A rotary cutting assembly is provided for cutting a panel from an envelope blank or the like. The die holder has an outer surface and a plurality of surface orifices radially communicating with corresponding feed tubes for supplying vacuum or air to the surface and into the vicinity of the envelope blank. A novel air delivery assembly is provided for delivering vacuum and/or air to the die holder comprising a stationary plate disposed at least at one end of the die holder and defining a groove member for selectively supplying vacuum and/or air so that when rotation of die holder aligns the longitudinal feed tubes with the groove member a supply of vacuum or air is selectively supplied at the surface orifices of the die holder. Another embodiment of the die holder may have an outer surface having a extending along the longitudinal axis for detachably receiving the leading end of the cutting die and a plurality of magnetic members disposed in the die holder surface for attracting the cutting die. In order to maximize the number of orifices while minimizing the number of magnetic members, it is preferred that the magnetic members be disposed in a plurality of rows wherein each row contains alternating magnets and orifices and a row of orifices are disposed between each adjacent row of magnets. A novel valve assembly is provided for controlling the flow of air to the surface orifices.
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0. 16. A rotary holder assembly adapted to carry a cutting die for cutting a panel from a material blank, the rotary holder assembly comprising:
a cylindrical die holder adapted to be mounted on a drive shaft for rotating about an axis, the die holder having an outer surface; a plurality of orifices disposed on the outer surface of the die holder; selecting means for selecting a first group of orifices and a second group of orifices from the plurality of orifices; vacuum delivery means for delivering vacuum to the first group of orifices at a first period of time during the rotation of the die holder and vacuum to the second group of orifices at a second period of time during the rotation of the die holder; and air delivery means for delivering air to the first group of orifices at a third period of time during the rotation of the die holder and air to the second group of orifices at a fourth period of time during the rotation of the die holder.
5. A rotary holder assembly adapted to carry a cutting die for cutting a pattern from a material blank, the assembly comprising:
a cylindrical die holder for rotating about an axis, the die holder having an outer surface and a plurality of orifices disposed on the outer surface, the plurality of orifices supplying to the surface vacuum at a first time or air at a second time, the orifices being in radial communication with a corresponding longitudinally directed feed tube; and a valve assembly for controlling the flow of air through each of the feed tubes comprising a valve hole in radial communication with said corresponding feed tube and adapted for receiving a valve member, the valve member being rotatable within the hole between open and closed positions wherein the valve member, having a cam surface that engages with a pin in the valve hole, permits flow through the feed tube in the open position and prevents flow through the feed tube in the closed position.
1. A rotary holder assembly adapted to carry a cutting die having edges and opposing sides for cutting a pattern from at least one material blank, the holder assembly comprising:
a cylindrical die holder adapted to be mounted on a drive shaft for rotating about an axis, the die holder having an outer surface and a plurality of orifices disposed on the outer surface wherein the orifices are in communication with a source of vacuum, at a first time, or air, at a second time, thereby selectively supplying the vacuum or the air to the surface; the die holder having at least one groove for receiving a holding key which cooperate to clamp one of the edges of the cutting die therebetween for securing the cutting die to the holder; and the holding key having an outer surface, a longitudinally directed feed tube, and a plurality of orifices disposed on the key outer surface and communicating with the feed tube for supplying the vacuum or the air to the surface of the key.
0. 11. A method for retaining and releasing a material blank and a pattern cut from the material blank, the material blank and the pattern being carried by a rotating die holder, the die holder having an outer surface and a plurality of orifice groups disposed in the outer surface, each orifice group being in communication with a corresponding feed tube having a transport end and a vacuum end, the method comprising:
closing the vacuum end and opening the transport end of each feed tube that corresponds to an orifice group in communication with the pattern; closing the transport end and opening the vacuum end of each feed tube that corresponds to an orifice group in communication with at least a portion of the blank other than the pattern; supplying vacuum to the transport ends of the feed tubes at a first predetermined period of time during the rotation of the die holder; supplying vacuum to the vacuum ends of the feed tubes at a second predetermined period of time during the rotation of the die holder; supplying air to the transport ends of the feed tubes at a third predetermined period of time during the rotation of the die holder; and supplying air to the vacuum ends of the feed tubes at a fourth predetermined period of time during the rotation of the die holder.
0. 9. A method for retaining and releasing a material blank and a pattern cut from the material blank, the material blank and the pattern being carried by a rotating die holder, the die holder having an outer surface and a plurality of orifice groups disposed in the outer surface, each orifice group being in communication with a feed tube having a transport end and a vacuum end, the method comprising:
closing the vacuum end and opening the transport end of each feed tube that corresponds to an orifice group in communication with the pattern; closing the transport end and opening the vacuum end of each feed tube that corresponds to an orifice group in communication with at least a portion of the blank other than the pattern; supplying vacuum to the transport ends of the feed tubes at a first predetermined period of time during the rotation of the die holder; and supplying vacuum to the vacuum ends of the feed tubes at a second predetermined period of time during the rotation of the die holder, wherein the ends of the feed tubes are opened and closed using a plurality of valve assemblies, each valve assembly comprising, in communication with an end of a corresponding one of the feed tubes, a valve member rotatable between an open position and a closed position wherein the valve means permits flow through the end of the corresponding feed tube in the open position and prevents the flow through the end of the corresponding feed tube in the closed position.
