Coursey, David J. (1210 Humpheries Road, Conyers, GA, 30012, US)
Myers, Rick D. (3951 Joyce Court, Conyers, GA, 30013, US)
Coursey, David J. (1210 Humpheries Road, Conyers, GA, 30012, US)
| 1. | A presser assembly for supporting blanking scrap during a blanking operation, the presser assembly comprising: a support rail ; a presser rail connected to the support rail ; and a connecting rail connecting the presser rail to the support rail and being adapted to pivot with respect to at least one of the support rail and the presser rail through a predetermined pivot angle range for changing a distance between the support rail and the presser rail thereby selectively effecting a folding and an unfolding of the presser assembly during the blanking operation. |
| 2. | The presser assembly according to claim 1, wherein: the presser rail is connected to the support rail respectively at a first end and at a second end thereof; the connecting rail comprises a first connecting rail and a second connecting rail connecting the presser rail to the support rail respectively at the first end and at the second end thereof, the first connecting rail and the second connecting rail each being adapted to independently pivot with respect to at least one of the support rail and the presser rail for changing a distance between the support rail and the presser rail to thereby enable folding of the presser assembly during the blanking operation. |
| 3. | The presser assembly according to claim 1, further comprising a biasing mechanism for biasing the presser rail away from the support rail. |
| 4. | The presser assembly according to claim 3, wherein the biasing mechanism is coupled to at least one of two ends of the connecting rail. |
| 5. | The presser assembly according to claim 4, wherein the biasing mechanism comprises a torsion spring. |
| 6. | The presser assembly according to claim 2, further comprising a biasing mechanism for biasing the presser rail away from the support rail, wherein: each of the first connecting rail and the second connecting rail has a presser end and a support end; and the biasing mechanism comprises a torsion spring disposed at at least one of the presser end and the support end of at least one of the first connecting rail and the second connecting rail. |
| 7. | The presser assembly according to claim 6, wherein the torsion spring includes a first torsion spring and a second torsion spring disposed at the presser end of the first connecting rail and at the presser end of the second connecting rail, respectively. |
| 8. | The presser assembly according to claim 2, wherein the presser rail is an elongated member having two parallel side walls and a bottom wall together defining a trough therebetween, the first connecting rail and the second connecting rail each having a presser end and a support end and further being pivotally connected to the presser rail such that presser ends thereof are disposed in the trough. |
| 9. | The presser assembly according to claim 2, wherein the presser rail is an elongated member having two parallel sidewalls and a bottom wall defining a trough therebetween, the presser rail further defining two pairs of recesses therein, each pair of the two pairs including a first recess in one sidewall of the presser rail and a second slot in another, facing sidewall of the presser rail, the recesses of each pair of recesses being in registration with one another in a direction transverse to a longitudinal direction of the presser rail, the two pairs of recesses further being disposed at a central region of the presser rail and being spaced from one another. |
| 10. | The presser assembly according to claim 14, wherein: each of the first connecting rail and the second connecting rail includes a support end and a presser end; the presser rail defines a first hole at a first end thereof and a second hole at a second end thereof; and the presser assembly further comprises: a first pin and extending through the first hole of the presser rail and through the presser end of the first connecting rail for pivotally securing the first connecting rail to the presser rail ; and a second pin and extending through the second hole of the presser rail and through the presser end of the second connecting rail for pivotally securing the second connecting rail to the presser rail. |
| 11. | A blanking press comprising a press and the presser assembly of claim 1. |
| 12. | A method comprising the steps of : providing the presser assembly of claim 1 ; pivoting the connecting rail with respect to at least one of the support rail and the presser rail for reducing an angle defined therebetween thereby folding the presser assembly for reducing a distance between the presser rail and the support rail ; and pivoting the connecting rail with respect to at least one of the support rail and the presser rail for increasing an angle defined therebetween thereby unfolding the presser assembly for increasing a distance between the presser rail and the support rail. |
| 13. | A plunger assembly for gripping blanking material during a blanking operation, said plunger assembly comprising: a base member; a pivoting gripper member; and at least one pair of connecting legs connecting the base member to the pivoting gripper member, said pair of connecting legs including a gripper leg and a base leg pivotally connected to one another, said gripper leg also being pivotably connected to said pivoting gripper member, said base leg also being pivotably connected to said base member, and said pivoting gripper member being pivotable with respect to said pair of connecting legs through a predetermined pivot angle range for changing a distance between the pivoting gripper member and the base member, thereby selectively effecting a folding and unfolding of the plunger assembly during a blanking operation. |
| 14. | The plunger assembly according to claim 13, wherein said at least one pair of connecting legs comprises two pairs of connecting legs that are mirror images of each other. |
| 15. | The plunger assembly according to claim 13, further comprising a biasing device for biasing the pivoting gripper member away from the base member. |
| 16. | The plunger assembly according to claim 15, wherein the biasing device is disposed for biasing the base leg away from the gripper leg and into an unfolded position. |
| 17. | The plunger assembly according to claim 15, wherein the biasing device comprises a torsion spring. |
| 18. | The plunger assembly according to claim 14, further comprising a biasing device for each pair of connecting legs, each biasing device comprising a torsion spring disposed at the pivot joint between the base leg and gripper leg of each pair of connecting legs. |
| 19. | The plunger assembly according to claim 14, wherein the biasing device comprises a torsion spring having a first spring arm that bears against the base leg, and a second spring arm that bears against the gripper leg. |
| 20. | The plunger assembly according to claim 14, wherein the gripper leg of each pair of connecting legs includes a trough, and the respective base leg of each pair of connecting legs is received in said trough in a fully folded state of the plunger assembly. |
| 21. | The plunger assembly according to claim 13, wherein the pair of connecting legs is configured for effecting a folding of the plunger assembly such that, in a fully folded state of the plunger assembly, the base member, the base leg, the gripper leg, and the pivoting gripper member are substantially parallel to one another. |
| 22. | A system for gripping a blanking sheet, said system including at least one folding presser assembly and at least one plunger assembly, said folding presser assembly comprising: a support rail; a presser rail connected to the support rail; and a connecting rail connecting the presser rail to the support rail and being adapted to pivot with respect to at least one of the support rail and the presser rail through a predetermined pivot angle range for changing the distance between the support rail and the presser rail thereby selectively effecting a folding and unfolding of the presser assembly during the blanking operation, and said plunger assembly comprising: a base member; a pivoting gripper member; and at least one pair of connecting legs connecting the base member to the pivoting gripper member, said pair of connecting legs including a gripper leg and a base leg pivotally connected to one another, said gripper leg also being pivotally connected to the pivoting gripper member so as to be pivotable through a predetermined pivot angle range and said base leg being pivotally connected to the base member so as to be pivotable through a predetermined pivot angle range for changing a distance between the pivoting gripper member and the base member to thereby selectively effect a folding and unfolding of the plunger assembly during a blanking operation. |
| 23. | The system of claim 22, wherein said presser assembly and said plunger assembly are attached to a common surface. |
BACKGROUND OF THE INVENTION TECHNICAL FIELD OF THE INVENTION This invention generally relates to a presser assembly for a blanking operation, and, more particularly, to a presser assembly for supporting and/or advancing blanking scrap, such as paper, paperboard, or carton blanking scrap, during a blanking operation.
DESCRIPTION OF RELATED ART In the manufacture of cartons and paper products, small sheets of material are typically cut out of larger sheets. These smaller sheets are known as blanks that, in turn, may be further formed into various shapes, such as, by way of example, into boxes. The blanks are formed during a process known as a blanking operation. In a blanking operation, the blanks are cut, but not removed, from the large sheet of paper, paperboard, cardboard or carton material. After the blanks have been cut, the sheet is positioned over a frame for support. The frame typically includes large openings that correspond in size and in position to the blanks previously cut. Below the frame is typically a mechanism for stacking the blanks. In order to knock the blanks from the
sheet of material and hold the scrap material, an assembly known in the art as a presser assembly is used. The presser assembly includes a support tool having a presser member and a presser rail depending therefrom. The presser rail is biased away from the support tool. As the support tool is lowered, the presser rail engages the sheet of material such that the sheet of material is secured between the presser rail and the frame. The support tool continues to be lowered such that the presser member engages the blanks and knocks the blank out of the sheet of material. The carton blanks fall onto a stacking mechanism wherein the blanks are stacked.
