System and method for thermally bonding grommets to fabric

Abstract

Apparatus and methods are disclosed for bonding first and second grommet portions positioned on opposite sides of a sheet by means of localized heat and pressure applied to the first and second grommet portions. Heat and pressure may be applied by first and second pedestals positioned facing the first and second grommet portions. A registration post may secure to the first pedestal and extend through apertures in the grommet portions and sheet. The second pedestal may define an aperture for receiving the registration post. The registration post may be resiliently mounted to the first pedestal and be depressible into the first pedestal. The first and second grommet portions may have a lower melting temperature than the sheet and may bond to one another through an aperture defined by the sheet.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A method for securing a grommet to a sheet, the method comprising:
 positioning a grommet portion adjacent a surface of the sheet, the grommet portion defining an aperture; and   applying localized heat and pressure to the grommet portion effective to fuse the grommet portion to the sheet.   
     
     
         2 . The method of  claim 1 , wherein the grommet portion is a first grommet portion and the aperture is a first aperture, the method further comprising positioning a second grommet portion adjacent the sheet opposite the first grommet portion, the second grommet portion defining a second aperture;
 wherein applying localized heat and pressure to the first grommet portion effective to fuse the first grommet portion to the sheet further comprises applying localized heat and pressure effective to fuse the first and second grommet portions to the sheet.   
     
     
         3 . The method of  claim 2 , wherein:
 the sheet defines a third aperture that is larger than the first and second apertures, the method further comprising positioning the third aperture such that first and second apertures overlap the third aperture and portions of the first and second grommet portions extend partially across the third aperture; and   applying localized heat and pressure effective to fuse the first and second grommet portions to the sheet further comprises applying localized heat and pressure effective to fuse the first and second grommet portions to one another through the third aperture.   
     
     
         4 . The method of  claim 1 , wherein positioning the grommet portion adjacent the surface of the sheet comprises:
 placing the grommet portion over a first pedestal; and   placing the sheet over the first pedestal.   
     
     
         5 . The method of  claim 4 , wherein applying localized heat and pressure to the grommet portion further comprises:
 pressing a second pedestal against the sheet and grommet portion opposite the first pedestal; and   heating one or both of the first and second pedestals.   
     
     
         6 . The method of  claim 4 , wherein:
 a registering post extends from the first pedestal;   placing the grommet portion over the first pedestal further comprises placing the registering post within the aperture; and   placing the sheet over the first pedestal further comprises placing the registering post in a second aperture defined by the sheet.   
     
     
         7 . The method of  claim 6 , wherein applying localized heat and pressure to the grommet portion further comprises:
 pressing a second pedestal against the grommet portion and sheet opposite the first pedestal effective to depress the registering post into the first pedestal; and   heating at least one of the first and second pedestals;   
     
     
         8 . The method of  claim 7 , wherein the second pedestal defines a registration receiver for receiving a portion of the registering post. 
     
     
         9 . The method of  claim 8 , wherein at least a portion of at least one of the registering post and registration receiver is tapered. 
     
     
         10 . The method of  claim 4 , wherein placing the placing the grommet portion on the first pedestal further comprises placing the grommet portion adjacent a heat conducting member positioned on the first pedestal. 
     
     
         11 . The method of  claim 10 , wherein the heat conducting member comprises a silicone ring. 
     
     
         12 . The method of  claim 1 , wherein the grommet portion has a lower melting point than the sheet. 
     
     
         13 . An apparatus for securing grommets to a sheet, the apparatus comprising:
 a plurality of first pedestals affixed to a first fixture and arranged according to a hole pattern defined by the sheet;   a second fixture positionable opposite the first fixture to apply pressure to the first pedestals; and   at least one heating element in thermal contact with at least one of the plurality of first pedestals and the second fixture.   
     
     
         14 . The apparatus of  13 , wherein the plurality of first pedestals have a distal surface shaped substantially identically to the grommets. 
     
     
         15 . The apparatus of  claim 13 , wherein the first pedestals include registration posts extending from a distal surface thereof. 
     
     
         16 . The apparatus of  claim 15 , wherein the first pedestals define first apertures for receiving the registration posts, the apparatus further comprising a plurality of biasing members interposed between the first pedestals and the registration posts. 
     
     
         17 . The apparatus of  claim 15 , wherein:
 at least distal portions of the registration posts are tapered;   a plurality of second pedestals are affixed to the second fixture and arranged according to the hole pattern defined by the sheet; and   the second pedestals define apertures for receiving at least portions of the registration posts.   
     
     
         18 . The apparatus of  claim 13 , further comprising a plurality of second pedestals affixed to the second fixture and arranged according to the hole pattern defined by the sheet. 
     
     
         19 . An article of manufacture comprising:
 a first grommet portion defining an aperture;   a second grommet portion defining a second aperture;   a sheet defining a third aperture;   wherein the sheet is positioned between the first and second grommet portions, the first and second grommet portions being bonded to the sheet and bonded to one another through the third aperture; and   wherein the first and second grommet portions are bonded to the sheet by local application of heat and pressure exclusively to an affected area substantially limited to an area of the sheet coextensive with the first and second grommet portions.   
     
     
         20 . The article of manufacture of  claim 19 , wherein the first and second grommet portions include a first material and the sheet includes a second material, the first material having a lower melting point than the second material.