0. 10. A method for retaining and releasing a material blank and a pattern cut from the material blank, the material blank and the pattern being carried by a rotating die holder, the die holder having an outer surface and a plurality of orifice groups disposed in the outer surface, each orifice group being in communication with a corresponding feed tube having a transport end and a vacuum end, the method comprising the steps of:
closing the vacuum end and opening the transport end of each feed tube that corresponds to an orifice group in communication with the pattern; closing the transport end and opening the vacuum end of each feed tube that corresponds to an orifice group in communication with at least a portion of the blank other than the pattern; supplying air to the transport ends of the feed tubes at a first predetermined period of time during the rotation of the die holder; and supplying air to the vacuum ends of the feed tubes at a second predetermined period of time during the rotation of the die holder, wherein the ends of the feed tubes are opened and closed using a plurality of valve assemblies, each valve assembly comprising, in communication with an end of a corresponding one of the feed tubes, a valve member rotatable between an open position and a closed position wherein the valve member permits flow through the end of the corresponding feed tube in the open position and prevents flow through the end of the corresponding feed tube in the closed position.
0. 21. A rotary holder assembly adapted to carry a cutting die for cutting a panel from a material blank, the rotary holder assembly comprising:
a cylindrical die holder adapted to be mounted on a drive shaft for rotating about an axis, the die holder having an outer surface, a vacuum end and a transport end; a plurality of orifices disposed on the outer surface of the die holder a plurality of feed tubes extending from the vacuum end of the die holder to the transport end of the die holder, each of the feed tubes being in communication with one or more of the orifices and having a vacuum end at the vacuum end of the die holder and a transport end at the transport end of the die holder; selecting means for selecting a first group of orifices and a second group of orifices from the plurality of orifices, the selecting means comprising opening and closing means for selectively opening and closing the transport and vacuum ends of the feed tubes, whereby the opening and closing means is used to open the vacuum end and close the transport end of each feed tube of a first set of feed tubes and to close the vacuum end and open the transport end of each feed tube of a second set of feed tubes so that the first group of orifices comprises the orifices in communication with the first set of feed tubes that communication with the vacuum side and not the transport side of the die holder and the second group of orifices comprises the orifices in communication with the second set of feed tubes that communicate with the transport side and not the vacuum side of the die holder; and air delivery means for delivery air to the orifices in the first group of orifices at a first period of time during the rotation of the die holder and air to the orifices in the second group of orifices at a second period of time during the rotation of the die holder.
0. 32. A rotary holder assembly adapted to carry a cutting die for cutting a panel from a material blank, the rotary holder assembly comprising:
a cylindrical die holder adapted to be mounted on a drive shaft for rotating about an axis, the die holder having an outer surface, a vacuum end and a transport end; a plurality of orifices disposed on the outer surface of the die holder a plurality of feed tubes extending from the vacuum end of the die holder to the transport end of the die holder, each of the feed tubes being in communication with one or more of the orifices and having a vacuum end at the vacuum end of the die holder and a transport end at the transport end of the die holder; selecting means for selecting a first group of orifices and a second group of orifices from the plurality of orifices, the selecting means comprising opening and closing means for selectively opening and closing the transport and vacuum ends of the feed tubes, whereby the opening and closing means is used to open the vacuum end and close the transport end of each feed tube of a first set of feed tubes and to close the vacuum end and open the transport end of each feed tube of a second set of feed tubes so that the first group of orifices comprises the orifices in communication with the first set of feed tubes that communicate with the vacuum side and not the transport side of the die holder and the second group of orifices comprises the orifices in communication with the second set of feed tubes that communicate with the transport side and not the vacuum side of the die holder; and vacuum delivery means for delivering vacuum to the orifices in the first group of orifices at a first period of time during the rotation of the die holder and vacuum to the orifices in the second group of orifices at a second period of time during the rotation of the die holder.
0. 27. A rotary holder assembly adapted to carry a cutting die for cutting a panel from a material blank, the rotary holder assembly comprising:
a cylindrical die holder adapted to be mounted on a drive shaft for rotating about an axis, the die holder having an outer surface, a vacuum end and a transport end; a plurality of orifices disposed on the outer surface of the die holder; a plurality of feed tubes extending from the vacuum end of the die holder to the transport end of the die holder, each of the feed tubes being in communication with one or more of the orifices and having a vacuum end at the vacuum end of the die holder and a transport end at the transport end of the die holder; selecting means for selecting a first group of orifices and a second group of orifices from the plurality of orifices, the selecting means comprising opening and closing means for selectively opening and closing the transport and vacuum ends of the feed tubes, whereby the opening and closing means is used to open the vacuum end and close the transport end of each feed tube of a first set of feed tubes and to close the vacuum end and open the transport end of each feed tube of a second set of feed tubes so that the first group of orifices comprises the orifices in communication with the first set of feed tubes that communicate with the vacuum side and not the transport side of the die holder and the second group of orifices comprises the orifices in communication with the second set of feed tubes that communicate with the transport side and not the vacuum side of the die holder; and vacuum delivery means for delivering vacuum to the orifices in the first group of orifices at a first period of time during the rotation of the die holder and vacuum to the orifices in the second group of orifices at a second period of time during the rotation of the die holder, wherein the opening and closing means comprises a plurality of valve assemblies, each valve assembly comprising, in communication with an end of a corresponding one of the feed tubes, a valve member rotatable between an open position and a closed position wherein the valve member permits flow through the end of the corresponding feed tube in the open position and prevents flow through the end of the corresponding feed tube in the closed position.
0. 13. A rotary holder assembly adapted to carry a cutting die for cutting a panel from a material blank, the rotary holder assembly comprising:
a cylindrical die holder adapted to be mounted on a drive shaft for rotating about an axis, the die holder having an outer surface, a vacuum end and a transport end; a plurality of orifices disposed on the outer surface of the die holder; a plurality of feed tubes extending from the vacuum end of the die holder to the transport end of the die holder, each of the feeds being in communication with one or more of the orifices and having a vacuum end at the vacuum end of the die holder and a transport end at the transport end of the die holder; selecting means for selecting a first group of orifices and a second group of orifices from the plurality of orifices, the selecting means comprising opening and closing means for selectively opening and closing the transport and vacuum ends of the feed tubes, whereby the opening and closing means is used to open the vacuum end and close the transport end of each feed tube of a first set of feed tubes and to close the vacuum end and open the transport end of each feed tube of a second set of feed tubes so that the first group of orifices comprises the orifices in communication with the first set of feed tubes that communicate with the vacuum side and not the transport side of the die holder and the second group of orifices comprises the orifice in communication with the second set of feed tubes that communicate with the transport side and not the vacuum side of the die holder; and vacuum delivery means for delivering means to the orifices in the first group of orifices at a first period of time during the rotation of the die holder and vacuum to the orifices in the second group of orifices at a second period of time during the rotation of the die holder; wherein the opening and closing means comprises a plurality of valve assemblies, each comprising, in communication with a corresponding one of the feed tubes, a valve hole adapted for receiving a valve member, the valve member rotatable within the valve hole between an open position and a closed position wherein the valve member permits flow through the corresponding feed tube in the open position and prevents flow through the corresponding feed tube in the closed position.