If the presser rail does not adequately hold the blanking scrap, the scrap may fall onto the stacking mechanism. A carton blanking scrap in the stacking mechanism may jam the mechanism, thereby causing downtime and expense. In order to securely hold the carton blank scrap, one conventional presser assembly provides presser rails interconnected to the support tool by a plurality of guide cylinders. Each guide cylinder biases the presser rail away from the support tool. This gives the presser rail a certain amount of flexibility when engaging the carton blanking scrap. However, even with this limited flexibility, present-day presser rails and assemblies have been found to be inadequate and require substantial assembly and various parts. An example of such a presser assembly is described in U. S. Patent No. 5,529,565, the subject matter of which is incorporated herein in its entirety by reference.
Furthermore, presser assemblies of the prior art, by virtue of their configuration and size, generally do not offer the possibility of holding relatively small portions of blanking scrap of a blanking sheet. Hence, where relatively small portions of blanking scrap of a blanking scrap sheet remains, it is possible that such smaller portions of the
blanking sheet may not be stabilized or engaged by conventionally sized and designed presser assemblies. Furthermore, because presser assemblies need to be positioned clear of cutting, scoring, creasing, and embossing tools, there is often insufficient space in which to position or mount a conventional presser assembly.
In short, the prior art fails to provide a presser assembly and/or a plunger assembly that offers a simple configuration, requires low cost to manufacture, is easy to assemble, and can easily and efficiently be mounted to a backer board of a blanking device.
SUMMARY OF THE INVENTION It is a purpose of the present invention to solve the above-mentioned problems.
To achieve the above purpose, the present invention provides a presser assembly for supporting blanking scrap during a blanking operation. The presser assembly includes : a support rail ; a presser rail connected to the support rail ; and a connecting rail connecting the presser rail to the support rail and being adapted to pivot with respect to at least one of the support rail and the presser rail through a predetermined pivot angle range. The pivot angle range is for changing a distance between the support rail and the presser rail to thereby selectively affect a folding and an unfolding of the presser assembly during the blanking operation.
The present invention further encompasses a die cutting or blanking press that includes a presser assembly for supporting blanking scrap during a blanking operation.
The assembly includes : a support rail ; a presser rail adapted to be connected to the support rail ; and a connecting rail adapted to connect the presser rail to the support rail and adapted to pivot with respect to at least one of the support rail and the presser rail
in an assembled state of the presser assembly. The pivoting is through a predetermined pivot angle range for changing a distance between the support rail and the presser rail thereby selectively effecting a folding and an unfolding of the presser assembly during the blanking operation. The assembly is operatively mounted on the die cutting or blanking press to support and/or advance a blank sheet or blanking scrap in a blanking operation.
Moreover, the present invention provides a presser assembly for supporting blanking scrap during a blanking operation, where the presser assembly includes: a support means; a presser means connected to the support means and supported thereby; and a connecting means for connecting the presser means to the support means and being adapted to pivot with respect to the presser means through a predetermined pivot angle range for changing a distance between the presser means and the support means thereby selectively affecting a folding and an unfolding of the presser assembly during the blanking operation.
Additionally, the present invention provides a method of using a presser assembly as described above. The method comprises the steps of : pivoting the connecting rail or means with respect to at least one of the support rail or means and the presser rail or means for reducing an angle defined therebetween, thereby folding the presser assembly for reducing a distance between the presser rail and the support rail ; and pivoting the connecting rail or means with respect to at least one of the support rail or means and the presser rail or means for increasing an angle defined therebetween, thereby unfolding the presser assembly for increasing a distance between the presser rail or means and the support rail or means.
The present invention also provides a method of forming blanks from a blanking sheet, where the method includes support and/or advancing a blanking sheet and a blanking press through the use of a presser assembly as described above.
According to a first embodiment of such a method, a presser assembly according to an embodiment of the present invention is used to hold, support, or secure a blanking sheet in a blanking press during a die cutting or blank forming operation. According to such an embodiment, the presser rail or presser means of the assembly contacts and biases the blanking sheet against a press support or counterplate positioned on a side of the blanking sheet, which is opposite the side contacted by the presser rail or presser means during a die cutting or blank forming operation. The blank sheet is thereby supported and stabilized during the die cutting operation to facilitate efficient and clean blank formation.
In another embodiment of the present invention, a plunger assembly is provided that includes: a base member; a pivoting gripper member; and pivoting, connecting legs connecting the base member to the gripping member. The legs include a biasing device to maintain the base member and the pivoting gripper member spaced from each other.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that while the detailed description and specific examples indicating preferred embodiments of the invention are given by way of illustration only, various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and are not intended to limit the present invention. In the drawings: Fig. 1 is a front-elevational view of a preferred embodiment of a presser assembly according to the present invention; Fig. 2 is a perspective, partially cut-away and enlarged view of a portion of the presser assembly shown in Fig. 1 showing a biasing mechanism according to a preferred embodiment of the present invention; Fig. 3 is a perspective, partially cut-away and enlarged view of a portion of the presser assembly shown in Fig. 1 showing a sliding mechanism according to a preferred embodiment of the present invention; Fig. 4 is a perspective view of a glide support according to a preferred embodiment of the present invention; Fig. 5a is a partially cut-away and broken-away end view of the device shown in Fig. 1 depicting the connecting rail connected to the support rail ; Fig. 5b is a front view of a guide pin as could be used in the embodiment of Fig. 1 according to a preferred embodiment of the present invention; Fig. 5c is a front view of one of the locking rings shown in Fig. 5a according to a preferred embodiment of the present invention;
Fig. 6a is a side view of a preferred embodiment of a presser rail according to the present invention; Fig. 6b is a bottom plan view of the presser rail shown in Fig. 6a; Fig. 6c is an end view of the presser rail shown in Fig. 6a; Fig. 7a is a side view of a preferred embodiment of a connecting rail according to the present invention; Fig. 7b is a bottom view of the connecting rail shown in Fig. 7a; Fig. 7c is a side view of the connecting rail shown in Fig. 7a; Figs. 8a and 8b are an end view and side view, respectively, of a bushing used in connecting the support rail to the connecting rails according to an embodiment of the present invention; Figs. 9a-9c are a side view, a bottom view, and an end view, respectively, of a presser rail according to yet another embodiment of the present invention; Figs. 10a-lOc are a side view, a top view, and an end view, respectively, of a support rail according to yet another embodiment of the present invention; Fig. lOd is end view of a support rail having flared edges according to one embodiment of the present invention; Fig. lla is a perspective, partial cutaway view of an end of a presser bar according to another embodiment of the present invention; Fig. 1 lob is a side in partial phantom of the presser bar embodiment shown in Fig. ! a; Fig.)) c is an enlarged view of circle portion I I c shown in Fig. 11 b ;
Figs. 12a and 12b are an end view and side view, respectively, of a furrel used in the coil spring of the embodiment of the present invention shown in Figs. l la-l l c ; and Figs. 13a and 13b are an end view and side view, respectively, of a hexagonal guide bushing for a coil spring rivet used in connection with the coil spring and furrel feature of the embodiment of the present invention shown in Figs. 11 a-l l c.
Fig. 14a is a bottom view in partial phantom of the base member of a plunger assembly as the assembly would be mounted on the top plate of a blanking press, according to an embodiment of the present invention; Fig. 14b is a side view in partial phantom of the base member shown in Fig.
