The present invention relates generally to a chopper device that distributes fiber material into a stream of resin material dispensed from a spray gun. In particular, the present invention relates to an anvil assembly used in the chopper device.
Chopper guns are frequently used in the composite material industry to form large, shaped products, such as in the marine and watercraft industries and pool and spa industries. Chopper guns comprise assemblies of a fiber chopper and a liquid spray gun. Compressed air is typically supplied to the chopper gun to power a pumping mechanism in the spray gun and an air motor in the fiber chopper. The spray gun typically receives a liquid resin material and a liquid catalyst material. Actuation of a trigger on the gun dispenses the materials into a mix chamber before being sprayed out of a nozzle of the gun. Mixing of the catalyst with the resin begins a solidification process, which eventually leads to a hard, rigid material being formed upon complete curing of the materials. The fiber chopper is typically mounted on top of the spray gun. The fiber chopper receives rovings of a fiber material, such as fiberglass, which passes between an idler wheel, an anvil and a cutter blade head. The fiber rovings are cut into small segments between the anvil and cutter blade head while being propelled out of the chopper by rotation of the anvil and the cutter blade head by the air motor. The segments of fiber are mixed into the sprayed mixture of resin and catalyst such that the final cured product is fiber reinforced.
The blade head and anvil of the fiber chopper include consumable pieces that must be replaced after a threshold wear level is surpassed. For example, the blade head typically includes a plurality of razor blades inserted into slots on a blade wheel. Also, the anvil includes a roller of soft material into which blades of the cutter blade head penetrate while slicing or chopping the fiber roving. Thus, it is necessary to frequently disassemble the fiber chopper to access the cutter blade head and anvil, after which further disassembly of those components is also needed. In particular, it is necessary to remove the anvil roller from an anvil wheel and each blade of the cutter blade head. In prior art anvils, the deformable roller was press fit over the anvil wheel. In these anvil assemblies, it is difficult to remove the worn anvil roller from the anvil wheel and to attach a new anvil roller. There is, therefore, a need for a simpler system and method for retaining anvil rollers on anvil wheels in an anvil assembly for a fiber roving chopper.
The present invention is directed to an anvil assembly for a fiber roving chopper. The anvil assembly comprises an annular roller and an annular anvil wheel. The annular roller comprises an inner diameter surface with a plurality of dovetails, and an outer diameter surface comprising a deformable material. The annular anvil wheel comprises an inner diameter surface forming a central bore for mounting the anvil assembly in the fiber roving chopper, and an outer diameter surface extending between a first end and a second end and having a plurality of dovetail slots that receive the plurality of dovetails.
In the embodiment shown, spray gun 10 comprises a two component mixing gun that receives two liquid components that mix when dispensed to produce a mixture that cures into a hardened material. A first component comprises a resin material, such as a polyester resin or a vinyl ester, and is fed into valve body 16 at material inlet 32. A second component comprises a catalyst material that causes the resin material to harden, such as Methyl Ethyl Ketone Peroxide (MEKP), and is fed into valve body 16 at catalyst inlet 34. Material inlet 32 and catalyst inlet 34 feed materials, respectively, into valves seated within valve body 16 and connected to valve assembly 28. Other inlets are provided to gun 10 for other fluids such as a solvent. Actuation of trigger 20 simultaneously causes valves of valve assembly 28 to open and causes pressurized components to flow into nozzle 18. As shown, spray gun 10 comprises an internal mixer where the two components are pressurized at inlets 32 and 34 by an external source (not shown) and mixed within tube 44 before entering nozzle 18. Pressurized air may also be provided to nozzle 18 to shape or direct the mixed flow stream. In other embodiments, the materials are mixed outside of gun 10 after being pressurized within valve body 16 with air from inlet 30 and atomized by a mixing nozzle.
Pressurized air from air inlet 30 is also fed through valve body 16 to outlet 36, which connects to an inlet (not shown) on air motor 22 of fiber chopper 12. Rovings or strands of a fiber material, such as fiberglass, are fed into cover 26 through openings in fiber inlet 38. Activation of air motor 22 by actuation of trigger 20 causes the rovings to be pulled into a cutter blade head by an anvil and idler wheel mounted on housing 24, as will be discussed in greater detail with respect to
It is frequently necessary to remove cover 26 from housing 24 of chopper 12 to perform routine maintenance after spray gun 10 and fiber chopper 12 are operated. Specifically, blades of the cutter blade head and a cutting surface of the anvil must be replaced, as the blades become dull from cutting the rovings and the cutting surface becomes lacerated from the blades. The anvil assembly of the present invention is quickly and easily removed from chopper 12 once cover 26 is removed. Furthermore, a roller body can be easily and safely replaced in the anvil assembly of the present invention.