2. The assembly as set forth in
3. The assembly as set forth in
4. The assembly as set forth in
6. The assembly as set forth in
0. 7. The assembly of
0. 8. The assembly of
0. 12. The method of
0. 14. The assembly of
a transport end plate mounted to the transport end of the die holder; and a vacuum end plate mounted to the vacuum end of the die holder and having a peripheral face, wherein the valve holes of valve assemblies for closing the transport ends of the feed tubes are located within the transport end plate and the valve holes of valve assemblies for closing the vacuum ends of the feed tubes are located within the vacuum end plate.
0. 15. The assembly of
the transport end plate has a peripheral face defining a plurality of orifices and each of the valve holes within the transport end plate communicates with a corresponding one of the plurality of the transport end plate orifices; and the vacuum end plate has a peripheral face defining a plurality of orifices and each of the valve holes within the vacuum end plate communicates with a corresponding one of the plurality of the vacuum end plate orifices, whereby the valve members within the valve holes are accessible via their corresponding end plate orifices.
0. 17. The assembly of
the die holder has a vacuum end and a transport end; the first group of orifices is in communication with a first set of one or more feed tubes extending from the vacuum end of the die holder to the transport end of the die holder; the second group of orifices is in communication with a second set of one or more feed tubes extending from the vacuum end of the die holder to the transport end of the die holder; each feed tube is in communication with one or more orifices in the plurality of orifices and has a vacuum opening on the vacuum end of the die holder and a transport opening on the transport end of the die holder; and the selecting means includes opening and closing means for selectively opening and closing the transport and vacuum ends of the feed tubes, whereby the opening and closing means can be used to open the vacuum end and close the transport end of each feed tube of the first set of feed tubes and to close the vacuum end and open the transport end of each feed tube of the second set of feed tubes so that the first group of orifices comprises the orifices in communication with the first set of feed tubes that communicate with the vacuum side and not the transport side of the die holder and the second group of orifices comprises the orifices in communication with the second set of feed tubes that communicate with the transport side and not the vacuum side of the die holder.
0. 18. The assembly of
0. 19. The assembly of
a first stationary plate disposed at the vacuum end of the die holder and defining a first vacuum groove sized and located for supplying vacuum at the first period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first vacuum groove, vacuum is supplied to the one or more orifices in communication with the feed tube aligned with the first vacuum groove; and a second stationary plate disposed at the transport end of the die holder and defining a second vacuum groove sized and located for supplying vacuum at the second period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tubes with the second vacuum groove, vacuum is supplied to the one or more orifices in communication with the feed tube aligned with the second vacuum groove.
0. 20. The assembly of
a first air groove defined by the first stationary plate and sized and located for supplying air at the third period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the first air groove; and a second air groove defined by the second stationary plate and sized and located for supplying air at the fourth period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tubes with the second air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the second air groove.
0. 22. The assembly of
0. 23. The assembly of
0. 24. The assembly of
a first stationary plate disposed at the vacuum end of the die holder and defining a first air groove sized and located for supplying air at the first period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the first air groove; and a second stationary plate disposed at the transport end of the die holder and defining a second air groove sized and located for supplying air at the second period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tubes with the second air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the second air groove.
0. 25. The assembly of
0. 26. The assembly of
0. 28. The assembly of
0. 29. The assembly of
a first stationary plate disposed at the vacuum end of the die holder and defining a first vacuum groove sized and located for supplying vacuum at the first period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first vacuum groove, vacuum is supplied to the one or more orifices in communication with the feed tube aligned with the first vacuum groove; and a second stationary plate disposed at the transport end of the die holder and defining a second vacuum groove sized and located for supplying vacuum at the second period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tubes with the second vacuum groove, vacuum is supplied to the one or more orifices in communication with the feed tube aligned with the second vacuum groove.
0. 30. The assembly of
0. 31. The assembly of
a first air groove defined by the first stationary plate and sized and located for supplying air at the third period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the first air groove; and a second air groove defined by the second stationary plate and sized and located for supplying air at the fourth period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tube with the second air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the second air groove.
0. 33. The assembly of
0. 34. The assembly of
0. 35. The assembly of
0. 36. The assembly of
a first stationary plate disposed at the vacuum end of the die holder and defining a first vacuum groove sized and located for supplying vacuum at the first period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first vacuum groove, vacuum is supplied to the one or more orifices in communication with the feed tube aligned with the first vacuum groove; and a second stationary plate disposed at the transport end of the die holder and defining a second vacuum groove sized and located for supplying vacuum at the second period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tubes with the second vacuum groove, vacuum is supplied to the one or more orifices in communication with the feed tube aligned with the second vacuum groove.
0. 37. The assembly of
0. 38. The assembly of
0. 39. The assembly of
a first air groove defined by the first stationary plate and sized and located for supplying air at the third period of time, so that when rotation of the die holder aligns the vacuum end of a feed tube in the first set of feed tubes with the first air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the first air groove; and a second air groove defined by the second stationary plate and sized and located for supplying air at the fourth period of time, so that when rotation of the die holder aligns the transport end of a feed tube in the second set of feed tubes with the second air groove, air is supplied to the one or more orifices in communication with the feed tube aligned with the second air groove.