14a; Fig. 15a is a bottom view in partial phantom of a base leg of a plunger assembly according to an embodiment of the present invention, that can be used in conjunction with the base member shown in Figs. 14a and 14b; Fig. 15b is a side view of the base leg shown in Fig. 15a ; Fig. 16a is a top view in partial phantom of a gripper leg of a plunger assembly according to an embodiment of the present invention, that can be used in conjunction with the base member shown in Figs. 14a and 14b and the base leg shown in Figs. 15a and 15b ; Fig. 16b is a side view of the gripper leg shown in Fig. 16a; Fig. 17a is a side view of a pivoting gripper member of a plunger assembly according to an embodiment of the present invention that can be used in conjunction with the base member, base leg, and gripper leg shown in Figs. 14a-16b ;
Fig. 17b is a top view of the pivoting gripper member shown in Fig. 17a; Fig. 18 is a side view in partial phantom of a plunger assembly according to an embodiment of the present invention, in a fully compressed position; Fig. 19 is a perspective view of the plunger assembly shown in Fig. 18, in an expanded position; and Fig. 20 is a side view in partial phantom of the plunger assembly shown in Fig.
19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention overcomes the problems of the prior art by providing a presser and a plunger assembly of simple construction having fewer components than presser and plunger assemblies of the prior art that use guide cylinders. The presser and the plunger assembly of the present invention therefore tend to advantageously be less costly to manufacture, be easily and completely assembled prior to shipment to die-cutting converters, and are easier to install. There is no need for the end user or die-cutting converter to assemble the presser and/or the plunger assembly as it can be shipped completely assembled. The presser and the plunger assembly, according to the present invention, can be easily and efficiently mounted to a backer board of a blanking device. In addition, the size and construction of the plunger assembly of the present invention enable the plunger assembly to be used in small or otherwise inaccessible locations, where larger presser assemblies cannot fit.
In order to achieve the above advantages, the present presser assembly includes at least one, and preferably two, connecting rails between a support rail and a presser
rail. The at least one connecting rail establishes and maintains a distance between the support rail and the presser rail, and is advantageously pivotable with respect to at least one of the support rail and the presser rail for allowing the presser assembly to be folded and unfolded, thereby reducing a distance between the support rail and the presser rail. An unfolding of the presser assembly would then involve a pivoting of the connecting rail with respect to at least one of the support rail and the presser rail such that a distance between the support rail and the presser rail is increased. The ability to decrease and increase the distance between the support rail and the presser rail, as recognizable by those skilled in the art, advantageously allows an efficient and clean blanking operation to take place. The fact of using at least one, and preferably two, connecting rails according to the present invention greatly simplifies the construction of a presser assembly and makes mounting of the presser assembly simple and efficient.
By"rail,"what is meant in the context of the present invention is any rigid member the length of which does not vary during a folding and unfolding of the presser assembly. Furthermore, a distance between the support rail and the presser rail may be"changed"according to the present invention by moving the support rail and the presser rail with respect to one another in either a translational movement and/or a pivoting movement of the support rail with respect to the presser rail. In either case, a distance between the support rail and the presser rail is changed. In addition, by "folding"the presser assembly, what is meant in the context of the present invention is a pivoting of parts of the presser assembly with respect to one another to draw the parts together and to make the assembly more compact.
With reference to the drawings, Figs. 1-3 show a preferred embodiment of the present invention. As seen in Fig. 1, a preferred embodiment of the present invention includes a presser assembly 10 for supporting blanking scrap during a blanking operation. Presser assembly 10 includes a support rail 12 and a presser rail 14 connected to the support rail as shown. At least one, and preferably two, connecting rails 16,18 connect the presser rail 14 to the support rail 12. In the shown preferred embodiment of the present invention, a first connecting rail 16 and a second connecting rail 18 connect the presser rail 14 to the support rail 12, respectively, at a first end 20 and at a second end 21 of the presser rail 14. The first connecting rail 16 and the second connecting rail 18 are each adapted to independently pivot with respect to at least one of the support rail 12 and the presser rail 14 for changing a distance between the support rail and the presser rail, thereby enabling folding of the presser assembly during the blanking operation.
In the shown preferred embodiment, the first connecting rail 16 and the second connecting rail 18 are pivotable with respect to presser rail 14 at respective pivot points 22 and 24 as shown. Preferably, the ratio of the distance between the holes defining pivot points 22 and 24 and the length of the presser rail 14 is about 0.8 or greater. The support rail 12 and the presser rail 14 are biased away from one another by biasing mechanisms 26. The biasing mechanisms shown are coupled to presser ends 28 and 30 of the first connecting rail 16 and the second connecting rail 18, respectively. However, it is to be understood that the present invention includes within its scope a biasing mechanism that is coupled to at least one of two ends of one or more connecting rails connecting the support rail with the presser rail.
In a preferred embodiment of the present invention, the biasing mechanism 26 comprises a torsion spring 32, shown in phantom in Fig. 1 and in partial phantom in Fig. 2, at only the presser end of the first connecting rail 16, it being understood that a torsion spring (not shown) is also provided at presser end 30. Each torsion spring includes a distal arm 34 and a proximal arm 36. The distal arm 34 rests against a corresponding one of the first connecting rail 16. There is a similar arrangement for the second connecting rail 18. The proximal arm 36 rests against a trough 38 of the presser rail 14. Each torsion spring 32 in this way biases the corresponding connecting rail to establish, with other separation limiting means, a default distance D between the support rail 12 and the presser rail 14. In this way, the connecting rails define an angle a between each connecting rail and the presser bar. The angle a at the default distance is preferably from about 30° to about 60°, for example, from about 40° to about 50°.
More preferably, the angle a is about 45 degrees. As shown in Figs. 1-3, the connecting rails, presser rail, support rail, and the presser assembly are in their default modes, or positions.
Preferably, according to the present invention, the presser assembly 10 further includes first pins 40, only one of which is depicted in Figs. 1-3, each pin 40 respectively extending through a respective presser end 28 or 30 of the first connecting rail 16 and the second connecting rail 18, respectively, for pivotally securing the first connecting rail and the second connecting rail to the presser rail. While only one pin 40 is shown in Fig. 1, it is to be understood that there is a pin 40 provided to secure a respective torsion spring 32 to each presser end of each of the first connecting rail 16 and the second connecting rail 18. The pin 40 preferably extends through holes 42 in
each of the presser ends 28 and 30, and through corresponding holes 44 at the first end 20 and second end 21 of the presser rail 14. It is to be understood that, similar to pin 40, although only one series of holes 40 and 42 are shown in Fig. 1, identical holes are provided at both the first end 20 and the second end 21 of the presser rail 14, and at both presser ends 28 and 30 corresponding to both connecting rails 16 and 18.
Referring now to Fig. 2 specifically, a perspective view is provided of the presser assembly shown in Fig. 1 in its default mode showing a portion thereof adjacent the first end 20 of presser rail 14. It is to be understood, however, that according to a preferred embodiment of the present invention, each end of the presser assembly is identical to or a mirror image of the other end thereof. Therefore, descriptions regarding Fig. 2 and pertaining to portions of the presser assembly adjacent first end 20 of presser rail 14 apply equally to the portions of the presser assembly adjacent second end 21 of presser rail 14. As shown in Fig. 2, the presser rail is preferably an elongated member defining a trough 46 therein. The trough 46 is more preferably defined between two parallel sidewalls 48,49, and a bottom wall 50, presser ends 28 and 30 resting against bottom wall 50, and proximal arm 36 of torsion spring 32 further resting against and being biased against bottom wall 50. Referring to Fig. 1, the first connecting rail 16 and the second connecting rail 18 respectively further have support ends 52 and 54 and are further pivotally secured to the presser rail. The presser ends 28 and 30 thereof are disposed in the trough 46.
