SYSTEM FOR GUIDING AND CLEANING FOAM MATERIALS DURING PROCESSING

Abstract

The present disclosure provides a system for processing foam materials. The system comprises an insertion assembly having a first roller and a second roller, each guiding a foam material along a predetermined path. A debris removal unit is positioned adjacent to the insertion assembly, wherein the debris removal unit comprises a plurality of air jets directed toward the foam material. A cutting assembly is positioned downstream from the debris removal unit and forms grooves in the foam material. Integrated with the cutting assembly, a cleaning unit comprises a rotary brush arranged to remove residual particles from the foam material after groove formation. Dated 11 November 2024 Jigneshbhai Mungalpara IN/PA- 2640 Agent for the Applicant

Specification

Description:System for Guiding and Cleaning Foam Materials During Processing
Field of the Invention
[0001] The present disclosure generally relates to material processing systems. Further, the present disclosure particularly relates to systems for processing foam materials.
Background
[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Processing systems for foam materials are widely utilized in industries where foam products require specific shaping, cleaning, and modification. Foam materials, being inherently lightweight and flexible, are often subjected to processes to remove debris, cut or groove sections, and eliminate residual particles. However, traditional processing systems are generally associated with drawbacks related to efficiency, accuracy, and reliability.
[0004] One conventional technique for processing foam materials includes the use of manual methods for debris removal and surface cleaning. Such manual methods typically involve brushing or wiping foam surfaces to remove particles and contaminants. Although such methods are straightforward, they are inherently labour-intensive and time-consuming. Manual methods also lack the ability to achieve consistent results, leading to varying degrees of cleanliness or surface preparation across foam batches. Moreover, these methods often fail to achieve adequate debris removal, leaving small particles adhered to the foam surface that affect subsequent processing steps. Hence, manual methods are not suitable for operations requiring high levels of cleanliness and efficiency.
[0005] In another conventional technique, automated systems employ belt conveyors to transport foam materials while performing processing tasks, such as cutting or cleaning, at designated stations. Such automated systems have been developed to improve the speed and consistency of foam processing. However, these systems are frequently limited by constraints on precision and versatility. For instance, conveyor systems typically rely on a fixed transport path, making the adjustment of foam material positioning challenging. Additionally, debris generated during cutting or other processing stages often remains on the conveyor belt or foam surface, causing blockages or defects in the final product. Cleaning units integrated within such systems are often incapable of thoroughly removing residual particles from complex foam geometries, leading to quality issues in processed foam materials.
[0006] Further, many existing foam processing systems incorporate basic air-blowing units to dislodge particles from foam surfaces. Such air-blowing units direct a stream of air at the foam material with the intent to dislodge debris. Although air-blowing units are effective in removing larger particles, finer debris and dust often adhere to foam surfaces due to static charges or the porous structure of the foam, resulting in insufficient cleaning. Furthermore, the position and orientation of air jets in such systems are often static, limiting their effectiveness in removing particles from intricate or uneven foam surfaces. Thus, such systems remain ineffective for foam applications that demand high cleanliness standards.
[0007] Additionally, certain processing systems utilize fixed cutting tools to create grooves or patterns on foam materials. Such cutting tools are generally designed to perform uniform cuts on foam materials. However, the fixed nature of said cutting tools restricts the flexibility of the system to perform varied and complex groove patterns. This lack of adaptability leads to limitations in the types of grooves that can be formed, impacting the versatility of the foam processing system. Furthermore, particles generated during cutting operations often remain embedded in the grooves or on adjacent surfaces, necessitating additional cleaning operations to prevent particle contamination of the final product. Existing cleaning units, such as static brushes, are frequently ineffective in thoroughly removing such embedded particles from foam grooves, thereby compromising the quality and integrity of processed foam materials.
[0008] Other conventional foam processing systems also incorporate various mechanisms for material guidance along a processing path. Such guidance mechanisms include roller-based systems to align foam materials during cutting or cleaning stages. However, roller-based guidance mechanisms often face challenges related to slippage or misalignment, particularly with soft and pliable foam materials. This misalignment results in inaccuracies during processing operations, leading to uneven cuts or incomplete debris removal. Consequently, traditional guidance mechanisms are inadequate in ensuring reliable foam material positioning along the processing path.
[0009] In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for processing foam materials, particularly in achieving effective debris removal, accurate material guidance, precise groove formation, and thorough particle cleaning.
[00010] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
Summary
[00011] Various objects, features, and advantages of the disclosed subject matter can be more fully appreciated with reference to the following detailed description of the disclosed subject matter when considered in connection with the following drawings, in which like reference numerals identify like elements.
[00012] The present disclosure generally relates to material processing systems. Further, the present disclosure particularly relates to systems for processing foam materials.
[00013] An objective of the present disclosure is to provide a system to process foam materials, achieving enhanced accuracy in guiding, cleaning, cutting, and particle removal. The system of the present disclosure aims to enable foam material guidance, particulate removal, groove formation, and cleaning while maintaining material integrity and alignment throughout processing.
[00014] In an aspect, the present disclosure provides a system for processing foam materials. The system comprises an insertion assembly with a first roller and a second roller to guide a foam material along a predetermined path. Adjacent to the insertion assembly, a debris removal unit with air jets is directed toward the foam material. A cutting assembly is positioned downstream from the debris removal unit, and forms grooves in the foam material. Integrated with the cutting assembly, a cleaning unit with a rotary brush removes residual particles from the foam material after groove formation.