0. 40. The assembly of
0. 41. The assembly of
0. 42. The assembly of
0. 43. The assembly of
0. 44. The assembly of
0. 45. The assembly of
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This is a continuation-in-part of application Ser. No. 08/172,033, filed Dec. 22, 1993, now abandoned.
The present invention relates generally to a rotary cutting device and more particularly a device for the cutting of windows, notches, orifices or other patterns in relatively thin, flexible sheet-like material in either sheet or web form.
Many envelopes have a transparent panel or window for allowing visual inspection of the enclosure. These window envelopes are manufactured from a web of paper material which is initially cut into blanks having a predetermined shape. A panel is subsequently cut from the blank by a panel cutting apparatus to form the window. Thereafter, the blank is then folded, gummed, printed and packaged to form the finished envelope.
U.S. Pat. No. 4,823,659 to Falasconi describes a conventional rotary panel cutting apparatus comprising a cutting tool in the form of a cutting plate or die and a rotary die holder which brings the cutting die into successive contact with the envelope blanks which advance on a conveyor system. The cutting die has a raised cutting edge which is adapted to engage the blank and cut the panel. The die holder, sometimes called a die cylinder or drum, is mounted for rotation on a drive shaft synchronized with the conveyor system so that the cutting die engages a different envelope blank for each rotation of the die holder.
The surface of the die holder has a plurality of transport and vacuum orifices which communicate with corresponding air chambers which, in turn, selectively communicate with a source of vacuum or compressed air. The transport orifices are adapted to engage the envelope blank and, when the vacuum source is activated, carry the blank adjacent to the surface of the die holder. The rotation of the die holder carries the envelope to a cutting station where the blank is passed between the cutting die and a cutting bar so as to cut the panel in the envelope blank. The vacuum orifices are disposed within the periphery of the dies' cutting edges and, when the vacuum source is activated, form a localized vacuum zone within the vicinity of the cutting die to retain and carry away the panel which is cut from the envelope blanks. The envelope blank and the cut panel may be released from the die holder and the cutting die, respectively, by terminating the vacuum source or applying the compressed air to the transport and vacuum orifices. The vacuum and compressed air supply to each opening is controlled by means of valves or attachment tubes which are manually attached to each individual orifice. The attachment tubes typically rotate in unison with the die holder.
Unfortunately, the prior art panel cutting apparatuses suffer from numerous drawbacks. Since the die holder typically rotates from zero to about 1500 rpm, it is extremely difficult to obtain a proper seal between the rotating vacuum tubes and the feed tubes which permits the envelope blank to move, resulting in improper alignment between the cutting die and the envelope blank. Similarly, it is extremely difficult to obtain a proper seal at the vacuum orifices between the die holder and the drive shaft due to wear and abrasion, resulting in insufficient vacuum to carry the envelope blank and the panel and jamming of the cutting apparatus. It is also difficult to apply the vacuum or air at the correct time during the rotation of the die holder.
Methods used to retain the cutting die adjacent to the die holder including mechanical clamp assemblies and magnetic clamp assemblies suffer several disadvantages. The mechanical clamp assemblies, which clamp one or both of the leading and trailing ends of the cutting die, are relatively complicated devices which are time consuming to assemble and disassemble and expensive and difficult to manufacture.
Another drawback is the lack of adjustability of the apparatus to cut out panels of different sizes as well as different locations on the blank. Attempts to provide an adjustable die holder capable of receiving different size cutting dies have been unsuccessful because the holding mechanisms, such as removable cover plates and holding keys, used to attach the cutting dies to the die holders leave significant areas without the vacuum orifices necessary to carry the envelope blank and the panel. In addition, these attempts have resulted in die holders which become unbalanced during rotation.
In order to minimize the assembly and disassembly downtime, magnetic clamp assemblies, having magnetic strips disposed in the surface of the die holder to magnetically attract and hold the cutting die, have been used. Unfortunately, the forces resulting from the rotation of the die holder may cause the cutting die to slide laterally on the surface of the magnets. To prevent the lateral movement of the cutting die, magnetic die holders have also utilized cumbersome mechanical clamping assemblies to hold at least the leading end of the cutting die while the magnetic clamps hold the remaining portion of the cutting die. Attempts to prevent lateral movement by increasing the magnetic force and maximizing the number of magnetic strips disposed in the die holder surface have resulted in minimizing the number of the vacuum orifices available for retaining the envelope blank and the panel.
Accordingly, it is an object of the invention is to provide an improved cutting tool for cutting panels from blanks of sheet-like material.
It is an object of the invention to provide a cutting tool having an improved air delivery system.
It is a more specific object of the invention to provide an improved air delivery system which efficiently delivers vacuum to the die holder with minimal leakage.
It is another object of the invention to provide a die holder which minimizes air leakage due to wear or abrasion.
Another object of the invention is to provide an improved die holder for a panel cutting tool.
Still another object of the invention is to provide a die holder which maximizes the vacuum openings disposed along its outer surface. A related object is to provide a cover plate and a holding key which is capable of retaining the envelope blank and the panel during the cutting operation.
It is an object of the invention to provide a die holder which functions in an efficient manner, is easily assembled and is adapted for operation with different size cutting dies.
It is a related object of the invention to provide a die holder which may be easily and readily adjusted to position the cutting die.
It is an object of the invention to provide a die holder having a more equal weight distribution.
It is an object of the invention to provide a die holder which may be easily removed from the die shaft.
It is an object of the invention to provide an improved magnetic cutting tool for cutting patterns from blanks of sheet-like material.
It is an object of the invention to provide a cutting tool having an improved distribution of magnets and air orifices.