Referring now to Fig. 3, a portion of presser assembly 10 including second end 21 of presser rail 14 is shown. Similar to Fig. 2, descriptions regarding Fig. 3 and pertaining to portions of the presser assembly adjacent and including second end 21 of
presser rail 14 apply equally to the portions of the presser assembly adjacent and including first end 20 of presser rail 14. As shown in Figs. 1-3, according to a preferred embodiment of the present invention, the support rail 12 is an elongated member defining a trough 56 therein, the first connecting rail 16 and the second connecting rail 18 are each slidably guidable within the trough at support ends thereof.
Trough 56 is defined between parallel sidewalls 58,59, and top wall 60 of the support rail 12.
Support ends 52 and 54 of connecting rails 16 and 18 are preferably made slidably guidable in trough 56 by providing two pairs of guide slots in support rail 12 according to the present invention. Additionally, a sliding mechanism 62 is provided for effecting a sliding of the support ends of the first connecting rail and the second connecting rail within the trough 56. The sliding mechanism preferably includes a guide pin 64 extending through a respective support end 52 and 54. As shown in Fig.
3, the pins 64 are slidably guidable within the guide grooves, as will be explained in further detail below.
A preferred embodiment of the present invention is shown in Fig. 3 and includes two pairs of guide slots 66, one pair of which is shown. A first pair of the two pairs of guide slots is preferably disposed adjacent the support end 52 of the first connecting rail 16, and is configured for guiding one of the guide pins 64 therein. The second pair 66 (shown in Fig. 3) of the two pairs of guide slots is preferably disposed adjacent the support end 54 of the second connecting rail 18 and is configured for guiding the other one of the guide pins 64 therein. Each pair 66 of guide slots more preferably includes two opposite and facing elongated holes 68, each defined in a
respective sidewall 58 of the support rail 12. Referring now to both Figs. 1 and 3, as the connecting rails 16 and 18 are pivoted so as to reduce angle a and reduce default distance D, each guide pin 64 slides forward in its corresponding slot 68, with each lateral part of each slot 68 serving as a stop for its corresponding guide pin. Therefore, in a default mode of the connecting rails, outer edges 70 of each slot 68 determine a stopping position of each connecting rail as it is biased outward, as readily recognizable by those skilled in the art.
Referring to Figs. 1-3, the sliding mechanism 62 further preferably includes a glide support 72 for each of the connecting rails 16 and 18, the glide support for connecting rail 18 being shown in Fig. 3. The glide support in the preferred embodiment of the present invention is connected to the support ends 52 and 54 of the first connecting rail 16 and the second connecting rail 18, respectively. Each glide support 72 is further configured to be guided within trough 56 for slidably guiding the support ends in the trough.
Fig. 4 depicts a perspective view of a preferred embodiment of a glide support 72 according to the present invention. As seen in Fig. 4, each glide support 72 includes an extended base portion 74 having side edges 76, and a narrowed head portion 78 defining a hole 80 therein for a guide pin 64. The glide support further preferably defines curved recesses 81 on each side thereof at a central region of its base portion for accommodating a pivoting motion of a corresponding end of a connecting rail. Thus, as readily recognizable by one skilled in the art, and as seen in Figs. 3 and 5a, each connecting rail is connected to its corresponding glide support 72 by being fastened thereto by way of guide pin 64 extending through hole 80 (Fig. 4) of
the glide support. Each glide support rests within the trough 56. The side edges 76 substantially abut the inner surfaces of sidewalls 58 of support rail 12. Thus, each glide support 72 is slidably guided within trough 56, in turn slidably guiding each support end of each connecting rail with respect to the support rail.
Referring now to Figs. 5a through 5c, connecting parts for connecting the support end of each connecting rail to its glide support and to the support rail are shown. As seen in Fig. 5a, a cross section of the portion of each support end 52/54 of each connecting rail 16,18 connected to the support rail 12 is shown in a plane transverse to the longitudinal direction of the support rail. Pin 64 extends through the slots 68 in the support rail 12, through corresponding holes 84 in the respective support end 52/54, and through hole 80 in each glide support 72 as shown. Each pin 64 is held in position by a pair of locking rings 86. As an alternative to pin 64 and rings 86, respective rivets can be used to permanently secure the respective support ends 52/54 of respective connecting rails 16,18, to the support rail 12. If rivets are used, they would preferably extend through slots 68 in the support rail 12, through holes 84 in the support ends of the connecting rails, and through holes 80 in each glide support.
Referring now to Fig. 5b, a side view of a preferred embodiment of a guide pin 64 is shown. The guide pin preferably has a body portion 88 adapted to extend within trough 56 of support rail 12, and end portions 90. Guide pin 64 has recesses 92 between each end portion 90 and the body portion 88 for accommodating a respective locking ring 86 (Fig. 5c) therein. As seen in Fig. 5c, the locking ring 86 is preferably substantially annular, and defines an opening 94 adapted to be snapped onto the guide pin 64 at a corresponding recess 92 of the guide pin 64. As mentioned above, rivets
can alternatively be used. The above arrangement ensures a secure slidable guiding connection between each connecting rail and the support rail. Preferably, a lubricant (not shown) is disposed in the trough for lubricating a sliding motion of each glide support within the trough. The lubricant may be disposed on trough surfaces of the support rail 12, at the underside of each glide support, and preferably on surface 60 along the entire sliding path of each glide support. The glide support 72 can be made of a self-lubricating material and/or a polytetrafluoroethylene or NYLATRON material.
According to an embodiment of the present invention, the holes 84 in the support ends 52/54 of the connecting rails can be fitted with bushings such as bushings 200 shown in Figs. 8a and 8b. Bushings 200 include a smaller diameter portion 204 and a larger diameter portion 202. The smaller diameter portion 204 is designed to rest snugly in a corresponding hole 84 of a respective connecting rail, and the larger diameter portion 202 is designed to be disposed between the connecting rail and the support rail 12. The smaller diameter portion is provided with a flattened portion 206 that is designed to mate with a corresponding squared-off portion of a hole (not shown) in a connecting rail, thereby preventing rotation of the bushing 200 in the hole of the connecting rail. The bushing 200 is also provided with a through hole 208 through which a guide pin or rivet can extend.
As seen in Figs. I through 3, the presser assembly according to the present invention preferably includes a pad 96, preferably made of a rubber or a similar, frictionally engaging, material. The pad 96 can be fixed to a lower surface of the presser rail 14 for frictionally engaging a scrap or blank sheet therewith during a
blanking operation. Preferably, the presser rail further defines two pairs of facing recesses 100 therein. As best seen in Fig. 2, each pair of the two pairs of recesses includes a first recess 100 in one sidewall 48 of the presser rail 14 and a second recess 100 in another, facing sidewall 49 of the presser rail 14. The recesses of each pair are in registration in a direction transverse to a longitudinal direction of the presser rail 14.
As seen in Fig. 1, the recesses of each pair are preferably spaced from one another such that, in a fully folded state of the presser assembly, the support rail 12, the connecting rail and the presser rail are substantially parallel to one another, and the first and second guide pins 64 are respectively received in a respective one of the two pairs of recesses 100 for allowing the presser assembly to fold fully, with the presser rail 14 fitting almost fully within the groove 56 of support rail 12.
As shown in Figs. 1 through 3, a preferred embodiment of the presser assembly according to the present invention includes two assembly flanges 110, one flange on each end of the support rail 12. As seen in Fig. 2, each flange includes one or more through holes 112 therein for allowing a fastening of the presser assembly to a male blanker board.
Optionally, a pair of resting pads 98, as seen in Fig. 1, are provided on bottom wall 50 of the presser rail. Each of the pads 98 is disposed at a respective one of the first end 20 and the second end 21 of the presser rail such that, in a default mode of the first connecting rail 16 and the second connecting rail 18 as shown in Fig. 1, a tip of the presser end of each of the first connecting rail 16 and the second connecting rail 18 rests against a corresponding one of the resting pads. The resting pads advantageously
prevent a scratching of the bottom wall 50 of the presser rail 14 by the tip of the presser ends of the connecting rails 16 and 18.