[00015] Moreover, the system minimizes displacement by compressing the foam material between a contoured first roller and a second roller, enhancing precision for subsequent processing. Further, the second roller's lateral orientation facilitates uniform alignment of the foam material, providing stability for debris removal. Additionally, the air jets in the debris removal unit are arranged at a clearance distance to intersect the foam material perpendicularly, maximising particulate dislodgement without altering its path. Air jets are positioned to converge, enhancing debris removal from multiple surface points. The cutting assembly, aligned with the debris removal unit, thereby provides consistent groove depth and spacing, preventing structural weakening of the foam material. Moreover, the rotary brush in the cleaning unit, arranged closely to the cutting assembly, removes residual particles immediately after cutting to maintain cleanliness for post-processing. The rotary brush comprises bristles of varying lengths for effective particle removal without affecting groove integrity. A suction port adjacent to the rotary brush removes particles away from the foam material, reducing recontamination and maintaining continuous cleaning.
Brief Description of the Drawings
[00016] The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
[00017] FIG. 1 illustrates a system (100) for processing foam materials, in accordance with the embodiments of the present disclosure.
[00018] FIG. 2 illustrates a sequential diagram of the system (100) for processing foam materials, in accordance with the embodiments of the present disclosure.
Detailed Description
[00019] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.
[00020] In view of the many possible embodiments to which the principles of the present discussion may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the claims. Therefore, the techniques as described herein contemplate all such embodiments as may come within the scope of the following claims and equivalents thereof.
[00021] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items.
[00022] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00023] The present disclosure generally relates to material processing systems. Further, the present disclosure particularly relates to systems for processing foam materials.
[00024] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00025] As used herein, the term "system for processing foam materials" is used to refer to a system that processes foam-based substances through several stages to modify physical properties, improve cleanliness, and enhance material handling. Such systems may include assemblies for guiding, cutting, cleaning, and debris removal, which collectively operate to facilitate the modification of foam material structure, surface, or composition. The system may further include mechanisms configured to engage with various foam material types, including but not limited to polyurethane, polyethylene, and memory foams. Said foam materials may be in block, sheet, or roll form and may vary in density, thickness, and texture, requiring processing along a predetermined path to ensure consistency. Foam materials processed within the system can be prepared for applications requiring high precision, such as automotive padding, insulation, or packaging inserts. Additionally, such systems for processing foam materials may support large-scale or continuous operations in industrial environments while maintaining uniformity and material integrity.
[00026] As used herein, the term "insertion assembly" is used to refer to an assembly that incorporates guiding mechanisms to align and advance foam materials into the processing path. Said insertion assembly comprises at least a first roller and a second roller, each positioned to contact the foam material with minimal surface deformation, enabling smooth progression along the processing path. Such rollers may feature surfaces or contours designed to provide consistent material conveyance without slippage or misalignment, ensuring that the foam material remains securely engaged during movement. Additionally, the insertion assembly may be constructed to handle foam materials of varying thicknesses, densities, and compositions, accommodating requirements in industrial processing environments. The first and second rollers may be manufactured from materials such as rubber, polyurethane, or other non-abrasive substances to prevent surface damage to the foam material. Furthermore, the insertion assembly provides stability to the foam material, enabling it to reach subsequent processing stages with maintained orientation and position.
[00027] As used herein, the term "debris removal unit" is used to refer to a unit designed to clear particulate matter from foam materials as they advance along the processing path. Said debris removal unit comprises a plurality of air jets positioned adjacent to the foam material. The air jets direct controlled airflow towards the foam material, dislodging debris, dust, and other unwanted particles from the surface. Such a unit is positioned near the insertion assembly to maximize efficiency in particle clearance before subsequent processing stages. The air jets may operate under variable pressures and angles to achieve targeted removal of debris from complex or porous foam surfaces. The positioning of the debris removal unit at an optimal distance from the foam material prevents interference with the material path while ensuring effective debris clearance. Additionally, the debris removal unit may function continuously or intermittently based on the processing requirements of the foam material type and density.
[00028] As used herein, the term "cutting assembly" is used to refer to an assembly that imparts specific grooves or patterns onto foam materials advancing along the processing path. Said cutting assembly is positioned downstream from the debris removal unit, allowing the foam material to enter a grooving stage with a clean surface. The cutting assembly may include one or multiple blades arranged to form consistent grooves on the foam material surface. Such grooves may vary in depth, spacing, and orientation depending on the desired material specifications and final application. The cutting assembly may accommodate a wide range of foam thicknesses, densities, and compositions, providing flexibility in the types of groove patterns achieved. Each blade within the cutting assembly may be constructed from materials suited for foam processing, such as hardened steel or coated alloy, to ensure clean cuts without damaging the foam structure. Additionally, the cutting assembly is aligned to enhance accuracy in grooving, supporting quality consistency in processed foam materials.
[00029] As used herein, the term "cleaning unit" is used to refer to a unit integrated with the cutting assembly to remove residual particles from the foam material after groove formation. Said cleaning unit comprises a rotary brush positioned to make contact with the foam material, thereby clearing particles that remain after the cutting process. The rotary brush may feature bristles of various lengths and stiffnesses, designed to dislodge debris from both the surface and within the grooves of the foam material. The cleaning unit may operate continuously or at specific intervals to maintain cleanliness, preventing recontamination before the foam material exits the processing path. The rotary brush may be positioned at an optimal distance from the cutting assembly to enable immediate particle removal after groove formation, ensuring that grooves are clear and ready for subsequent processing or application. Additionally, the cleaning unit may be constructed to withstand extended operational periods in industrial environments without significant wear, ensuring consistent particle removal and surface preparation of foam materials.