A more specific object of the invention is to provide a magnetic cutting tool which minimizes the number of magnetic strips while maximizing the number of vacuum orifices disposed over the die holder surface.
Another object of the invention is to provide a magnetic die holder which prevents the cutting die from moving laterally on the die holder surface.
A rotary cutting assembly is provided for cutting a panel from an envelope blank or the like. The cutting assembly comprises a cutting die mounted on a die holder adapted to be mounted on a drive shaft for rotating about an axis. The die holder has a plurality of surface orifices radially communicating with corresponding longitudinally directed feed tubes for supplying vacuum or air to the surface and into the vicinity of the envelope blank.
In accordance with one aspect of the invention, a novel air delivery assembly is provided for delivering vacuum and/or air to the die holder. The air delivery assembly comprises a stationary plate disposed at least at one end of the die holder and defining a groove member for selectively supplying vacuum and/or air so that a supply of vacuum or air is selectively supplied at the surface orifices of the die holder when rotation of the die holder aligns the longitudinal feed tubes with the groove member.
In one embodiment, the air delivery assembly comprises a transport assembly and a vacuum assembly disposed on opposing sides of the die holder. The transport assembly is adapted to feed vacuum to the die holder in order to retain the envelope blank adjacent to the die holder and "transport" the envelope blank as the holder rotates through the cutting operation. The vacuum assembly, in turn, is adapted to feed vacuum to the die holder in order to retain the panel cut from the envelope blank adjacent to the die holder until a predetermined position is reached wherein the panel is released from the die holder. At predetermined positions, the transport and vacuum assemblies may feed compressed air to the die holder in order to release the envelope blank and the panel, respectively.
In accordance with certain objects of the invention, the die holder has at least one groove for receiving a holding key which cooperate to clamp one of the edges of the cutting die therebetween for securing the cutting die to the holder. In one embodiment, the holding key may have a plurality of orifices for supplying vacuum or air to the surface of the key and at least one longitudinally directed feed tube which radially communicates with the orifices for supplying vacuum and/or air to the orifices. In another embodiment, a transport key is provided which is adapted to engage and retain the leading edge of the envelope blank adjacent to the outer surface of the key as the die holder rotates. A feeder key is also provided which is adapted to engage and retain the envelope blank or the panel cut from the blank adjacent to the outer surface of the key as the die holder rotates.
In accordance with certain objects of the invention, the die holder may have a removable cover plate having a plurality of orifices disposed on the plate surface and feed tubes subjacent the plate surface which communicate with the orifices for supplying vacuum or air to the orifices. In one embodiment, the feed tube extends in the longitudinal direction so as to communicate with both ends of the cover plate. In another embodiment, the feed tube only communicates with one end.
The operator may select whether individual feed tubes (and the corresponding orifices) communicate with either the transport assembly or the vacuum assembly. In applications where the envelope blank is adjacent to the certain predetermined orifices and it is desired to retain the envelope blank adjacent the die holder, the feed tubes corresponding to the predetermined orifices communicate with the transport assembly. Conversely, if the panel is adjacent to the predetermined orifices, the feed tubes corresponding to the predetermined orifices communicate with the vacuum assembly.
In accordance with certain objects of the invention, the die holder may have an outer surface having a slot extending along the longitudinal axis for detachably receiving the leading end of the cutting die and a plurality of magnetic members disposed in the die holder surface for attracting the cutting die. In a preferred embodiment, the die holder may have a plurality of orifices disposed between adjacent magnetic members for delivering vacuum or air to the die holder surface. In order to maximize the number of orifices while minimizing the number of magnetic members, it is preferred that the magnetic members be disposed in a plurality of rows wherein each row contains alternating magnets and orifices and a row of orifices are disposed between each adjacent row of magnets.
These and other features and advantages of the invention will be more readily apparent upon reading the following description of a preferred exemplified embodiment of the invention and upon reference to the accompanying drawings wherein:
Referring to the drawings and more particularly to
The die holder 16 cooperates with an air delivery assembly in order to receive and retain the envelope blank B during the cutting operation. One embodiment of an air delivery assembly in accordance with certain objects of the invention is generally referenced as 90 although conventional air delivery assemblies may also be used. The die holder 16 has a transport side which is generally depicted as the left side in
As shown in
The cutting die 14 also comprises a central opening 20 which is defined by the cutting edge 18. The cutting die opening 20 permits the die holder 16 and the air delivery assembly 90 to communicate with the envelope blank B through the cutting die 14 so that the die holder 16 may feed vacuum into the vicinity of the cutting edges 18 to retain the panel P in the cutting die 14 and to carry the panel P away from the blank B. Similarly, the opening 20 permits the die holder and the air delivery assembly 90 to feed compressed air into the vicinity of the cutting edges 18 so as to release the panel P from the cutting die 14 at an appropriate time.
The rotary die holder 16 is adapted for holding the cutting die 14 in selected positions around its outer surface 21. As best shown in
Referring to
Each key 42, 43, 44, 45 is adapted to cooperate with its corresponding groove 32, 34, 36, 38 to clamp one of the edges 14a or 14b of the cutting did 14 therebetween. Any two keys may be used to selectively mount different size cutting dies 14 to the die holder 16 depending upon the predetermined size and location of the panel P to be cut from the envelope blank B. The die holder 16 may also be adapted to receive other sizes of cutting dies 14 by adding additional keys around the periphery of the die holder 16 or by changing the location of the keys along the periphery of the die holder 16.
In the embodiment illustrated in
In order to retain the envelope blank B and the panel P adjacent to the surface 21 of the die holder 16 during the cutting operation, the die holder 16 is capable of feeding vacuum from the air delivery assembly 90 to the outer surface 21 and into the vicinity of the adjacent envelope blank B and panel P. Referring to
Turning first to the two cylindrical sections 22, 24, it will be seen in
Each feed tube 80 is adapted to communicate with the air delivery assembly 90 so that vacuum may be supplied to the feed tubes 80 so as to create a vacuum in the corresponding orifices 70 and retain the envelope blank B or panel P adjacent to the surface 21 of the corresponding orifices 70. Conversely, supplying compressed air to the feed tubes 80 will blow air through the corresponding orifices 70 and release the envelope blank B or panel P.
