Rotary cutting system, die board and scrap ejection device for a rotary cutting system, and assembly method

Abstract

Disclosed herein are components for a rotary cutting system, including a die board and a scrap ejector, as well as methods for assembling the system and components. The system includes a die board including a substrate and a scrap ejector. The die board includes at least one oblong fastener-receiving hole that receives a fastener to connect the die board to a die drum. The oblong shape of the fastener allows movement of the die board relative to the die drum after inserting a plunger into the die drum through the scrap ejector hole, while the fastener remains within the oblong fastener-receiving hole and the aligned recess in the die drum. The die board is rotatable such that the scrap ejector hole is no longer aligned with the plunger, preventing the plunger from exiting the die drum through the hole.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of Provisional Application No. 63 / 429,058, filed November 30, 2022, which is incorporated herein by reference.

[0002] background Technical Field

[0002] The present disclosure generally relates to rotary cutting systems for forming corrugated packaging blanks, components associated with forming features in the corrugated packaging blanks, and methods for assembling rotary cutting systems and associated components of such systems. [Background technology]

[0003] Description of the Prior Art

[0003] Rotary cutting systems are used to remove portions of corrugated packaging blanks during the manufacturing process (e.g., to form handles). The removed portions are typically referred to as scrap or trim. The portions are removed prior to other assembly steps (e.g., folding) of the corrugated packaging blank into a container. Once the portions (scrap) are removed, the remaining portion of the corrugated packaging blank may be referred to as the container in its flat / unerrected form. The container is typically folded into an erected container after removal from the rotary cutting system.

[0004]

[0004] Known rotary cutting systems include a pair of rollers, including a die drum that rotates about an axis in one rotational direction and an anvil drum that rotates about another axis in another rotational direction opposite to the direction of rotation of the die drum. The die drum typically includes a plurality of threaded holes that facilitate attachment of one or more die plates / boards to the die drum. The die drum and anvil drum rotate in opposite directions such that an object (e.g., a corrugated packaging blank) interposed in the nip (contact point / area) between the die drum and anvil drum is gripped and translated therebetween.

[0005]

[0005] Known die boards include blades, typically made from steel rules, that at least partially separate a portion of the corrugated packaging blank from the remainder of the corrugated packaging blank as the blank passes between the die drum and the anvil drum. The cutting blades may each form a cutout area, typically an enclosed shape, such that when the cutting blade contacts the corrugated packaging blank, a portion of the corrugated packaging blank that is the same shape as the cutout area is separated from the remainder.

[0006]

[0006] The separated portions of the corrugated packaging blank may become lodged in the blades as the corrugated packaging blank passes between the die drum and the anvil drum. If the separated portions of the corrugated packaging blank are not removed from within the enclosed shape formed by the blades, the blades may not be able to separate the respective corrugated packaging blank portions during subsequent rotations of the die drum. Furthermore, the cutting blades may break and / or separate from the base of the die board to which they are secured as a result of continued jamming of scrap into the enclosed shape during subsequent rotations.

[0007]

[0007] Known die boards include scrap ejectors that remove separated portions of the corrugated packaging blank from the enclosed shape formed by the blades. Some known scrap ejectors include a resilient member (e.g., rubber, cork, some other resilient / elastic material, or a high-density material). The resilient member may be positioned inside the enclosed shape formed by the blades so that when a portion of the corrugated packaging blank is separated from the remaining portion, the portion compresses the resilient member. As the blades progress along their rotation until they no longer face the anvil drum, the resilient member expands / returns to its neutral state, and in doing so, the resilient member pushes the separated portion of the corrugated packaging blank out of the enclosed shape and releases it from contact with the blades. Summary of the Invention [Problem to be solved by the invention]