Referring now to Figs. 6a through 6c, a preferred embodiment of a presser rail 14 according to the present invention is depicted. The presser rail 14 shown in Figs. 6a to 6c has slanted sides 115 inclined with respect to top surface 125 and bottom surface 126 of the presser rail 14 by an angle y, preferably equal to about 45 degrees. Each of the slanted sides 115 has rounded edges defining a radius Rs2 preferably equal to about 0.125 inch and a radius Rs3 preferably equal to about 0.188 inch. Moreover, each of the slanted sides 115 is bounded on one side thereof by a side 116 adjoining outer surface 125 of presser rail 14, and having a height k of about 0.125 inch. A combined height i of sides 115 and 116 is moreover preferably about 0.437 inch.
Holes 44 in the presser rail preferably have a radius Rs4 of about 0.155 inch, and semi- circular recesses 100 preferably have a radius Rsl of about 0.203 inch. A distance hl from a center of each of the recesses 100 to outer surface 125 is further preferably about 0.329 inch, while a distance j from a center of each of the holes 44 to outer surface 125 is preferably about 0.25 inch. Each recess 100 further preferably has a diameter g of about 0.406 inch.
Preferably, the ratio of a distance between the two pairs of recesses and a length of the presser rail is about 0.2 to 1. The inner surface 126 of presser rail 14 defines a linear recess 120 therein at the region of recesses 100 as shown. Recess 120 is provided to accommodate side edges 76 of glide support 72 therein (see Fig. 4) in a fully folded state of the presser assembly. Linear recess 120 preferably has a depth h2 of about 0.062 inch, and a length d that is preferably about 2.562 inches. A distance e
between respective inner corners of recesses 100 being preferably about 1.094 inches.
Additionally, a distance f between the outer corner of each recess 100 and a closest edge of recess 120 is preferably about 0.328 inch. A distance c between respective centers of recesses 100 is preferably about 1.5 inches, and a distance b between a center of each recess 100 and a center of a hole 44 closest thereto is preferably about 2.5 inches. Moreover, a distance, designated"a", between a center of each hole 44 and a side edge 116 of the presser rail 14, is preferably about 0.75 inch. As seen in Fig. 6b, a total length o of the presser rail 14 is preferably about 8 inches, and its outer width p is preferably about 0.482 inch. As seen in Fig. 6c, an inner thickness n of the presser rail 14 is preferably about 0.386 inch, and its wall thickness m is preferably about 0.048 inch.
As seen in Figs. 7a, 7b, and 7c, a preferred embodiment of a connecting rail 16, 18 according to the present invention is shown, and includes a support end 28/30, and a presser end 52/54. As seen in Fig. 7a, the support end 52/54 has a rounded portion 130 and an angled portion 132. The support end 52/54 further defines support hole 84 for allowing a connection of the connecting rail 16/18 to support rail 12 in a sliding manner, as previously described. Rounded portion 130 defines an outer radius Rc2 of preferably about 0.37 inch, and hole 84 has a radius Rcl of preferably about 0.251 inch. The hole 84 is adapted to receive a support pin therein, such as pin 64 depicted in Fig. 2, for pivotally securing the connecting rail to the support rail.
Hole 84 in the preferred embodiment of Fig. 7a has a straight region 85 having a maximum thickness a'relative to the normal curvature of the hole 84 of preferably about 0.02 inch. The straight region stops the rotation of a pin 64 in the hole 84.
Straight region 85 further defines an angle 8 with respect to outer surface 134 of connecting rail 16/18 that preferably measures about 22.214 degrees. Angled region 132 defines an angle 0 of preferably about 44.427 degrees.
As suggested in Fig. 3, rounded portion 130 can at least partially be received within recess 81 of glide support 72, and angled portion 132 abuts against glide support 72 in an unfolded mode of the presser assembly and acts as a stop against a further biasing of the support rail 12 away from the presser rail 14. Outer surface 134 defines a recess 138 bounded on one side thereof by rounded portion 130, and on another side thereof by a slanted surface 140. Surface 140 is slanted with respect to a line perpendicular to surface 134 by an angle p that is preferably about 45 degrees. A distance b'between a line intersecting a center of hole 84 and parallel to surface 134, on the one hand, and surface 134 on the other hand, is preferably about 0.188 inch. A distance c'between a recessed surface of recess 138 of the connecting rail 16/18 and outer surface 134 preferably measures about 0.063 inch. The connecting rail 16/18 further defines a hole 141 therein that is preferably polygonal as shown. Hole 141 is provided for allowing a pivotal connection of connecting rail 16/18 to presser rail 14, as suggested in Fig. 3, for example, by way of pin 40. Hole 141 moreover has a height e'that is preferably about 0.251 inch.
The connecting rail 16/18 according to a preferred embodiment of the present invention has a slanted side 142 inclined with respect to surfaces 134 and 136 by an angle 11 preferably of from about 40 to about 45 degrees, such as about 42.685 degrees.
Slanted side 142 rests, in an unfolded state of the presser assembly 10, against the presser rail 14, and preferably against bottom wall 50 of the presser rail 14 as
suggested in Fig. 2. The angle p can in turn determine the inclination angle of the connecting rail 16/18 with respect to the presser rail 14 and the support rail 12 in an unfolded state of the presser assembly 10. Slanted side 142 further has a rounded edge at the inner surface 136 thereof defining a radius Rc3 preferably equal to about 0.2 inch, for example, about 0.187 inch.
A main function of the rounded edge is to facilitate a pivoting of the connecting rail 16/18 during a folding and unfolding of the presser assembly 10. The rounded edge eliminates or minimizes frictional engagement of the presser rail during a pivoting of the connecting rail 16/18. Moreover, slanted side 142 is bounded on one side thereof adjoining the outer surface 134 of the connecting rail 16/18 by a truncated corner 144 having a height c'of preferably about 0.06 inch, for example, about 0.063 inch. A combined height d'of side 142 is preferably about 0.437 inch. Truncated corner 144 defines a truncation region that truncates the length of the rail 16/18 if otherwise without a truncated corner, by a length z of about 0.05 inch, while the length of the connecting rail 16/18 is preferably about 3.35 inches. The truncation region is defined between surface 144 and an imaginary line 150 coinciding with an extrapolation of surfaces 134 and 142. The outer side of connecting rail 16/18 is further preferably provided with a rectangular opening 146 that, in a fully folded state of the presser assembly, accommodates at least a portion of torsion spring 32 therein.
As seen in Fig. 7b, the connecting rail 16/18 of Fig. 7a is shown as viewed from its side 134. In this figure, the thickness v of the connecting rail 16/18 is preferably about 0.375 inch. A distance s from a center of hole 84 to the center of hole 141 is preferably about 2.5 inches; a distance r between the edge of surface 140 closest
to hole 84 and one edge of opening 146 measures preferably about 1.563 inches. The length x of opening 146 is preferably about 0.562 inch, and the width u of opening 146 is preferably about 0.279 inch. A distance q between the edge of surface 140 furthest from hole 84 on the one hand and a transition point 148 (see Fig. 7a) between rounded region 130 and angled region 132, is preferably about 0.813 inch. Additionally, a shortest distance w between a center of hole 141 and line 150 measures preferably about 0.48 inch, while a shortest distance y between an edge of opening 146 and line 150 measures preferably about 0.292 inch.
Referring now to Fig. 7c, connecting rail 16/18 has an outer thickness g'of preferably about 0.375 inch, and an inner thickness f'of preferably about 0. 279 inch.
A wall thickness h'of the connecting rail 16/18 is further preferably about 0.048 inch.