[00030] FIG. 1 illustrates a system (100) for processing foam materials, in accordance with the embodiments of the present disclosure. In an embodiment, an insertion assembly 102 includes a first roller 104 and a second roller 106 positioned in close proximity along a predetermined path within system 100. The insertion assembly 102 guides foam material 108 along said path, ensuring alignment and stability for subsequent stages. The first roller 104 and the second roller 106 are positioned at an adjustable distance from each other to compress foam material 108 lightly, which provides effective alignment without deformation. Said rollers may be cylindrical, constructed from materials such as rubber, silicone, or polyurethane, each selected to offer appropriate friction and resilience when in contact with foam material 108. Such rollers are mounted on respective axles and may be rotatably supported by bearings, enabling smooth and consistent rotation as foam material 108 advances through insertion assembly 102. In certain embodiments, first roller 104 may have a series of longitudinal grooves or channels on its surface, complementing corresponding contours on second roller 106, enhancing the grip and preventing material slippage along the processing path. The compression provided by the contoured rollers minimizes foam displacement during conveyance and promotes precise positioning for processing stages downstream. Furthermore, the insertion assembly 102 may be driven by a motorized mechanism to achieve a controlled, consistent feed rate that aligns with processing requirements. Said insertion assembly 102 may further incorporate sensors or guides to ensure foam material 108 remains centered, mitigating lateral movement or misalignment that could impact subsequent processing steps. Additionally, first roller 104 and second roller 106 may be configured to rotate in opposite directions, thereby creating a counteracting movement that guides foam material 108 firmly along the predetermined path.
[00031] In an embodiment, a debris removal unit 110 is positioned adjacent to insertion assembly 102 to clear foam material 108 of loose particles or dust before further processing stages. Said debris removal unit 110 includes a plurality of air jets 112 arranged to direct targeted airflow towards foam material 108. Air jets 112 are positioned at a specific angle and clearance distance to achieve efficient particulate dislodgement, which may otherwise interfere with subsequent stages such as cutting and cleaning. Each air jet 112 may be connected to an air compressor or blower that generates sufficient airflow pressure, facilitating the removal of dust and debris adhered to foam material 108. Air jets 112 may be oriented in a pattern, such as alternating or converging configurations, ensuring a comprehensive coverage area across the surface of foam material 108. Additionally, said air jets 112 may be operated in timed intervals or bursts, synchronized with the speed of insertion assembly 102, optimizing the airflow intensity for effective debris removal. In some embodiments, debris removal unit 110 may include an air filtration or collection system positioned nearby to capture airborne particles dislodged by the air jets 112, minimizing environmental contamination and maintaining operational cleanliness. The arrangement of air jets 112 may also allow for adjustments in the angle and distance relative to foam material 108, offering adaptability for different types of foam material and debris removal requirements.
[00032] In an embodiment, a cutting assembly 114 is positioned downstream from debris removal unit 110 to form grooves in foam material 108 as part of the processing operation. Said cutting assembly 114 includes a series of blades or cutting edges spaced apart and aligned perpendicularly or at a designated angle to the path of foam material 108. Each blade within cutting assembly 114 is positioned to make precise contact with foam material 108, creating uniform grooves of specified depth based on predetermined processing requirements. Said blades may be constructed from durable materials, such as hardened steel, ceramic, or alloy composites, chosen for resilience and to prevent wear during repeated cutting operations. In some embodiments, the spacing and angle of the blades in cutting assembly 114 may be adjustable, allowing for the customization of groove width, depth, and pattern according to the intended application of the foam material. Cutting assembly 114 may also include an adjustable support mechanism, such as a spring-loaded mount or linear guide, to maintain consistent pressure between the blades and foam material 108 during grooving. Additionally, cutting assembly 114 may be connected to a motorized or pneumatic actuator that drives the blades in a reciprocating or continuous motion, enhancing the precision and efficiency of groove formation on foam material 108. In certain embodiments, cutting assembly 114 may include safety shields or guards around the blades to protect operators and prevent material from jamming during processing. The cutting assembly 114 is further aligned to receive foam material 108 from debris removal unit 110 in a clean and stable condition, ensuring the accuracy and quality of groove patterns.
[00033] In an embodiment, a cleaning unit 116 is integrated with cutting assembly 114 to perform a final cleaning stage by removing residual particles from foam material 108 after groove formation. Said cleaning unit 116 includes a rotary brush 118 positioned adjacent to cutting assembly 114 to make contact with foam material 108 immediately following the cutting process. Rotary brush 118 may include bristles of varying lengths and stiffnesses, arranged to access and clean the grooves formed by cutting assembly 114, effectively dislodging any particles remaining within or on the foam surface. The brush bristles may be constructed from materials such as nylon, polyester, or other non-abrasive synthetic fibers, selected to provide effective cleaning without compromising the integrity of foam material 108. Rotary brush 118 may be mounted on a rotatable shaft, which is driven by a motorized mechanism to provide consistent brushing action across the surface of foam material 108. Said cleaning unit 116 may further include a collection system, such as a suction port or filter, positioned nearby to capture the particles removed by rotary brush 118, thereby preventing recontamination of foam material 108. Additionally, rotary brush 118 may be positioned at an adjustable angle or proximity to cutting assembly 114, allowing for customization based on the type of foam material processed or the specific cleaning requirements. In some embodiments, cleaning unit 116 may operate in synchronization with cutting assembly 114, ensuring that residual particles are removed immediately after grooving, preserving cleanliness and enhancing readiness for further processing or application of foam material 108.