By selectively sealing the proper side of the feed tube 80, the operator may select whether the individual feed tube 80 (and the corresponding orifices 70) communicates with either the transport or the vacuum side of the air delivery assembly 90. In applications where the envelope blank B is adjacent to the certain predetermined orifices 70 and it is desired to retain the envelope blank adjacent the die holder 16, the transport side 80t of the feed tubes 80 corresponding to the predetermined orifices 70 are left open so that the feed tubes 80 communicate with the transport side of the air delivery assembly 90 whereas the vacuum side 80v is sealed. Conversely, if the panel P is adjacent to the predetermined orifices 70, the vacuum side 80v of the feed tubes 80 corresponding to the predetermined orifices 70 are left open so that the feed tubes 80 communicate with the vacuum side of the air delivery assembly 90 whereas the transport side 80t are sealed.
As best seen in
In order to retain an envelope blank B adjacent the outer surface 50a of the cover plate 50, the cover plate 50 also has a plurality of orifices 72 disposed about its entire outer surface 50a. The orifices 72 communicate with a plurality of corresponding feed tubes 82 subjacent the outer surface 50a of the cover plate 50. Like the feed tubes 80 in the two cylindrical sections 22 and 24 of the die holder 16, the cover plate feed tubes 82 extend generally along the axis 30 of the die holder 16 and are adapted to feed vacuum or compressed air from the air delivery assembly 90 to the air orifices 72 and into the vicinity of the envelope blank B.
In the embodiment of the cover plate 50 best illustrated in
As with the feed tubes 80 in the cylindrical sections 23 and 24, the operator may select whether the individual feed tube 82 (and the corresponding orifices 72) communicate with either the transport or the vacuum side of the air delivery assembly 90 by selectively sealing one side of the feed tube 82. Referring to
In applications where the cutting die 14 is not disposed over the cover plate 50, the vacuum side 82v of the feed tubes 82 are sealed whereas the transport side 82t are left open because the cover plate 50 is only utilized to transport the envelope blank B. It should now be appreciated that at least one side of each feed tube 82 must be covered to prevent the transport and vacuum sides of the air delivery assembly 90 from simultaneously communicating with the same feed tube 82.
In another embodiment of the cover plate 150 illustrated in
Three embodiments of the keys used to secure the cutting die 14 to the die holder 16 are illustrated in
A conventional clamping bar 43 which is utilized to clamp the sides 14a, 14b of the cutting die to the die holder 16 is illustrated in FIG. 10. The clamping bar 43, which may be attached to the die holder 16 using screw holes 43a, is not adapted to feed vacuum or air to its outer surface 43b. In order to insure retention of cutting die between the clamping bar 43 and the corresponding groove, the side face 43c of each key preferably has a channel 43e disposed therein for receiving the lip 15a, 15b of the cutting die 14. It will be appreciated that the other holding keys 42, 44 and 45 may also have a channel to receive the die lip 15a, 15b.
One embodiment of a holding key which is also adapted for retaining the leading edge of the envelope blank B adjacent to the die holder surface 21 so that the envelope blank B is accurately and securely held in position during the rotation of the die holder and when the cutting die cuts the panel P is illustrated by the transport bar 45 illustrated in FIG. 8. If the leading edge is not securely retained by the die holder 16, it is possible that air may lodge underneath the leading edge and cause the envelope blank B to become misaligned, resulting in inaccurate cuts by the cutting die 14. In the embodiment of the transport bar 45 illustrated in
Another embodiment of a key which is capable of feeding vacuum or compressed air to the key surface for retaining the envelope blank B or the panel P thereto is depicted by the feeder bar 42 in FIG. 9. The feeder bar 42 should have at least one feed tube 42e which communicates with a plurality of the orifices 42a on the outer face 42f of the feeder bar 42. In the embodiment illustrated in
In accordance with certain objects of the invention, a novel air delivery assembly 90 is provided for supplying vacuum or compressed air to the die holder 16. The air delivery assembly 90 comprises a transport assembly 92 and a vacuum assembly 94. The transport assembly 92 is adapted to feed vacuum to the die holder 16 in order to retain the envelope blank B adjacent to the die holder 16 and "transport" the envelope blank B as the holder 16 rotates through the cutting operation. The vacuum assembly 94, in turn, is adapted to feed vacuum to the die holder 16 in order to retain the panel P cut from the envelope blank B adjacent to the die holder 16 until a predetermined position is reached wherein the panel P is released from the die holder 16. At predetermined positions, the transport and vacuum assemblies 92, 94 may feed compressed air to the die holder 16 in order to release the envelope blank B and the panel P, respectively.
In accordance with one aspect of the invention, the air delivery assembly comprises a stationary plate disposed at least at one end of the die holder and defining a groove member for selectively supplying vacuum and/or air. The die holder is operatively connected to the stationary plate so that a supply of vacuum or air is selectively supplied at the surface orifices of the die holder when rotation of the die holder aligns the longitudinal feed tubes with the groove member.
In the embodiment illustrated
Referring to the vacuum assembly 94 in
The connector plate 95v has an interior side 96v adapted for matedly engaging the vacuum side 62v of the die holder 16 and an exterior side 97v adapted for engaging the interface seal 105v. The connector plate 95v has a central bore 101v for receiving the drive shaft 12. Since the inclined cover plate side 50v and key faces 42b and 44b project outwardly from the vacuum side 62v of the die holder 16, the interior side 96v of the connector plate 95v has inclined insets 98v, 99v, adapted to receive and engage the cover plate 50 and the keys 42, 44, respectively. When the cover plate 50 and the keys 42, 44 are attached to the cylindrical sections 22, 24 and the screws 52 are tightened, the force exerted by the inclined faces 50v, 42b and 44b on the inclined insets 98v and 99v assist in forming a substantially air-tight seal.