While Figs. 6a-6c and 7a-7c show, respectively, a presser rail 14 and a connecting rail 16/18 according to a preferred embodiment of the present invention, it is to be understood that other preferred embodiments of the presser rail 14 and of the connecting rail 16/18 include those embodiments where at least two or more of the respective dimensions mentioned above, although not equal or approximately equal to the stated dimensions above, exhibit approximately the same proportions as corresponding ones of the stated dimensions above.
Another embodiment of the present invention is shown in Figs. 9a-13b.
According to this embodiment, a presser rail 214 is provided similar to the presser rail 14 shown in the embodiment of Figs. 1-3. The presser rail 214 includes recesses 216, 218 which function in a similar manner as recesses 100 shown in Figs. 1-3. The presser rail 214 of Figs. 9a-9c includes a frictionally engaging pad 220 that acts in a
fashion similar to pad 96 shown in the embodiment of Figs. 1-3. The presser rail 214 includes cut-out portions 222,224 for accommodating biasing coil springs such as those shown and described in connection with Figs. 11 a-1 1 c.
Figs. l0a-lOc show a support rail 230 that can have a flared edge (not shown) used in conjunction with the presser rail 214 of Figs. 9a-9c. The support rail 230 included mounting holes 232,234,236,238 for mounting the support rail to 230 to a press, such as a blanking press (not shown). The support rail 230, preferably including flared edge 231 (Fig. 10d), includes guide slots 240,242 for accommodating guide pins or rivets (not shown) used to connect connecting rails to the support rail 230.
Support rail 230 also includes cut-out regions 244, and 246 for accommodating guide pins or rivets used to connect a presser rail to connecting rails in a similar arrangement, as shown with respect to Figs. 1-3. Presser rail 230 also includes a notch 248 and a protrusion 250 designed to mate with a corresponding protrusion and a corresponding notch respectively, of adjacent support rails so that adjacent support rails can be closely mounted to support rail 230 on a press device. Support rail 230 is also provided with sidewalls 252 and 254, each of which terminates in a flanged distal portion 256,258, respectively. The flanged portions 256 and 258 are designed to accommodate a presser rail, such as presser rail 214 (shown in Figs. 9a-9c), when a presser assembly including support rail 230 and presser rail 214 is in a completely folded position.
Figs. 1 la-t Ic show portions of a presser assembly that includes a presser rail 214 and support rail 230 as shown in Figs. 9a-lOc. Presser rail 214 is connected to support rail 230 by a connecting rail 260. While a guide pin 262 and locking ring 264
are shown connecting the connecting rail 260 to support rail 230, it is to be understood that a rivet can be used instead. The connecting rail 260 is connected to presser rail 214 by a rivet 266 extending through a hole 268 (shown in Fig. 9a), and through a hexagonal bushing 268 (Figs. 13a and 13b) that is fitted in hexagonal holes provided in the connecting rail 260. The rivet 266 extends through the hexagonal bushing 268.
The hexagonal bushing 268 is preferably made of a hard plastic material such as polytetrafluoroethylene or NYLATRON. The connecting rail 260 is preferably biased away from presser rail 214 by a coil spring 270 through which a furrel 272 (Figs. 12a and 12b) extends. The hexagonal busing 268 in turn extends through the furrel 272.
Ends 274 and 276 of the coil spring 270 bias against surfaces of the presser rail 214 and connecting rail 260, respectively. The furrel 272 is preferably made of a stainless steel material. The furrel 272 has a smaller diameter portion 280 that is just slightly smaller than the internal diameter of the coil spring 270. The furrel 272 has a larger diameter portion 282 having a diameter that is larger than the outer diameter of the coil spring 270.
Preferably, according to the present invention, at least the support rail, presser rail, and connecting rails are made of steel or aluminum, and are die punched for rigidity. The support rail, presser rail, and/or connecting rail can be made of a hard, durable plastic material. The glide supports are in turn preferably made of a hard, durable plastic, preferably a slidable plastic such as polytetrafluoroethylene or another fluoropolymer.
As can be appreciated from the figures, the connecting rails are configured for effecting a folding of the presser assembly such that, in a fully folded state of the
presser assembly, the support rail, the connecting rail, and the presser rail are substantially parallel to one another. Advantageously, the invention provides a presser assembly that is easy to install on male blanker boards and that, by virtue of its simple construction, is easily manufactured, is generally less costly to manufacture than presser assemblies of the prior art, and is removed from male blanker boards of blanking devices with ease for being changed or reused. Furthermore, the presser assembly according to the present invention maintains the advantages of prior art presser assemblies, such as the ability to adjust to unequal pressure on the assembly, while substantially eliminating the possibility that the assembly will jam, as happens with presser assemblies of the prior art using guide cylinders. Additionally, the presser assembly according to a preferred embodiment of the present invention, unlike the presser assemblies of the prior art, does not require height adjustment, and thus can be much more efficiently mounted onto male blanker boards. Typically, the presser assembly according to a preferred embodiment of the present invention may be mounted or installed in two to three minutes.
The presser assembly of the present invention further includes a kit for forming a presser assembly for supporting blanking scrap during a blanking operation. The kit according to the present invention includes: a support rail, such as support rail 12 ; a presser rail, such as presser rail 14 adapted to be connected to the support rail ; and at least one connecting rail adapted to connect the presser rail to the support rail and adapted to pivot with respect to at least one of the support rail and the presser rail in an assembled state of the presser assembly through a predetermined pivot angle range for changing a distance between the support rail and the presser rail. A reduction of the
distance between the support rail and the presser rail, such as of the distance D shown in Fig. 1, affects a folding of the presser assembly during the blanking operation. The kit according to the present invention encompasses the components of the presser assembly adapted to be connected to one another for forming the presser assembly.
Thus, the kit includes, in a preferred embodiment of the present invention, the first connecting rail and the second connecting rail adapted to connect the presser rail to the support rail, respectively, at the first end and at the second end thereof. The kit according to the preferred embodiment of the present invention further includes the biasing mechanism, which in turn includes the torsion or coil spring.
In operation, as is readily recognizable to those skilled in the art, the support rail may be pushed toward the presser rail for pivoting the connecting rails with respect to at least one of the support rail and the presser rail for reducing the angle a thereby folding the presser assembly and reducing a distance between the presser rail and the support rail. For unfolding the presser assembly, the method according to the present invention includes the step of pivoting the connecting rails 16 and 18 with respect to at least one of the support rail and the presser rail for increasing the angle a defined therebetween, thereby unfolding the presser assembly for increasing a distance between the presser rail and the support rail. For achieving a fully folded state of the presser assembly, the method according to the present invention includes the step of pivoting the connecting rail for achieving a fully folded state of the presser assembly wherein the support rail, the connecting rail and the presser rail are substantially parallel with respect to one another, and preferably such that the presser rail almost fully rests within a groove of the support rail.
The present invention further includes within its scope a presser assembly for supporting blanking scrap during a blanking operation, the presser assembly including: a support means; a presser means connected to the support means and supported thereby; and a connecting means for connecting the presser means to the support means, and being adapted to pivot with respect to the presser means through a predetermined pivot angle range for changing a distance between the presser means and the support means, thereby selectively effecting a folding and an unfolding of the presser assembly during the blanking operation. The means mentioned above are substantially shown and described in relation to Figs. 1 through 7c.
According to an embodiment of the present invention, the invention provides a plunger assembly, for example, as shown in Figs. 19 and 20 (described below), that includes at least one pair of connecting legs between a base member and a pivoting gripper member. The pair of connecting legs establishes and maintains a distance between the base member and the pivoting gripper member. The pair is advantageously pivotable with respect to at least one of the base member and the pivoting gripper member for allowing the plunger assembly to be folded, thereby reducing the distance between the base member and the pivoting gripper member.