[00034] In an embodiment, the first roller 104 comprises a contoured surface, incorporating a plurality of channels that interface with the surface of second roller 106. Said channels provide a structured surface on first roller 104, allowing for a rotational engagement with second roller 106, which effectively creates a compressed conveyance passage for guiding foam material 108 along the predetermined path. The contoured channels on first roller 104 are configured to interlock with the surface of second roller 106, resulting in controlled pressure applied to foam material 108. This pressure is calibrated to reduce any undesired displacement of foam material 108, which might otherwise occur due to the material's flexibility and lightweight properties. Such a compressed passage further improves the accuracy of foam positioning as foam material 108 advances along the processing path. By minimizing lateral shifts and reducing slippage between the rollers, the contoured channels on first roller 104 support precise positioning for each subsequent processing stage. In various embodiments, first roller 104 and second roller 106 are positioned at an optimal spacing, which can be manually or automatically adjusted based on the thickness or density of foam material 108. The interface between the two rollers may also be maintained by a pressure-adjustment mechanism to achieve consistent conveyance conditions for a wide range of foam materials without deforming them.
[00035] In an embodiment, second roller 106 is arranged in a lateral orientation relative to first roller 104, establishing a specific alignment that enables uniform conveyance of foam material 108 along the predetermined path. The lateral arrangement of second roller 106 is intended to facilitate continuous engagement between the two rollers, which supports the stable advancement of foam material 108 during processing. This orientation minimizes any vertical or lateral displacement of foam material 108 that may otherwise arise from uneven pressure distribution. By maintaining consistent engagement with first roller 104, second roller 106 contributes to improved alignment of foam material 108 throughout the conveyance path, optimizing the material's readiness for subsequent operations such as debris removal, cutting, or cleaning. In various embodiments, second roller 106 may incorporate a textured or friction-enhancing surface to ensure a firm yet non-damaging grip on foam material 108. The lateral positioning further allows second roller 106 to adjust dynamically, maintaining contact even if minor variations in foam thickness occur. Additionally, second roller 106 may be mounted on an adjustable axle, allowing for the calibration of roller orientation to suit different material types or specific processing requirements, thereby supporting a stable and uniform conveyance environment for foam material 108.
[00036] In an embodiment, debris removal unit 110 is positioned at a defined clearance distance from foam material 108, facilitating effective particulate removal without interfering with the material's predetermined trajectory. The clearance distance enables air jets 112 within debris removal unit 110 to direct airflow precisely at foam material 108, maximizing particulate dislodgement while preserving the alignment achieved by insertion assembly 102. Each air jet 112 is angled to create an airflow that intersects perpendicularly with foam material 108, which enhances the force applied to dust and debris particles adhered to the foam surface. The perpendicular alignment of air jets 112 relative to foam material 108 allows for optimal cleaning efficiency by focusing airflow impact at direct contact points, thereby loosening particles effectively without shifting foam material 108. The defined clearance also prevents unwanted turbulence around foam material 108, ensuring a controlled environment for particulate removal. In various embodiments, debris removal unit 110 may include adjustable supports, allowing air jets 112 to be repositioned as needed for different foam thicknesses or particulate removal requirements. Each air jet 112 may be connected to an air compressor or blower calibrated to provide sufficient airflow velocity, thereby ensuring consistent cleaning without impacting the foam structure.
[00037] In an embodiment, each air jet 112 within debris removal unit 110 is arranged to converge with an adjacent air jet at a predetermined intersection point, resulting in a cohesive airflow pattern that enhances particulate removal from multiple surface points on foam material 108. The convergence of airflow from multiple jets creates a concentrated force at each intersection, which dislodges embedded particles more effectively than individual airflow streams. Such converging airflow directs particles away from foam material 108, preparing it optimally for downstream processing operations. The intersection points of air jets 112 can be adjusted based on material characteristics, such as foam density and particulate type, allowing for customization of debris removal according to specific requirements. In various embodiments, debris removal unit 110 may feature alignment guides to position air jets 112 precisely, ensuring the convergence angle is consistent along the entire foam surface. The airflow pattern created by the converging jets may also facilitate particulate dispersion into a collection system positioned nearby, preventing re-accumulation on foam material 108 and maintaining operational cleanliness throughout the processing path.
[00038] In an embodiment, cutting assembly 114 is disposed in sequential alignment with debris removal unit 110, enabling foam material 108 to engage precisely with said cutting assembly after debris removal. The alignment of cutting assembly 114 following debris removal unit 110 minimizes interference from particulate matter, allowing for consistent and accurate groove formation on foam material 108. Cutting assembly 114 includes one or more blades, which are positioned in alignment with the conveyance path established by insertion assembly 102, enabling precise contact with foam material 108 at each groove location. This configuration allows cutting assembly 114 to achieve a uniform depth and spacing of grooves without deviation, as foam material 108 reaches said cutting assembly in a stabilized and clean condition. In various embodiments, cutting assembly 114 may include adjustable blade mounts, allowing for customization of groove dimensions to accommodate specific material requirements. Each blade within cutting assembly 114 may be driven by a motorized actuator, enabling a continuous or reciprocating cutting motion based on the processing speed and desired groove pattern. Additionally, the alignment of cutting assembly 114 following debris removal unit 110 reduces material inconsistencies by eliminating particle interference, thereby supporting accurate and efficient groove formation across the foam surface.