In order to communicate vacuum and compressed air to the die holder 16, the connector plate 95v has a plurality of holes 102v corresponding to any feed tubes, including for example feed tubes 80, 82, 42c, 44c, in the die holder 16. As shown in
Once the connector plate 95v is properly aligned with the die holder side 62, the connector plate 95v and the die holder side 62 are attached together using screws 100v. It will be appreciated that the die holder 16 and the connector plate 95v rotate in unison together.
Although any suitable metals or other materials may be used, it will be appreciated that the connector plate 95 and the stationary plate 110 are typically machined from aluminum so that direct contact between the rotating connector plate 95 and the stationary plate 110 is abrasive. In order to reduce such abrasion, the interface seal 105v is disposed between the connector plate 95 and the stationary plate 110. The interface seal 105v has a plurality of openings generally designated as 106v in
The stationary plate 110v has an interior side 111v adapted to engage the interface seal 105v. The interior side 111v defines a vacuum groove 112v which is in communication with a vacuum source (not shown) via vacuum hose 114v, an air supply groove 116v which is in communication with a compressed air source (not shown) via air hose 118v, and a central bore 120v adapted to rotatably receive the drive shaft 12.
As the connector plate 95v rotates relative to the stationary plate 110, the connector plate holes 102v rotate and sequentially communicate with the vacuum and air grooves 112v, 116v. When the connector plate openings 102v and thus, the corresponding feed tubes 80, 82, 42c, 44c, in the die holder 16 are in communication with the vacuum groove 112v, the vacuum source is supplied to the corresponding orifices in communication with the feed tubes. Similarly, when the openings 102v are in communication with the air supply groove 116v, compressed air is supplied to the corresponding orifices in the surface 21 of die holder 16. Thus, it will be appreciated that extremely precise timing of the vacuum and compressed air may be supplied to the die holder 16 by adjusting the configuration and position of the vacuum groove 112v and the air groove 116v.
Referring to
As the die holder 16 and the connector plate 95v rotate relative to the stationary plate 110v, the open feed tubes sequentially communicate with the vacuum groove 112v and the air groove 116v. When the appropriate feed tube communicates with the vacuum groove 112v, vacuum is supplied to the surface 21 of the die holder 16 and the cutting die 14 so as to retain the panel P cut from the blank B within the die opening 20. Similarly, compressed air is supplied to the surface 21 of the die holder 16 and the cutting die 14 so as to blow the panel P from the cutting die 14 when the open feed tubes communicate with the air groove 114t.
The transport assembly 92, illustrated in
The connector plate 95t has an interior face adapted to matedly engage the transport side of the die holder. In the embodiment illustrated in
The interface seal 105t, disposed between the connector plate 95t and the stationary die 110t, is identical with the interface seal 105v associated with the vacuum assembly except that its physical configuration will correspond with the holes 102t and bore 101t.
The stationary plate 110t is similar to the stationary plate 110v in that it has a vacuum groove 112t and air groove 116t. The orientation and physical size of the vacuum and air grooves 112t and 116t may be different to accommodate the timing differences associated with the transport assemblies' goal of retaining the envelope blank B as compared with the vacuum assemblies' goal of retaining the panel P.
During the cutting operation, it will be appreciated that the envelope blank B will be disposed adjacent the periphery of the die holder 16 so that certain orifices and the corresponding feed tubes will communicate with the envelope blank B. In order for the transport assembly 92 to feed vacuum or compressed air to the envelope blank B, the operator preselects the orifices and feed tubes which communicate with the envelope blank B. The transport side of feed tubes which communicate with the envelope blank B are left open. The other feed tubes which do not communicate with the envelope blank B are sealed.
As the die holder 16 and the connector plate 95t rotate, the open feed tubes communicate with the vacuum groove 112t and the air groove 116t in the stationary plate 110t. When the connector plate openings 102v are aligned and communicate with the vacuum groove 112t, vacuum is supplied to the surface 21 of the die holder 16 so as to retain the envelope blank B in the desired position. Similarly, compressed air is supplied to the surface 21 of the die holder 16 so as to release the envelope blank B from the die holder 16. Since the feed tubes which do not communicate with the envelope blank B are sealed the transport assembly does not feed vacuum or compressed air thereto.
Since the vacuum assembly 94 acts to control the release of the panel P cut from the envelope blank B whereas the transport assembly 92 acts to control the release of the envelope blank B, it will be appreciated that the configuration and position of the vacuum and air grooves 112, 116 in the vacuum and transport assemblies 94, 92 will vary with the position and size of the die cutter 10 and the size and position of the envelope blank B. Similarly, although the air delivery assembly 90 has been described with respect to the illustrated embodiments of the feed tubes associated with the illustrated die holder 16, the number, configuration and radially position of the feed tubes may be varied as long as the feed tubes are capable of communicating with the vacuum and air grooves in the air delivery assembly during the die holder's rotation.
In operation, the rotary cutter 10 is adapted to be installed on a conventional drive shaft 12. Typically, the cylindrical sections 22 and 24 may be disposed so that the bore 28 engages the shaft 12 and the screws 26 are tightened to attach the sections 22 and 24 about the shaft 12. The cutting die 14 and the keys may be attached to the cylindrical sections 22 and 24 as previously explained.