Connecting legs connected to the base member are herein referred to as base legs, and connecting legs connected to the pivoting gripper member are herein referred to as gripper legs. Each pair of connecting legs are also adapted to pivot at the joint between the two legs. The joint is preferably provided with a biasing device or torsion means to bias the legs in an extended position maximizing the distance between the base member and the pivoting gripper member.
The pivoting gripper member is also referred to herein as a plunger member, and can be provided with a pad or cushion attached thereto that makes contact with a blank to be gripped or held in a blanking press. Folding the plunger assembly involves pivoting the pair of connecting legs with respect to at least one of the base member and the pivoting gripper member such that the distance between the base member and the pivoting gripper member is decreased. The ability to decrease and increase the distance between the base member and the pivoting gripper member, as is recognizable to those skilled in the art, advantageously allows an expedient gripping, blanking, and knock-out operation to take place. In a preferred embodiment, the legs can be compressed or extended independent of each other.
In the present description, when an element is said to be"connected"to another element, those elements may be connected to one another either directly or indirectly, that is, with one or more elements interposed therebetween.
In the drawing figures, Fig. 14a is a bottom view in partial phantom of a base member 310 of a plunger assembly according to a preferred embodiment of the present invention. Exemplary dimensions of the base support member are a length of 2.875 inches, a width of 0.5 inch, and a thickness of 0.094 inch. The base member 310 includes first and second mounting holes 311,311', preferably located near respective ends of the base support member 310 as shown. Mounting screws can be used through the mounting holes 311,311'to mount the base member 310 and a respective plunger assembly to a platen or counterplate of a blanking press. Fig. 14a also shows the exemplary locations of two base pivot flanges or nodes 312,312', that are located
between the mounting holes 311,311', but project away from the top surface 450 of the base member 310, as shown also in Fig. 14b.
Fig. 14b is a side view in partial phantom of the base support member showing the mounting holes 311, 311'and the upwardly projecting base pivot flanges 312,312'.
In an exemplary embodiment, each base pivot flange 312,312'projects upwardly 0.327 inches from the top surface of the base member 310. Each pivot flange 312,312' is equipped with a respective opening 420,422 that can house an axle, screw, or other connecting pin or pivot device (not shown) to which can be attached a base leg 440/442 (Figs. 15a and 15b). The pivot device can be a projection from both faces of each pivot flange 312,312'onto which is attached or snapped a pivotable base leg 440/442 whereby a pivoting action between the base leg 440/442 and the pivot device can be provided.
Fig. 15a is a bottom view in partial phantom of a base leg 440/442, which has a lower recess 315 adapted to straddle the pivot flange 312,312'and pivotably attach to the base member 310 with a pin or other pivot device. The exemplary dimensions of the base leg 440/442 are a length of 1.159 inches, with a width of 0. 312 inch, and a depth of 0.25 inch. The base leg 440/442 also has an inner recess 316 adapted to receive, straddle, and stabilize an arm of a torsion spring 317 (not shown in Fig 15a).
An exemplary spring 317 is depicted in Fig. 18 in a compressed position and is mounted on or within the base leg 440/442 bridging the pivotable joint formed between the base leg 440/442 and the gripper leg 480/482. The torsion spring 317 can comprise a wound metal wire or other spring mechanism known to those skilled in the art. Preferably, the torsion spring 317 is movably mounted on an axle 490 forming a
pivot joint between the gripper leg 480/482 and the base leg 440/442. Preferably, the torsion spring 317 biases the gripper leg 480/482 and the base leg 440/442 into an open or extended position, whereby the distance between the base member 310 and the pivoting gripper member 324 is maximized.
Fig. 15b is a side view of the base leg 440/442 shown in Fig. 15a. The base leg 440/442 has first and second connecting holes 500,502, located near respective ends of the base leg 440/442. Connecting hole 502 of the base leg 440/442 pivotably attaches to the pivot device associated with either opening 420 or 422 in the respective pivot flange 312 or 312'of the base member 310. The pivotal attachment forms the base leg pivot joint described above. Connecting hole 500 receives an axle 490,491 (Figs. 18-20), forming a pivot joint between the gripper leg 480/482 and the base leg 440/442. The apex"a"of base leg 440/442 forms a brake or stop, wherein the biasing of the base leg 440/442 in an extended manner is stopped by the contact of apex"a" with the surface 450 of base member 310. Thus, the size, shape and angle of apex"a" can be varied to achieve the desired maximum extension of, and angle between, the pivotable connecting base leg and the gripper leg.
Fig. 16a is a top view in partial phantom of a gripper leg 480/482 having a first hole 510 and a second hole 512, located near respective ends of the gripper leg 480/482. The second hole 512 receives the axle 490. The second hole 510 pivotably receives a pivot pin 520 that projects laterally from the face of a downwardly projecting flange or ridge 323 (Figs. 17a, 17b) located on the underside of the pivoting gripper member 324. The gripper leg 480/482 has a recess 325 adapted to receive and straddle the downwardly projecting flange 323 of the pivoting gripper member 324.
The gripper leg 480/482 also has a recess 326 adapted to receive and straddle the entire base leg 440/442 when the plunger assembly is compressed into a completely or partially folded position. The recess 326 of the gripper leg 480/482 also is adapted to receive an arm of the torsion spring 317. In an exemplary embodiment, the gripper leg 480/482 is 1.604 inches long, 0.375 inch wide, and 0.5 inch deep. The lower end of gripper leg 480/482 can overlap the upper end of the base leg 440/442, and through the overlapped region the axle 490 passes to thereby form the pivot joint between the gripper leg 480/482 and the base leg 440/442.
Fig. 16b is a side view of the gripper leg 480/482. In a preferred embodiment, the first hole 510 and the second hole 512 are located approximately 1.188 inches apart on a gripper leg 1.604 inches long.
Fig. 17a is a side view of a pivoting gripper member 324, which, in an exemplary embodiment, is about 1 inch long, about 0.5 inch wide, and about 0.094 inch deep at its base. The pivoting gripper member 324 has a downwardly projecting flange or ridge 323 which, in a preferred embodiment, is straddled by the recess 325 of each gripper leg 480/482. The downwardly projecting flange or ridge 323 has pivot holes 520,522, which can be replaced with or filled by laterally projecting pivoting means (not shown) extending from each side of the flange 323. Whether projections or holes for pins are used, each is adapted to pivotably engage hole 510 in gripper leg 480/482, thereby forming a pivotable joint between the gripper leg 480/482 and the downwardly projecting flange 323 of the pivoting gripper member 324. The pivoting gripper member 324 can also have on its upper surface a pad or cushion 327 to
improve the frictional engagement of the plunger assembly with the cut or uncut blank sheets.
Fig. 17b is a top view of the pivoting gripper member 324 and illustrates an exemplary embodiment of the approximate location of the holes 520,522.
Fig. 18 is a side view in a partial phantom of an embodiment of the present invention in a fully compressed or fully folded position, wherein the distance between the pivoting gripper member 324 and the base member 310 has been minimized by application of a compressing force against the bias of the torsion springs 317. In an exemplary embodiment, the fully compressed plunger assembly of the present invention has a height of about 0.688 inch and a length of about 3.219 inches.
Fig. 19 is a perspective view of the plunger assembly shown in Fig. 18 in an expanded or fully unfolded position. As can be seen in Fig. 19, the top pivoting gripper member 324 can pivot on laterally projecting pivoting pins or projections through or integral with holes 520,522 (not shown) in the pivoting gripper member 324 at the pivot joint formed at the upper end of the gripper legs 480/482. This pivoting can occur with or without any compression of the respective torsion spring 317, or movement of the respective base leg 440/442.
Fig. 20 is a side view in partial phantom of the plunger assembly shown in Fig.
19. In an exemplary embodiment as shown, the angle between the upper and lower legs when biased at full extension is about 122°, the angle between the base member 310 and the base leg 440/442 is about 67°, and the angle between the gripper leg 480/482 and the pivoting gripper member 324 is about 55°.