[00039] In an embodiment, cutting assembly 114 comprises a series of spaced-apart blades arranged to form uniform grooves on foam material 108. Each blade within cutting assembly 114 makes contact with a defined portion of foam material 108 to achieve grooves of specific depth, with the spacing between each blade configured to prevent structural weakening of foam material 108 during processing. The arrangement of blades allows for consistent groove formation, ensuring the integrity of foam material 108 is maintained while meeting dimensional specifications. The spacing between the blades can be customized based on material thickness and groove depth requirements, with each blade mounted on a support frame to provide stability during the cutting process. Each blade may be manufactured from wear-resistant materials, such as hardened steel or alloy, which enhances durability and reduces the need for frequent replacement. Cutting assembly 114 may also include mechanisms for height adjustment, allowing each blade to reach varying depths in foam material 108 as needed.

[00040] In an embodiment, rotary brush 118 of cleaning unit 116 is positioned in close axial proximity to cutting assembly 114, enabling immediate contact with foam material 108 following groove formation. Said positioning of rotary brush 118 ensures that any residual particles remaining after the cutting process are effectively removed before re-contamination can occur. Rotary brush 118 may be driven by a motor, enabling continuous rotation as foam material 108 advances along the processing path. The bristles of rotary brush 118 are designed to reach into the grooves formed by cutting assembly 114, clearing embedded particles without causing abrasion to foam material 108. Close axial positioning of rotary brush 118 relative to cutting assembly 114 provides a seamless transition between cutting and cleaning stages, preserving the cleanliness of foam material 108 and maintaining groove integrity. In various embodiments, cleaning unit 116 may incorporate a collection or filtration system positioned nearby, capturing particles removed by rotary brush 118.
[00041] In an embodiment, rotary brush 118 comprises bristles of variable lengths, allowing each bristle to make intermittent contact with foam material 108 to dislodge residual particles without affecting groove integrity. The varying bristle lengths facilitate targeted cleaning across both surface and grooved areas of foam material 108, ensuring a comprehensive cleaning effect across the entire processed surface. The intermittent contact provided by bristles minimizes wear on foam material 108, preventing compression or deformation during the cleaning stage. Each bristle may be manufactured from resilient synthetic materials, such as nylon or polyester, which offer flexibility and durability for continuous operation. Rotary brush 118 may be positioned at an angle that optimizes bristle contact with grooves, enhancing particle removal effectiveness without compromising the structural characteristics of foam material 108. In various embodiments, rotary brush 118 may be replaceable to ensure consistent performance and accommodate cleaning requirements for various foam densities and groove patterns.
[00042] In an embodiment, cleaning unit 116 is equipped with a suction port positioned adjacent to rotary brush 118, drawing removed particles away from foam material 108 to prevent recontamination. The suction port may be connected to a vacuum or air filtration system, creating a controlled airflow that captures dislodged particles immediately upon removal by rotary brush 118. This feature maintains the cleanliness of foam material 108 as it exits the processing path, ensuring that no residual particles remain embedded on or within the material's surface. The suction port may be positioned at an adjustable distance from rotary brush 118, allowing the system to accommodate varying foam thicknesses and cleaning requirements. Additionally, the suction port may include filters to capture fine particulate matter, ensuring that only clean air is recirculated within the processing environment. In various embodiments, the suction port may operate in synchronization with rotary brush 118, ensuring efficient particle removal and maintaining operational continuity within cleaning unit 116.
[00043] FIG. 2 illustrates a sequential diagram of the system (100) for processing foam materials, in accordance with the embodiments of the present disclosure. The system 100 for processing foam materials incorporates an insertion assembly 102 with first roller 104 and second roller 106, guiding foam material 108 along a set path. Positioned adjacent to the insertion assembly 102 is a debris removal unit 110, consisting of multiple air jets 112 directed toward foam material 108 to clear debris as it moves along. After the debris removal stage, foam material 108 reaches a downstream cutting assembly 114. The cutting assembly 114 creates grooves along the surface of foam material 108, preparing it for additional processing or application. Integrated with the cutting assembly 114 is a cleaning unit 116 containing a rotary brush 118, which eliminates any remaining particles from foam material 108 after groove formation. Each component works in sequence to maintain material cleanliness, precise alignment, and structural integrity throughout the processing stages, achieving a refined and ready-to-use foam material output.
[00044] In an embodiment, the insertion assembly 102 comprising first roller 104 and second roller 106 is structured to guide foam material 108 along a predetermined path, ensuring stable alignment and minimal slippage. The rotational engagement of first roller 104 and second roller 106 provides a controlled conveyance of foam material 108, reducing potential misalignment that could disrupt downstream processing. By establishing a defined path for foam material 108, the insertion assembly 102 facilitates uniform material handling, which is critical for precision in subsequent stages such as cutting and cleaning. The positioning of first roller 104 and second roller 106 also enables foam material 108 to move continuously and without interruption, allowing for an efficient workflow through the processing system 100. Each roller may be constructed from non-abrasive materials to prevent damage to foam material 108, ensuring smooth conveyance without compromising material integrity.
