the peripheries of the ventilation holes 21 of the second and third unit materials are not welded to each other.

(33) On the other hand, the peripheries of the ventilation holes 21 of the first and second unit cell materials 20 and the peripheries of the ventilation holes 21 of the third and fourth unit cell materials 20 are not blocked by the first adhesion-preventing film 30. Accordingly, when the peripheries of the ventilation holes 21 are melted, they are weld to each other and the hole-circumference welding portions 11 are formed between them.

(34) The contour processing cutter 90 is disposed at a side of the hole-processing cutter 70 and cuts the circumferences of the first finishing unit cell material 50, the unit cell materials 20, the second adhesion-preventing film 40, and the second finishing unit cell material 60 along the contours of the unit cells 10.

(35) The contour welding heater 100 is disposed on the contour-processing cutter 90 to heat the contour-processing cutter 90 and welds the contours of the first finishing unit cell material 50, the unit cell material 20, and the second finishing unit cell material 60 that are not blocked by the second adhesion-preventing film 40 by transmitting heat to the contours of the first finishing unit cell material 50, the unit cell materials 20, and the second finishing unit cell material 60 that are punched by the contour-processing cutter 90.

(36) FIG. 7 is a schematic cross-sectional view showing a state in which a contour welding portion 12 is formed at the contour of the unit cell material 20 after the contour of the unit cell material 20 is cut.

(37) When the contour-processing cutter 90 is operated and the first finishing unit cell material 50, the unit cell materials 20, the second adhesion-preventing film 40, and the second finishing unit cell material 60 are punched, the circumferences are cut along the contour of the unit cell 10.

(38) When the contour welding heater 100 is operated and heats the contours of the first finishing unit cell material 50, the second finishing unit cell material 60, and the unit cell materials 20 after punching by the contour-processing cutter 90, the cut contours are melted. In this state, the unit cell materials 20 at the upper and lower portions where the second adhesion-preventing film 40 are not welded to each other, even though their contours are melted.

(39) However, the contours of two sides being in contact with each other because there is not provided the second adhesion-preventing film 40 are melted and welded to each other.

(40) The welded portion and the non-welded portion are described hereafter with reference to FIG. 7.

(41) Since the second adhesion-preventing film 40 is not disposed between the first finishing unit cell material 50 and the unit cell material 20 over it, they are welded when the contours are heated.

(42) Since the second adhesion-preventing film 40 is disposed between the first unit cell material 20 and the second unit cell material 20 and between the third unit cell material 20 and the fourth unit cell material 20, they are not welded to each other even if their contours are melted.

(43) However, since the second adhesion-preventing film 40 is disposed between the second unit cell material 20 and the third unit cell material 20, they are welded when the contours are heated.

(44) Further, since the second adhesion-preventing film 40 is not disposed between the fourth unit cell material 20 and the second finishing unit cell material 60, they are welded when the contours are heated.

(45) The 3D bellows of the present invention is manufactured as follows.

(46) First, unit cell materials 20 that for a side of the unit cell 10 are prepared.

(47) The second adhesion-preventing film 40 is seated on a unit cell material 20 that forms the contour of the unit cell 10 when the unit cell material 20 are prepared.

(48) Another unit cell material 20 is seated on the second adhesion-preventing film 40.

(49) When the unit cell material 20, the second adhesion-preventing film 40, and another unit cell material 20 are sequentially seated, the first adhesion-preventing film 30 is seated on another unit cell material 20 where ventilation holes 21 are formed.

(50) According to the present invention, it is possible to increase the number of the unit cells 10 by repeatedly laminating the laminated structure described above as many as the number of the unit cells 10 to be manufactured. That is, it is possible to repeatedly laminate the unit cell material 20, the second adhesion-preventing film 40, another unit cell material 20, and the first adhesion-preventing film 30 to fit to the number of the unit cells 10 to be manufactured.

(51) When a plurality of cell materials and films are laminated, the cell materials and films are pressed and supported by a pressing cushion 120, and ventilation holes 21 are formed in the unit cell materials 20 by pressing the hole-processing cutter 70 having the hole-circumference welding heater 80 to the laminated unit cell materials 20 and first adhesion-preventing films 30.

(52) Since the circumference of the ventilation hole 21 is heated by heating the hole-processing cutter 70 with the hole-circumference welding heater 80, so the peripheries of ventilation holes 21 of two adjacent unit cell materials 20 that are not blocked by the first adhesion-preventing film 30 are welded to each other.

(53) When the peripheries of the ventilation holes 21 of unit cell materials 20 being in close contact with each other are welded, both sides of the unit cells 10 are finished by positioning the first finishing unit cell material 50 and the second finishing unit cell material 60 having the air injection hole 61 to both outermost sides of the laminated unit cell materials 20.

(54) When the first finishing unit cell material 50 and the second finishing unit cell material 60 are positioned on both outermost sides of the unit cell materials 20, they are pressed and supported by the pressing cushion 120, and the first finishing unit cell material 50, the unit cell materials 20, and the second finishing unit cell material 60 are cut along the contours of the unit cells 10 by pressing the contour-processing cutter 990 having the contour welding heater 100 to the laminated first finishing unit cell material 50, unit cell materials 20, second adhesion-preventing films 40, and the second finishing unit cell material 60.