It should be noted that the dimensions recited above for exemplary embodiments are not limitations, and assemblies with greater or lesser dimensions are fully contemplated within the scope of the present, invention. It is to also be understood that other preferred embodiments of the plunger assembly of the present invention include those embodiments where at least two or more of the respective dimensions mentioned above, although not equal or approximately equal to the stated dimensions above, exhibit approximately the same proportions as corresponding ones of the stated dimensions above.
In addition, the gripper legs 480/482, the base legs 440/442, the base member 310, and the pivoting gripper member 324 are depicted as solid pieces, but the present invention also includes variations wherein one or more of the aforementioned parts is or are hollow, grooved, perforated or otherwise not fully solid.
The embodiment depicted in the figures has the gripper legs that overlap the. base legs at the pivotable joint between the gripper legs and the base legs. It is also included in the present invention to have the base legs overlap the gripper legs instead at the pivotable joints between the gripper legs and the base legs.
It is preferred, but not required, herein that the component parts of the plunger assembly of the present invention are made of plastic materials or metal materials, preferably lightweight, inexpensive, easily machined, stamped, and/or extruded, metals. Examples of such preferred plastic materials include, but are not limited to, polyester, polyamide, polyimide, epoxy, acrylic, polycarbonates, and the like.
Examples of preferred metals include, but are not limited to, aluminum, stainless steel, copper, titanium, nickel, iron, chromium, and the like.
In operation, as is readily recognizable to those skilled in the art, the base member 310 may be pushed toward the pivoting gripper member 324 for pivoting the connecting legs 440/442 and 480/482 with respect to at least one of the base member 310 and the pivoting gripper 324. The pushing reduces the angle between the gripper leg 480/482 and the base leg 440/442, as well as the angle between the base leg 440/442 and the base member 310, thereby folding the plunger assembly and reducing the distance between the pivoting gripper member 324 and the base member 310. In a similar but alternative manner, the pivoting gripper member 324 can be pushed toward the base member 310. For unfolding the plunger assembly, the method according to the present invention includes the step of pivoting the connecting legs 440/442 and 480/482 with respect to at least one of the base member 310 and the pivoting gripper member 324 for increasing the aforementioned angles defined therebetween, thereby unfolding the plunger assembly and increasing the distance between the pivoting gripper member 324 and the base member 310. For achieving a fully folded, compressed, or nested state of the plunger assembly, the method according to the present invention includes the step of pivoting the connecting legs fully to achieve a fully folded, compressed, or nested state of the plunger assembly. When completely folded, the base support member, the connecting legs, and the plunger member are substantially parallel with respect to one another, and preferably such that the downwardly projecting flange on the underside of the pivoting gripper member 324 rests upon the base member 310.
A particular advantage of the plunger assembly of the present invention is its ability to pivot in two directions, but its rigidity and resistance to movement in a third
direction. The plunger device can compress in the depth, or"z"direction, can pivot in the"y"direction, but will not move laterally in the"x"direction. Such lateral, sideways, or"x"direction, movement relative to the length of the plunger assembly device can be undesirable. Preventing lateral,"x"direction, movement improves the ability to maintain registration of the blanking sheet.
The small and simple plunger assembly of the present invention can fit into many locations that are inaccessible to larger, conventional presser assemblies.
The present invention further includes within its scope a plunger assembly for supporting blanking scrap during a blanking operation, wherein the plunger assembly includes: connecting means for connecting a gripping means to a support means and being adapted to pivot with respect to the gripping means through a predetermined pivot angle range for changing a distance between the gripping means and the support means. The connecting means can thereby selectively effect a folding and unfolding of the plunger assembly during a blanking operation. The connecting means can be those means substantially shown and described above, for example, with reference to the connecting legs shown in Figs. 14a through 20. The gripping means can be those means substantially shown and described above, for example, with reference to the pivoting gripper member shown and described in connection with Figs. 14a through 20. The support means can be those means substantially shown and described above, for example, with reference to the base member shown and described in connection with Figs. 14a through 20.
In another embodiment, the plunger assembly further comprises a torsion means such as a spring, accommodated in recesses in each pair of connecting legs. The
plunger assembly of the present invention can include one or more pairs of connecting legs such as a first leg and a second leg. The legs respectively include a first recess and a second recess. The first leg can be a base leg as described above, including a spring arm recess. The second leg can be a gripper leg, as described above, including a trough for receiving the gripper leg and against the bottom of which the opposite spring arm can rest. The spring can be a torsion spring each including a distal arm and a proximal arm, with the distal arm resting in the recess of the gripper leg and the proximal arm resting against the bottom of the trough of the base leg.
As can be appreciated from the figures, the plunger assembly device is configured for effecting a folding or compressing of the plunger assembly device such that, in a fully folded state of the plunger assembly, the pivoting gripping member, the connecting legs, and the base member are substantially parallel to each other.
Advantageously, the invention provides a plunger assembly that is easy to install on blanker boards, for example, male blanker boards, and that, by virtue of its simple construction, is easily manufactured, generally less costly to manufacture than presser assemblies of the prior art, and can be removed from blanker boards with ease to be changed or reused. Furthermore, the plunger assembly according to the present invention maintains the advantages of prior art presser assemblies, such as the ability to adjust to unequal pressure on the assembly while substantially eliminating the possibility that the assembly will jam, as happens with presser assemblies of the prior art.
In another embodiment, the present invention also provides a kit for forming a plunger assembly for gripping a blanking sheet during a blanking operation. The kit,
according to the present invention, includes packaged together at least one base member, a pivoting gripper member, adapted to be connected to the base member; and a pair of connecting legs adapted to connect the base member to the pivoting gripper member and adapted to pivot with respect to at least one of the base member and the pivoting gripper member. The connecting legs can preferably pivot in an assembled state of the plunger assembly through a predetermined pivot angle for changing a distance between the base member and the pivoting gripper member. The kit preferably contains a torsion means or spring in the plunger assembly to bias the connecting legs into a position to maximize the distance between the base member and the pivoting gripper member. The kit of the present invention can further include, packaged together, at least one folding presser assembly for supporting blanking scrap during a blanking operation. The presser assembly preferably is the presser assembly of the present invention.
The present invention is also directed to a system including a blanking sheet presser assembly and at least one plunger assembly according to the present invention, wherein the presser assembly and the plunger assembly are mounted on a common surface. The presser assembly can be a folding presser assembly as described in U. S.
Patent Application No. 10/054,127 to Myers et al., filed October 22,2001 and entitled "Folding Presser Assembly" (Atty. Docket No. 3660-015-01). The aforementioned patent application and all other patents and publications mentioned herein are hereby incorporated herein in their entireties by reference.
The present invention is further directed to a kit containing at least one folding presser assembly and at least one plunger assembly, wherein the folding presser assembly and the plunger assembly are packaged together.
In another embodiment of the present invention, the invention includes a system for gripping a blanking sheet. The system includes at least one folding presser assembly, and at least one plunger assembly. The folding presser assembly includes at least one folding presser assembly as described above. The plunger assembly can be any of the plunger assemblies described above. In a preferred embodiment of the system, the presser assembly and the plunger assembly are each attached, fixed, connected, or mounted in the same or similar manner, on, or to, a common surface, for example, a blanking press platen or counter plate. In a more preferred embodiment, both the folding presser assembly and the plunger assembly are attached to a platen or die press plate.
The present invention also relates to a blanking press, printing press, stripping press, punching press, embossing press, or other press device that includes a presser and/or a plunger assembly according to the present invention, and methods of forming blanks or other products by using such a press device and presser and/or assembly. As such, it will be apparent to those skilled in the art that the disclosed invention may be modified in numerous ways and may assume many embodiments other than the preferred forms specifically set out and described above. Accordingly, it is intended that the appended claims cover all modifications of the present invention that fall within the true spirit and scope of the present invention.