[00045] In an embodiment, first roller 104 is contoured with a series of channels that interface with second roller 106, creating a compressed passage that securely guides foam material 108 along the predetermined path. The channels on first roller 104 apply a controlled compression to foam material 108, stabilizing it between first roller 104 and second roller 106 to prevent unwanted lateral movement. This compression minimizes displacement and holds foam material 108 in a fixed orientation, ensuring that the material reaches subsequent stages with consistent positioning. The interaction between the contoured surface of first roller 104 and second roller 106 effectively reduces variability in foam material 108's trajectory, which is essential for achieving precise cutting and cleaning. The compressed conveyance provided by this configuration enhances overall process accuracy by maintaining a stable and predictable material path.
[00046] In an embodiment, second roller 106 is oriented laterally relative to first roller 104, creating a spatial arrangement that supports uniform alignment of foam material 108 as it advances. The lateral orientation facilitates a balanced engagement between the rollers, which stabilizes foam material 108 and reduces the risk of deviation from the predetermined path. This orientation provides a continuous engagement between first roller 104 and second roller 106, ensuring that foam material 108 remains securely positioned throughout conveyance. The stable positioning afforded by the lateral configuration of second roller 106 is beneficial for effective debris removal, as it enables air jets to target foam material 108 without disruption. This arrangement supports an uninterrupted process flow, which is advantageous for achieving high-quality results in subsequent processing stages.
[00047] In an embodiment, debris removal unit 110 is positioned at a specified clearance distance from foam material 108, enabling air jets 112 to direct airflow with precision. Each air jet 112 is angled to create an airflow that intersects perpendicularly with foam material 108, maximizing the efficiency of particulate dislodgement. The perpendicular alignment of air jets 112 enhances the effectiveness of the cleaning process by ensuring that particles are lifted directly from the foam surface, reducing the likelihood of particles adhering to the material. The defined clearance distance prevents air turbulence that could disrupt the trajectory of foam material 108, allowing it to maintain its position along the predetermined path. The optimized placement and orientation of debris removal unit 110 contribute to a thorough cleaning of foam material 108 without altering its alignment for subsequent stages.
[00048] In an embodiment, each air jet 112 within debris removal unit 110 is strategically positioned to converge with an adjacent jet at predetermined intersections, producing a cohesive airflow pattern. This converging airflow amplifies the force applied to particulate matter on foam material 108, enhancing the removal of embedded or stubborn debris. The intersecting airflows provide concentrated pressure at multiple points across foam material 108, ensuring comprehensive particle dislodgement. This configuration prepares foam material 108 optimally for groove formation, as the thorough cleaning minimizes the risk of residual particles interfering with the cutting process. The convergence of air jets 112 allows debris removal unit 110 to achieve high levels of cleanliness, which contributes to overall process reliability and material quality in downstream operations.
[00049] In an embodiment, cutting assembly 114 is arranged in sequential alignment with debris removal unit 110, providing an uninterrupted transition from cleaning to cutting. This alignment ensures that foam material 108, after undergoing particulate removal, is immediately subjected to groove formation without delay. The clean surface of foam material 108 enables cutting assembly 114 to achieve consistent groove patterns, as there are no residual particles to obstruct the cutting blades. The sequential arrangement improves groove accuracy by reducing the chance of inconsistencies that could arise from particle interference. By receiving foam material 108 in a stable and clean state, cutting assembly 114 contributes to improved texture consistency along the foam surface, which is beneficial for applications requiring high precision.
[00050] In an embodiment, cutting assembly 114 includes a series of spaced-apart blades, each of which makes contact with a designated portion of foam material 108 to form grooves of specified depth. The spacing between the blades is carefully configured to prevent structural weakening of foam material 108, maintaining the integrity of the material while achieving the desired groove pattern. The blades are arranged to provide uniform groove depth across the foam surface, resulting in a consistent texture that meets dimensional specifications. The spacing allows for controlled material removal, reducing the likelihood of over-cutting or damage to foam material 108. This arrangement supports high-quality groove formation, with each blade operating independently yet in alignment to produce a cohesive pattern without compromising material strength.
[00051] In an embodiment, rotary brush 118 within cleaning unit 116 is positioned in close axial proximity to cutting assembly 114, enabling immediate particle removal following groove formation. This proximity allows rotary brush 118 to clear residual particles from foam material 108 directly after the cutting process, preventing recontamination and maintaining groove cleanliness. The positioning of rotary brush 118 enhances the continuity of groove formation by ensuring that particles dislodged during cutting do not settle back into the grooves. By maintaining clean grooves, cleaning unit 116 prepares foam material 108 for post-processing applications, where surface quality is essential. The close axial positioning of rotary brush 118 contributes to an integrated workflow, reducing downtime between cutting and cleaning.
[00052] In an embodiment, rotary brush 118 is equipped with bristles of variable lengths, allowing each bristle to make intermittent contact with foam material 108. The varying bristle lengths enable effective cleaning by reaching both surface-level and deeper grooves, dislodging particles without affecting the structural integrity of foam material 108. The intermittent contact provided by the variable bristle lengths minimizes friction, reducing the potential for surface damage while maximizing particle removal. This arrangement produces smoother surfaces on foam material 108, which is advantageous for applications that require clean, uniform finishes. The configuration of rotary brush 118 with variable-length bristles enhances the effectiveness of the cleaning process, supporting high-quality output.
