METHOD OF MANUFACTURING MULTI PIECE CURVED MOLDING FROM PLANAR MATERIAL

Abstract

Method of manufacturing multi piece curved molding from planar material including the steps of, milling locating holes in the bottom side of sheet material proximate ends of curved sections, milling curved section from sheet material including the finished outer radius, the finished inner radius and milled ends, milling the profile to produce the profiled top side on curved section, placing locating holes in corresponding locating pins in a precision cut off fixture and precision cutting ends of curved section thereby producing a precision cut end and discarding waste portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention, a method of manufacturing multi piece curved moldings from planar material will now be described by way of example only with reference to the following drawings in which:

FIG. 1 is a top perspective view of a CNC table together with sheet material placed thereon.

FIG. 2 is a top perspective view of the CNC table showing the curved sections being cut out of the sheet material.

FIG. 3 is a top perspective view of the CNC table showing the curved sections being removed from the sheet material after being cut.

FIG. 4 is a top plan view of the CNC table wish sheet material thereon showing pockets being cut out of the strategic locations.

FIG. 5 shows CNC table with a sheet material thereon with locating holes being cut in strategic locations.

FIG. 6 is a top plan view of a CNC table with a sheet material thereon showing the curved sections cut out of the sheet material together with the locating holes defined in the back side of the material.

FIG. 7 is a top plan view of a curved section shown being fed through a profiling tool which cuts a profiled top side onto the curved section.

FIG. 8 is a top perspective view of a curved section showing profiling tools cutting a profiled top side into the top side of the curved section.

FIG. 8 shows the bottom side of the curved sections being painted in strategic locations.

FIG. 10 is a top plan view showing schematically the sequence of steps taken into place a curved section onto a fixture.

FIG. 11 is a top plan schematic view of a curved section shown in a locked position, wherein the locating pins are seated in the locating holes on fixtures.

FIG. 12 shows schematically a cut off saw together with the fixture and a curved section, wherein the curved section is cut off by a saw blade at a precision cut line.

FIG. 13 is a top plan view showing schematically a curved section in a locked position on the fixture after it has been cut in the cut off saw showing the curved section cut at a precision cut end and the waste portion being discarded.

FIG. 14 shows schematically one end of a curved section, wherein one half of a hinge is being fitted into a pocket located in the back of the curved section.

FIG. 15 is a side plan view of the curved section and hinge shown in FIG. 14.

FIG. 16 is a top plan view showing schematically two curved sections being jointed together at the precision cut end with a hinge.

FIG. 17 is a side plan view of the two curved sections show in FIG. 16.

FIG. 18 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 19 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 20 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 21 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 22 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 23 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 24 is a bottom plan view of an alternate embodiment of a curved section.

FIG. 24 is an alternate embodiment of a bottom plan view of a curved section together with locating pins.

FIG. 26 is a top plan view showing schematically the sequence of steps taken in order to place a curved section onto a fixture having a locating block.

FIG. 27 is a top plan schematic view of a curved section shown in a locked position located on a locating block.

FIG. 28 is a top plan view showing schematically the sequence of steps taken in order to place a curved section onto a locating block located on a fixture.

FIG. 29 is a top plan schematic view of a curved section shown in a locked position.

FIG. 30 is a top plan view showing schematically the sequence of steps taken in order to place a curved section onto a fixture.

FIG. 31 is a top plan schematic view of a curved section shown in the locked position.

FIG. 32 is a top plan view showing schematically the sequence of steps taken in order to place a curved section onto a fixture.

FIG. 33 is a top plan schematic view of a curved section shown in the locked position.

FIG. 34 is a top plan schematic view of a curved section being placed on a fixture.

FIG. 35 is a top plan schematic view of a curved section shown in locked position.

FIG. 36 is a side schematic perspective view of a curved section being placed onto a fixture.

FIG. 37 is a side schematic perspective view of a curved section shown in the locked position on a fixture.

FIG. 38 is a schematic perspective view of a cut off saw together with a fixture and a curved section, wherein the curved section is cut off by a saw blade at a precision cut line.

FIG. 39 is a top plan view showing schematically a curved section in a locked position on a fixture after it has been cut off and the cut off saw showing the curved section cut at a precision cut and the waste portion being discarded.

Claims

1) Method of manufacturing multi piece curved sections from planar sheet material including the steps of; a) milling at least one female locating feature in a bottom side of the planar sheet material;b) milling at least one curved section from the planar sheet material including the finished outer radius, the finished inner radius and milled ends;c) placing the curved section onto a male locating fixture such that the female locating feature registering with the male locating fixture to securely position the curved section for subsequent precision cutting;d) precision cutting at least one end of the curved section thereby producing a precision cut end.

2) The method of manufacturing multi piece curved sections from planar material claimed in claim 1 further including the step of milling a pocket into the bottom side of the curved section adapted to receive a portion of a hinge therein.

3) The method of manufacturing multi piece curved molding from planar material claimed in claim 1 further including the step of milling a profile on the top side thereby producing a profiled top side.

4) A Method of manufacturing multi piece curved sections from planar material including the steps of; a) milling at least one female locating feature in the planar sheet material;b) milling at least one curved section from the planar sheet material including the finished outer radius, the finished inner radius and milled ends such that the locating feature is located on the curved section,c) placing the curved section onto a male locating fixture such that the female locating feature registering with the male locating fixture to securely position the curved section for subsequent precision cutting,d) precision cutting at least one end of the curved section thereby producing a precision cut end.

5) The method of manufacturing multi piece curved molding from planar material claimed in claim 4 wherein the female locating feature including locating indents defined in the curved section.

6) The method of manufacturing multi piece curved molding from planar material claimed in claim 4 wherein the female locating feature including a locating block defined in the curved section.

7) The method of manufacturing multi piece curved molding from planar material claimed in claim 4 wherein the female locating feature including locating holes defined in the curved section.

8) A system for manufacturing precision cut curved sections from planar material comprising: a) milling at least one female locating feature in the planar sheet material;b) cutting out at least one curved section from the planar sheet material by milling the finished outer radius, the finished inner radius and milled ends,c) placing the curved section onto a male locating fixture such that the female locating feature registering with the male locating fixture to securely position the curved section for subsequent precision cutting,d) precision cutting at least one end of the curved section thereby producing a precision cut end.

9) The system for manufacturing precision cut curved sections from planar material claimed in claim 8 such that the female locating feature is located on a bottom side of the curved section.

10) The system for manufacturing precision cut curved sections from planar material claimed in claim 8 wherein the female locating feature is located proximate the end of the curved section.

11) The system for manufacturing precision cut curved sections from planar material claimed in claim 8 wherein the female locating feature including locating holes defined in the bottom surface of the curved section.

12) The system for manufacturing precision cut curved sections from planar material claimed in claim 8 further including milling a pocket into the bottom side of the curved section located proximate to the precision cut end adapted to receive a portion of a hinge therein.

13) The system for manufacturing precision cut curved sections from planar material claimed in claim 12 inserting a hinge into the pockets of two adjacent curved sections such that the precision cut ends abut one another in a hinge unfolded position.

14) The system for manufacturing precision cut curved sections from planar material claimed in claim 12 wherein the pocket and hinge dimensioned to ensure the hinge is recessed and below the bottom side and in a folded position the bottom side of each curved section lies adjacent and juxtaposed.

15) The system for manufacturing precision cut curved sections from planar material claimed in claim 12 further including milling a profile on the top side of the curved section thereby producing a profiled top side