Method And Apparatus For Forming Profiled Articles

Abstract

An apparatus ( 40 ) for forming a profiled article ( 46 ) comprises: a forming path ( 41 ) through which a blank of deformable material to be formed into the profiled article passes; a pair of complementary and opposing body forming die members ( 45, 45 ′) adapted to travel along the forming path ( 41 ); and a drive ( 44, 44 ′) that facilitates travel of the body forming die members ( 45, 45 ′) along the forming path ( 41 ), wherein the pair of body forming die members ( 45, 45 ′) is adapted to act on the blank of deformable material independently to form a desired profile on the blank. Locating elements ( 75 ) that locate the blanks may be provided. A method of forming material is also provided. Further, there is provided a length of deformable material for use with the apparatus.

1 . An apparatus for forming a profiled article comprising:
 a forming path through which a blank of deformable material to be formed into said profiled article passes;   a pair of complementary and opposing body forming die members adapted to travel along said forming path; and   a drive that facilitates travel of said body forming die members along said forming path,   wherein said pair of body forming die members is adapted to act on said blank of deformable material independently to form a desired profile on said blank.   
     
     
         2 . An apparatus according to  claim 1 , comprising a plurality of pairs of body forming die members, each pair of body forming die members being adapted to act on a respective blank of deformable material independently to form a desired profile on each respective blank. 
     
     
         3 . An apparatus according to  claim 2 , wherein neighbouring body forming die members of said plurality of pairs of body forming die members are hingedly connected to one another. 
     
     
         4 . An apparatus according to  claim 3 , wherein said neighbouring body forming die members are hingedly connected with minimal clearance therebetween. 
     
     
         5 . An apparatus according to any one of  claims 2  to  4 , comprising locating elements mounted between adjacent body forming die members, said locating elements being adapted to locate said blanks prior to engagement of said blanks with said body forming die members. 
     
     
         6 . An apparatus according to  claim 5 , wherein said locating elements comprise locating pins. 
     
     
         7 . An apparatus according to  claim 5  or  6 , wherein adjacent blanks are connected to one another with a web and wherein said locating elements are disposed between adjacent body forming die members on a lower section of said forming path and, in use, locate on one or both sides of respective webs. 
     
     
         8 . A apparatus according to  claim 7 , wherein an upper section of said forming path comprises gaps between adjacent body forming die members, said gaps cooperating with and receiving respective locating elements in use. 
     
     
         9 . An apparatus according to any one of the preceding claims, wherein said pair of body forming die members, or each of said pair of body forming die members, is adapted to form said blank of deformable material into said profiled article in a single pass along said forming path. 
     
     
         10 . An apparatus according to any one of the preceding claims, wherein said pair of body forming die members, or each of said pair of body forming die members, is adapted to form said blank of deformable material into a profiled intermediate in a single pass along said forming path, said apparatus comprising at least one additional pair of body forming die members adapted to independently act on said profiled intermediate in at least one additional pass along said forming path, or along an additional forming path of said apparatus, to form said profiled article. 
     
     
         11 . An apparatus according to  claim 10 , wherein said apparatus comprises at least one additional forming path along which a respective pair of said at least one additional pair of body forming die members travels. 
     
     
         12 . An apparatus according to any one of the preceding claims, wherein said pair of body forming die members, or each of said pair of body forming die members, is of a length substantially equivalent to that of said blank of deformable material and acts along the length of said blank. 
     
     
         13 . An apparatus according to any one of the preceding claims, comprising first and second mounts that define said forming path therebetween and which mount first and second body forming die members of said pair of body forming die members. 
     
     
         14 . An apparatus according to  claim 13 , wherein said first and second mounts comprise drive cogs that engage said first and second body forming die members and which are driven by said drive. 
     
     
         15 . An apparatus according to  claim 13  or  14 , wherein said first and second mounts define first and second endless paths along which a first set of first body forming die members and a second set of second body forming die members respectively travel. 
     
     
         16 . An apparatus according to  claim 13  or  14 , wherein said first and second mounts define a limited path along which said pair of body forming die members travel in forward, forming, motion and reverse, resetting, motion. 
     
     
         17 . An apparatus according to any one of  claims 13  to  16 , wherein at least one of the first and second mounts comprises a large radius surface through said forming path. 
     
     
         18 . An apparatus according to  claim 17 , wherein each of the first and second mounts comprises a large radius surface through said forming path. 
     
     
         19 . An apparatus according to  claim 18 , wherein the respective radii of the large radius surfaces are substantially equal, or are different. 
     
     
         20 . An apparatus according to  claim 18  or  19 , wherein the curvature centres of radii are on respective opposite sides of said forming path, or are on the same side of the forming path. 
     
     
         21 . An apparatus according to  claim 17 , wherein one of the first and second mounts comprises a large radius surface through said forming path and the other of said first and second mounts comprises a substantially flat surface through said forming path. 
     
     
         22 . A method of forming a profiled article comprising:
 passing a blank of deformable material to be formed into said profiled article through a forming path comprising a pair of complementary and opposing body forming die members adapted to travel along said forming path; and   progressively engaging said blank with said pair of complementary and opposing body forming die members;   wherein said pair of body forming die members is adapted to act on said blank of deformable material independently to form a desired profile on said blank.   
     
     
         23 . A method according to  claim 22 , wherein said forming path comprises a plurality of pairs of body forming die members, and wherein said method comprises passing a plurality of blanks of deformable material through said forming path and engaging a respective blank with a respective pair of body forming die members to independently to form a desired profile on each respective blank. 
     
     
         24 . A method according to  claim 23 , comprising locating said blanks prior to engagement of said blanks with said body forming die members, said locating being achieved with locating elements mounted between adjacent body forming die members. 
     
     
         25 . A method according to  claim 24 , wherein said locating elements comprise locating pins. 
     
     
         26 . A method according to any one of  claims 22  to  25 , wherein said pair of body forming die members forms said blank of deformable material into said profiled article in a single pass along said forming path. 
     
     
         27 . A method according to any one of  claims 22  to  25 , wherein said pair of body forming die members forms said blank of deformable material into a profiled intermediate in a single pass along said forming path, said method further comprising:
 passing said profiled intermediate through at least one additional forming path comprising a respective at least one additional pair of complementary and opposing body forming die members adapted to travel along said a respective at least one additional forming path; and 
 progressively engaging said profiled intermediate with said at least one additional pair of body forming die members, 
 wherein said at least one additional pair of body forming die members independently acts on said profiled intermediate in at least one additional pass along said at least one additional forming path to form said profiled article. 
 
     
     
         28 . A method according to any one of  claims 22  to  27 , wherein said pair of body forming die members is of a length substantially equivalent to that of said blank of deformable material and acts along the length of said blank. 
     
     
         29 . A length of deformable material for use with an apparatus as claimed in any one of  claims 5  to  8 , comprising a plurality of blanks of said deformable material, wherein consecutive blanks of said length of deformable material are connected to one another by a web of material, said web and said consecutive blanks defining recesses adapted to engage the locating elements of the apparatus. 
     
     
         30 . A length of deformable material according to  claim 29 , wherein said blanks and said webs are integral with one another. 
     
     
         31 . A length of deformable material according to  claim 29  or  30 , wherein said length of deformable material is in the form of a roll that can be fed to the forming path of the apparatus. 
     
     
         32 . A profiled article formed in an apparatus of any one of  claims 1  to  21 , or formed by a method of any one of  claims 22  to  28 .