[00053] In an embodiment, cleaning unit 116 incorporates a suction port positioned adjacent to rotary brush 118, enabling efficient particle removal immediately after dislodgement. The suction port draws particles away from foam material 108, minimizing the risk of recontamination and preserving the cleanliness of the processed surface. The placement of the suction port near rotary brush 118 ensures that dislodged particles are captured quickly, preventing them from resettling on foam material 108. The integration of a suction mechanism maintains operational efficiency within the cleaning unit 116 by continuously clearing particles from the work area, supporting a consistent workflow without manual intervention. This feature contributes to maintaining the quality of foam material 108 throughout the cleaning process.
[00054] Further, while operations are depicted in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Likewise, while several specific implementation details are contained in the above discussions, these should not be construed as limitations on the scope of the subject matter described herein, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
[00055] The term "memory," as used herein relates to a volatile or persistent medium, such as a magnetic disk, or optical disk, in which a computer can store data or software for any duration. Optionally, the memory is non-volatile mass storage such as physical storage media. Furthermore, a single memory may encompass and in a scenario wherein computing system is distributed, the processing, memory and/or storage capability may be distributed as well.
[00056] Throughout the present disclosure, the term 'server' relates to a structure and/or module that include programmable and/or non-programmable components configured to store, process and/or share information. Optionally, the server includes any arrangement of physical or virtual computational entities capable of enhancing information to perform various computational tasks.
[00057] Throughout the present disclosure, the term "network" relates to an arrangement of interconnected programmable and/or non-programmable components that are configured to facilitate data communication between one or more electronic devices and/or databases, whether available or known at the time of filing or as later developed. Furthermore, the network may include, but is not limited to, one or more peer-to-peer network, a hybrid peer-to-peer network, local area networks (LANs), radio access networks (RANs), metropolitan area networks (MANS), wide area networks (WANs), all or a portion of a public network such as the global computer network known as the Internet, a private network, a cellular network and any other communication system or systems at one or more locations.
[00058] Throughout the present disclosure, the term "process"* relates to any collection or set of instructions executable by a computer or other digital system so as to configure the computer or the digital system to perform a task that is the intent of the process.
[00059] Throughout the present disclosure, the term 'Artificial intelligence (AI)' as used herein relates to any mechanism or computationally intelligent system that combines knowledge, techniques, and methodologies for controlling a bot or other element within a computing environment. Furthermore, the artificial intelligence (AI) is configured to apply knowledge and that can adapt it-self and learn to do better in changing environments. Additionally, employing any computationally intelligent technique, the artificial intelligence (AI) is operable to adapt to unknown or changing environment for better performance. The artificial intelligence (AI) includes fuzzy logic engines, decision-making engines, preset targeting accuracy levels, and/or programmatically intelligent software.













Claims
I/We Claim:
1. A system (100) for processing foam materials, comprising:
an insertion assembly (102) comprising a first roller (104) and a second roller (106), each positioned to guide a foam material (108) along a predetermined path;
a debris removal unit (110) positioned adjacent to said insertion assembly (102), said debris removal unit (110) comprising a plurality of air jets (112) directed toward said foam material (108);
a cutting assembly (114) positioned downstream from said debris removal unit (110), said cutting assembly (114) configured to form grooves in said foam material (108); and
a cleaning unit (116) integrated with said cutting assembly (114), said cleaning unit (116) comprising a rotary brush (118) arranged to remove residual particles from said foam material (108) after groove formation.
Claim 2:
The system (100) of claim 1, wherein the first roller (104) is contoured with a plurality of channels that interface with the second roller (106) in a rotational engagement, establishing a compressed conveyance passage for guiding said foam material (108) along said predetermined path, such compression minimizing displacement and enhancing precision of foam positioning for subsequent processing stages.
Claim 3:
The system (100) of claim 2, wherein the second roller (106) is arranged in a lateral orientation relative to said first roller (104), such orientation facilitating uniform alignment of said foam material (108) as it advances, enabling continuous engagement between the rollers and ensuring stability of said foam material (108) through said predetermined path for effective debris removal.
Claim 4:
The system (100) of claim 3, wherein said debris removal unit (110) is positioned at a defined clearance distance from said foam material (108) such that each air jet (112) is angled to generate an airflow that intersects perpendicularly with said foam material (108), thereby dislodging particulate matter with maximum efficiency while maintaining the trajectory of said foam material (108) along said predetermined path.
Claim 5:
The system (100) of claim 4, wherein each air jet (112) is positioned to converge with an adjacent jet at a predetermined intersection, the converging airflow creating a cohesive force that enhances particulate removal from multiple surface points on said foam material (108), thereby preparing it optimally for subsequent groove formation.
Claim 6:
The system (100) of claim 5, wherein said cutting assembly (114) is disposed in sequential alignment with said debris removal unit (110), such alignment enabling precise engagement of said foam material (108) after particulate matter removal, enhancing the accuracy of groove formation and thereby contributing to improved texture consistency along the foam surface.