Although any type of conveyor assembly may be used which moves the envelope blanks B in serial order to the rotary cutter 10 which cuts out the panels P, in the illustrated embodiment, the conveyor system comprises a cylinder R which delivers the uncut envelope blank B to the rotary cutter 10 and a cylinder L which transports the cut envelope blank B away from the rotary cutter 10. In the embodiments illustrated in
Turning first to
As the die holder 16 rotates, the feed tube 45b and the envelope blank B pass between the cutting bar 122 and the die holder 16 (point X) but since the cutting die 14 is not present, the envelope blank B passes through without being cut. The feed tube 45b continues to communicate with the vacuum groove 112t until the end of the vacuum groove 112t at which point the envelope blank B is ready to be transferred to the transfer cylinder L as shown in
The transport bar 45 continues to rotate to the transfer cylinder R to obtain the next successive envelope blank B at point W as shown in FIG. 11c.
Turning next to
As the die holder 16 rotates, the feed tubes F2 and the cutting die 14 engage the envelope blank B at point W. The feed tubes F2 remain inactive because they are not in communication with the vacuum or air grooves 112v, 116v of the vacuum assembly 94.
As shown in
As the die holder 16 continues to rotate, the transport bar 45 reaches the transfer point Y with cylinder L and the envelope blank B is transferred to cylinder L. The cutting die 14 subsequently reaches the transfer point Y, but the feed tubes F2 remain in communication with the vacuum groove 112v so that the panel P is not released from the die holder 16.
As shown in
In order to assist the disassembly of die holder 16 from the drive shaft 12, the cylindrical section 22 may have a plurality of holes 125 which cooperate with a screw handle 126. When the screw handle 126 is screwed into the holes 125, the tip 126a of the handle 126 creates space between the cylindrical sections 22, 24 and the drive shaft 12 which enables the operator to easily disengage the die holder 16 therefrom. The handle tip 126a may be made from a relatively soft metal such as brass or the like which will not damage the drive shaft 12. The screw handle 126 may also be used to carry the die holder 16.
Instead of a mechanical clamp assembly as illustrated in
In the embodiment illustrated in
As shown in
As soon as the cutting die 14 is brought near the die holder surface 21, the magnets 220 attract the thin metal cutting die 14. The cutting die 14 is, thus, magnetically retained adjacent to the surface 21 of the die holder 16. The magnetic force will flatten the entire area of the cutting die 14 against the die holder surface 21 so that there is no slack present between the die holder surface 21 and the cutting die 14. The cutting die 14 must be properly positioned and orientated so that it properly cuts the envelope blanks B.
A plurality of air orifices 240 are disposed in the die holder surface to retain the envelope blank B and the panel P adjacent to the die holder surface 21. The other portions of the die holder surface which do not receive the blank B or the panel P do not require orifices 240. The air orifices 240 are in radial communication with the plurality of corresponding air feed tubes 80. The feed tubes 80 and the corresponding orifices 240 may be connected to the novel vacuum and compressed air delivery system described above or to a conventional source of vacuum and compressed air (not shown).
It is generally preferred to maximize the number and distribution of the orifices 240 while minimizing the number and distribution of the expensive magnets 220. Thus, it is preferred that at least some orifices 240 be disposed between substantially all of the adjacent magnets 220 in order to maximize the distribution and effect of the orifices 240, thereby permitting the cutting die 14 to be placed anywhere on the die holder surface 21 and the panel P cut from the blank B to be retained during the cutting operation. It will be appreciated that any number of orifices may be disposed between adjacent magnets.
In the embodiment illustrated in
It should now be appreciated that the illustrated embodiments maximize the ability of the die opening 20 to communicate with orifices 240 wherever the cutting die 14 is disposed on the die holder surface 21. In contrast, many conventional magnetic die holders which have alternating rows of magnets and orifices or alternating columns of magnets and orifices tend to limit the placement of the cutting die 14 because the die holder may have an insufficient number orifices in the vicinity of the die opening 20 for retaining the panel P.
In order to increase the magnetic effect of the magnets 220, the individual magnets 220 may have a magnetic wire 250 extending between the individual magnets 220. In
The cutting die 14 may be removed from the die holder 216 by exerting a significant tangential force thereon or by reducing the local induction of the magnets 240. Unfortunately, the cutting operation may create sufficient tangential forces including, for example, the forces created by the rotation of the die holder 216, which may displace a cutting die 14 of the type illustrated in
The valve member 260 has a bore 266 which is capable of selectively aligning with the corresponding end plate hole 102. When the valve bore 266 is aligned with the end plate hole 102 as shown in
In accordance with certain objects of the invention, a preferred embodiment provides a valve member 260 which is capable of selective and controlled rotation between a first closed position wherein the valve member 260 prevents flow through the end plate hole 102 (as shown in
The valve member 260 also has a seal member 280 which provides a relatively air-tight seal between the valve member 260 and the end plate 95. Although the illustrated embodiment of the valve member 260 is disposed in the end plate 95, it will be appreciated that the valve member 260 may also be disposed in the die holder 216 such that it communicates with the feed tube 80.
Thus, it will be seen that a die cutting apparatus and related cutting devices have been provided which attain the aforenoted objects. Although the structure and operation of the cutting die apparatus has been described in connection with the cutting of window panel from an envelope blank, it is not intended that the invention be limited only to such operations. Various additional modifications of the described embodiments of the invention specifically illustrated and described herein will be apparent to those skilled in the art, particularly in light of the teachings of this invention. The invention may be utilized in the cutting of any pattern from any relatively thin and flexible sheet-like material blank, including, for example, paper, cloth or plastic materials and labels, sanitary napkins, and the like. The invention is also applicable in butt-cutting operations wherein one blank is cut from a stack of multiple adjacent blanks, and may be used with solid or flexible dies. The invention also permits the selective control of the transport, retention, and release of the separate blank and pattern members during the rotation of the die holder. It is intended that the invention cover all modifications and embodiments which fall within the spirit and scope of the invention. Thus, while preferred embodiments of the present invention have been disclosed, it will be appreciated that it is not limited thereto but may be otherwise embodied within the scope of the following claims.
Okonski, Frank, Porento, Sr., Edward J.
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