(55) When the contours of the cell materials are cut, the peripheries of the cut first finishing unit cell material 50, unit cell materials 20, and second finishing unit cell material 60 are heated by heating the contour-processing cutter 90 with the contour welding heater 100, so the contours of two adjacent unit cell materials 20 that are not blocked by the second adhesion-preventing film 40 are welded to each other.

(56) The 3D bellows of the present invention has the following effects.

(57) In the present invention, a unit cell material 20, the second adhesion-preventing film 40, another unit cell material 20, and the first adhesion-preventing film 30 are repeatedly laminated as many as the number of the unit cells 10 to be manufactured. Ventilation holes 21 are formed in the unit cell materials 20 by pressing the hole-processing cutter 70 having the hole-circumference welding heater 80 to the laminated unit cell materials 20 and first adhesion-preventing film 30 and then the circumferences of the ventilation holes 21 are heated, so the peripheries of the ventilation holes 21 of two adjacent unit cell materials 20 that are not blocked by the first adhesion-preventing film 30 are welded to each other. Both sides of the unit cells 10 are finished by positioning the first finishing unit cell material 50 and the second finishing unit cell material 60 having the air injection hole 61 to both outermost sides of the laminated unit cell materials 20, and then the first finishing unit cell material 50, the unit cell materials 20, and the second finishing unit cell material 60 are cut along the contours of the unit cells 10 by pressing the contour-processing cutter 80 and the cut circumferences are heated, so the peripheries of two unit cell materials 20 that are not blocked by the second adhesion-preventing film 40 are welded to each other.

(58) Accordingly, a plurality of unit cells 10 is formed, the unit cells 10 are bonded, and the insides of the unit cells 10 communicate with each other, by the work or laminating the unit cell material 20, the first adhesion-preventing film 30, the second adhesion-preventing film 40, the first finishing unit cell material 50, and the second finishing unit cell material 60, the work of punching ventilation holes 21, and the work of punching contours.

(59) Accordingly, by two-time punching work, not only a plurality of unit cells 10 is manufactured and the unit cells 10 are bonded to each other, but the insides of the unit cells 10 are connected to each other, so mass production is possible and the manufacturing cost can be significantly reduced.

(60) FIG. 11 is a schematic cross-sectional view showing another embodiment of the present invention, FIG. 12 is a schematic cross-sectional view showing a state in which the periphery of a ventilation hole 21 is welded after the ventilation hole 21 is formed by a hole-processing cutter 70, FIG. 13 is a schematic perspective view showing a state in which a plurality of unit cells 10 is laminated, and FIG. 14 is a schematic cross-sectional view showing a state in which one unit cell 10 is filled with air.

(61) The 3D bellows of the present invention includes a tube-shaped unit cell material 20, in which a plurality of tube-shaped separators 110 smaller than the unit cell material may be disposed. The first adhesion-preventing film 30 is inserted in the separators 110.

(62) As in FIG. 11, when unit cells 10 are prepared and laminated, the hole-processing cutter 70 is operated and form ventilation holes 21 in the unit cell material 20 and the separators 110. When the ventilation holes 21 are formed, the hole-circumference welding heater 80 is operated and welds the circumferences of the ventilation holes 21.

(63) Accordingly, the separators 110 and the unit cell material 20 around the ventilation hole 21 are welded. In this state, though not shown, the first finishing unit cell material 50 and the second finishing unit cell material 60 are positioned on both outermost sides of the unit cell material 20 and then the contours are cut and welded using the contour-processing cutter 90 and the contour welding heater 100.

(64) In this state, when air is injected into the unit cell 10, the inside expands and the separators 110 are folded, so five separated cells are defined in the unit cell 10.

(65) Accordingly, the inside of the unit cell 10 is divided into several sections by the separators 110 and the sections prevent convection in the unit cell 10, so they minimize hot air transmitted to an air mattress or cold air transmitted to a body.

(66) According to the present invention, it is possible to manufacture various shapes of bellows by two-time bonding using the method of welding a bellows, and it is possible to simply manufacture a bellows, for example, which is used for sensors, dust covers, ad lifts.

(67) FIG. 15 is schematic plan views showing other embodiments of the present invention, in which the first bellows from the left size is a donut-shaped bellows with the center and the circumference cut, the second bellows is a triangular bellows with the center and the circumference cut in a triangle, the third bellows is a rectangular bellows with the center and the circumference cut in a rectangle, and the fourth bellows is a U-shaped bellows with the circumference cut in the U-shape.

(68) As described, according to the method of welding a 3D bellows of the present invention, it is possible to simply and quickly manufacture various shapes of bellows.

(69) On the other hand, the second adhesion-preventing film 40 that is polyurethane may be bonded to the unit cell material 20 that is a fabric, in which there is no need for inserting the second adhesion-preventing film 40 between the unit cell materials 20.

(70) Further, according to the present invention, the second adhesion-preventing film 40 may be laminated on a unit cell material 20, the laminated unit cell material 20 may be punched, and a washer made of polyurethane may be welded at the punched portion.

(71) According to the present invention, a unit cell material 20 is laminated, a washer portion is cut by the hole-processing cutter 70, and then the circumference of the cut washer is heated and welded by operating the hole-circumference welding heater 80.