Cover 26 comprises a multi-sided body having an opening that mates with housing 24 to conceal cutter blade head 46, anvil 48 and idler wheel 50. Cover 26 includes an opening to allow chopped rovings from cutter blade head 46 to be thrown from chopper 12. Dispenser chute 42 mounts to cover 26 with fasteners 43A and 43B near the opening to receive chopped rovings from cutter blade head 46. Dispenser chute 42 comprises a three-sided angled plate along which chopped rovings pass after being cut by chopper head assembly 46. The angle of dispenser chute 42 on fasteners 43A can be adjusted using fasteners 43B to change the trajectory of the chopped roving pieces. Knob 45 extends into cover 26 to engage tube 55 (
With reference to
Air motor 22 rotates cutter blade head 46 by rotation of a drive shaft that extends substantially coaxially with shaft support 57 of air motor 22. Engagement of blades 54 with roller 62 causes anvil assembly 48 to rotate as well. Anvil assembly 48 drives rotation of idler wheel 50 through engagement with roller 68. Rovings fed into fiber inlet 38 are grabbed by anvil assembly 48 and idler wheel 50 and pushed between anvil assembly 48 and cutter blade head 46. Blades 54 of cutter blade head 46 are pushed into roller body 62, which comprises a deformable material. The rovings are sliced between blades 54 and roller body 62 as blades 54 rotate anvil assembly 48 and cut into roller 62. Spacer spool 58 maintains blades 54 at even intervals so that the fibers are consistently cut into similarly sized lengths. Blades 54 and roller body 62 become worn and eventually need to be replaced to prevent unacceptable performance degradation of fiber chopper 12. Roller 68 is slid off its mounting shaft and removed from housing 24 to perform maintenance. Blade cartridge 56 can be replaced after retention cap 60 is removed. Fasteners are removed from spacer spool 58 to allow cutter blade head 46 to slide off of its shaft. Similarly, anvil assembly 48 is slid off its mounting shaft so that roller body 62 can be replaced. Although, roller body 62 can be replaced by simply removing retention cap 64.
Anvil wheel 63 comprises a rigid annular structure that provides support to roller body 62 and that can be mounted to housing 24 of chopper 12 (
Outer diameter surface 80 provides a smooth cylindrical surface upon which roller body 62 can be mounted. Dovetail slots 82A-82D are formed into outer diameter surface 80. Dovetail slots 82A-82D are approximately equally spaced around the circumference of outer diameter surface 80. Dovetail slots 82A-82D comprise base surfaces 98 that extend approximately parallel to the axis of anvil wheel 63, and sidewalls 100 that extend generally radially outward from base surface 98. However, sidewalls 100 within a single dovetail slot are angled toward each other to overhang base surface 98 to form a dovetail configuration.
Outer diameter surface 80 of anvil wheel 63 is substantially the same diameter as or slightly smaller in diameter than inner diameter surface 72 of roller body 62. This permits anvil roller 62 to be easily slid over outer diameter surface 80. In other embodiments, outer diameter surface 80 is slightly larger than inner diameter surface 72 to provide a snug fit, but not so as to cause an interference fit. First end 95A includes roller retention flange 84 that prevents anvil roller 62 from sliding off of anvil wheel 63.
Roller body 62 comprises an annular shape in which inner diameter surface 72 and outer diameter surface 74 extend co-axially with the central axis of anvil wheel 63. Outer diameter surface 74 of roller body 62 forms an engagement surface for razor blades 54 of cutter blade head 46 (
Inner diameter surface 72 slides over outer diameter surface 80 of anvil wheel 63 and, if desired, is sized to deform to snuggly fit on anvil wheel 63. Inner diameter surface 72 includes dovetails 76A-76D that slide into dovetail slots 82A-82D of anvil wheel 63. Dovetails 76A-76D include inner surfaces 102 and sidewalls 104. Inner surfaces 102 extend approximately parallel to the central axis of anvil wheel 63 and, thus, parallel to base surfaces 98 of dovetail slots 82A-82D. Sidewalls 104 extend generally radially inwardly from base surfaces 98. However, sidewalls 104 within a single dovetail are angled away from each other to overhang inner diameter surface 72 to form a dovetail configuration.
The embodiment of
Retention cap 64 is configured to engage anvil wheel 63 within inner diameter surface 78. Specifically, retention spring 86 is pushed by end plate 90 to push retention plate 96 into roller body 62, as discussed with reference to
As discussed with reference to
With reference to
The present invention provides a system for maintaining an anvil roller body on an anvil wheel that can be easily assembled and disassembled. For example, by simply pushing and twisting retention cap 64, full access to roller body 62 can be gained. Roller body 62 provides an easy to manufacture and disposable component that is easily slid off of anvil wheel 63 without having to stretch roller body 62. As such, anvil assembly 48 of the present invention increases efficiency in operating fiber roving chopper 12.
While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
This application claims priority under 35 U.S.C. §120 to U.S. provisional application Ser. No. 61/263,469, entitled “ANVIL CHOPPER,” filed Nov. 23, 2009 by inventor James Rohrer, the contents of which are incorporated by this reference. This application claims priority under 35 U.S.C. §119 to PCT application Serial No. PCT/2010/______, entitled “ANVIL FOR FIBER ROVING CHOPPER,” filed Nov. 23, 2010 by inventor James Rohrer, the contents of which are incorporated by this reference. The present application is related to the following co-pending application filed on the same day as this application, entitled “CUTTER BLADE HEAD FOR FIBER ROVING CHOPPER” by inventors James Rohrer and Jonathan McMichael and having U.S. patent application Ser. No. ______/Attorney Docket Number G372.12-019, the contents of which are incorporated by this reference.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US10/03030 | 11/23/2010 | WO | 00 | 4/10/2012 |
Number | Date | Country | |
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61263469 | Nov 2009 | US |