Claim 7:
The system (100) of claim 1, wherein said cutting assembly (114) comprises a series of spaced-apart blades, each blade arranged to make contact with a defined portion of said foam material (108) for forming uniform grooves of specified depth, wherein the spacing between the blades is configured to prevent structural weakening of said foam material (108).
Claim 8:
The system (100) of claim 7, wherein said rotary brush (118) of said cleaning unit (116) is positioned in close axial proximity to said cutting assembly (114), said positioning enhancing the continuity of groove formation by removing residual particles immediately after cutting, thereby maintaining cleanliness of grooves for post-processing applications.
Claim 9:
The system (100) of claim 8, wherein said rotary brush (118) comprises bristles configured at variable lengths, each bristle making intermittent contact with said foam material (108) to remove residual particles effectively without compromising the integrity of the formed grooves, resulting in smoother surfaces on said foam material (108).
Claim 10:
The system (100) of claim 9, wherein said cleaning unit (116) is equipped with a suction port adjacent to said rotary brush (118), said suction port drawing removed particles away from said foam material (108), thereby minimizing recontamination and maintaining operational efficiency of the cleaning process.





Dated 11 November 2024 Jigneshbhai Mungalpara
IN/PA- 2640
Agent for the Applicant



System for Guiding and Cleaning Foam Materials During Processing
Abstract
The present disclosure provides a system for processing foam materials. The system comprises an insertion assembly having a first roller and a second roller, each guiding a foam material along a predetermined path. A debris removal unit is positioned adjacent to the insertion assembly, wherein the debris removal unit comprises a plurality of air jets directed toward the foam material. A cutting assembly is positioned downstream from the debris removal unit and forms grooves in the foam material. Integrated with the cutting assembly, a cleaning unit comprises a rotary brush arranged to remove residual particles from the foam material after groove formation.


Dated 11 November 2024 Jigneshbhai Mungalpara
IN/PA- 2640
Agent for the Applicant



, Claims:Claims
I/We Claim:
1. A system (100) for processing foam materials, comprising:
an insertion assembly (102) comprising a first roller (104) and a second roller (106), each positioned to guide a foam material (108) along a predetermined path;
a debris removal unit (110) positioned adjacent to said insertion assembly (102), said debris removal unit (110) comprising a plurality of air jets (112) directed toward said foam material (108);
a cutting assembly (114) positioned downstream from said debris removal unit (110), said cutting assembly (114) configured to form grooves in said foam material (108); and
a cleaning unit (116) integrated with said cutting assembly (114), said cleaning unit (116) comprising a rotary brush (118) arranged to remove residual particles from said foam material (108) after groove formation.
Claim 2:
The system (100) of claim 1, wherein the first roller (104) is contoured with a plurality of channels that interface with the second roller (106) in a rotational engagement, establishing a compressed conveyance passage for guiding said foam material (108) along said predetermined path, such compression minimizing displacement and enhancing precision of foam positioning for subsequent processing stages.
Claim 3:
The system (100) of claim 2, wherein the second roller (106) is arranged in a lateral orientation relative to said first roller (104), such orientation facilitating uniform alignment of said foam material (108) as it advances, enabling continuous engagement between the rollers and ensuring stability of said foam material (108) through said predetermined path for effective debris removal.
Claim 4:
The system (100) of claim 3, wherein said debris removal unit (110) is positioned at a defined clearance distance from said foam material (108) such that each air jet (112) is angled to generate an airflow that intersects perpendicularly with said foam material (108), thereby dislodging particulate matter with maximum efficiency while maintaining the trajectory of said foam material (108) along said predetermined path.
Claim 5:
The system (100) of claim 4, wherein each air jet (112) is positioned to converge with an adjacent jet at a predetermined intersection, the converging airflow creating a cohesive force that enhances particulate removal from multiple surface points on said foam material (108), thereby preparing it optimally for subsequent groove formation.
Claim 6:
The system (100) of claim 5, wherein said cutting assembly (114) is disposed in sequential alignment with said debris removal unit (110), such alignment enabling precise engagement of said foam material (108) after particulate matter removal, enhancing the accuracy of groove formation and thereby contributing to improved texture consistency along the foam surface.
Claim 7:
The system (100) of claim 1, wherein said cutting assembly (114) comprises a series of spaced-apart blades, each blade arranged to make contact with a defined portion of said foam material (108) for forming uniform grooves of specified depth, wherein the spacing between the blades is configured to prevent structural weakening of said foam material (108).
Claim 8:
The system (100) of claim 7, wherein said rotary brush (118) of said cleaning unit (116) is positioned in close axial proximity to said cutting assembly (114), said positioning enhancing the continuity of groove formation by removing residual particles immediately after cutting, thereby maintaining cleanliness of grooves for post-processing applications.
Claim 9:
The system (100) of claim 8, wherein said rotary brush (118) comprises bristles configured at variable lengths, each bristle making intermittent contact with said foam material (108) to remove residual particles effectively without compromising the integrity of the formed grooves, resulting in smoother surfaces on said foam material (108).
Claim 10:
The system (100) of claim 9, wherein said cleaning unit (116) is equipped with a suction port adjacent to said rotary brush (118), said suction port drawing removed particles away from said foam material (108), thereby minimizing recontamination and maintaining operational efficiency of the cleaning process.





Dated 11 November 2024 Jigneshbhai Mungalpara
IN/PA- 2640
Agent for the Applicant

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