[0008] One problem that arises from the use of a resilient member as a scrap ejector (referred to herein as a "passive" scrap ejector) is that scrap (i.e., separated portions of the corrugated packaging blank) may be ejected "upward" (i.e., radially outward from the axis of rotation of the die drum to which the die board is fixed) onto the remaining moving portion of the corrugated packaging blank, causing the scrap to be carried towards other components of the rotary cutting system where it may jam or otherwise malfunction. Another undesirable result that can result from the upward and outward ejection of scrap is that the scrap may "merge" with the remaining portion of the corrugated packaging blank, resulting in a "contaminated" or unsatisfactory finished product. [Means for solving the problem]

[0009] To overcome this problem, scrap ejectors with controllable actuation have been developed. Controllable scrap ejectors (also referred to herein as "active" scrap ejectors) allow for a rotary cutting system in which the die drum is positioned below the anvil drum. These active scrap ejectors may include a plunger. The plunger is controllable (i.e., movable when located within a desired portion of the die drum's rotation about its axis of rotation). Some known active scrap ejectors include a lever (e.g., in the form of a plate or plate-like member) fixed to the die board such that a plate is rotatable relative to the die board about its axis of rotation, while all other relative movement between the plate and the die board is prevented.

[0010] The plunger receiving hole in the die drum is in a fixed position, and if the plunger receiving hole is not in a position aligned with the enclosed shape of the blade, the lever may be provided to "reach" into the enclosed shape of the blade. Actuation of a plunger positioned "under" a plate (e.g., in the die drum) causes the plunger to impact the lever, thereby moving the lever, including the portion of the lever positioned within the enclosed shape.

[0011]

[0011] When the plunger reaches a position along its rotation (e.g., when the nip is at 0° along the path of rotation), which may be when the plunger is between 90° (e.g., perpendicular to the direction of gravity) and 180° (parallel to the direction of gravity), the plunger is actuated (i.e., translated away from the axis of rotation of the die drum and toward the plate). The plunger may be actuated by a cam positioned within the die drum. When actuated, the plunger moves into contact with a lever, causing the lever to rotate about the axis of rotation of the active scrap ejector.

[0012] Rotation of the lever causes a portion of the plate (e.g., one or more raised or flat extensions positioned within the enclosed shape of the cutout area) to push the separated portion of the corrugated packaging blank out from within the enclosed shape of the blade. The operating position of the plunger faces "down" from the remainder of the corrugated packaging blank, thereby avoiding the ejection of scrap into the rotary cutting system or the remainder of the corrugated packaging blank.

[0013]

[0013] Assembly of these known systems, particularly positioning the plunger relative to the plate, is complicated because it involves the use of small, removable parts. Furthermore, some rotary cutting systems include multiple die boards and / or multiple scrap ejectors fixed to each die board. As the number of scrap ejectors increases, the setup time for each plunger / scrap ejector combination increases significantly.

[0014] overview

[0014] The present disclosure provides an improved rotary cutting system for cutting objects, such as corrugated packaging blanks, as they pass between a rotating die drum and an anvil drum that rotates in a direction opposite to that of the die drum. The objects may be flat (e.g., having a thickness that is less than both their width and length), planar, curved, or any other shape that passes between the counter-rotating die and anvil drums.

[0015] According to one embodiment, a method for assembling a rotary cutting system includes aligning a first through-hole of a die board with a first anchor point of a die drum, the die drum being rotatable in a first rotational direction about a rotation axis, the first through-hole of the die board having an elongated oblong shape along the first rotational direction. The method further includes aligning a through-hole of a scrap ejector supported by the die board with a recess in the die drum and aligning a second through-hole of the die board with the recess in the die drum. The method further includes inserting a portion of a fastener through the first through-hole and into the first anchor point so that the fastener is secured relative to the die drum, inserting a plunger through the through-hole of the scrap ejector and through the second through-hole of the die board into the recess, and rotating the die board and scrap ejector relative to the die drum and plunger until the through-hole of the scrap ejector and the plunger are misaligned such that exit of the plunger from the recess is blocked by the scrap ejector.

[0016]

[0016] Additional embodiments described herein provide a method of assembling a die board, the method including positioning a lever within a cutout in a substrate, the cutout including an opening in a convex surface of the substrate, the cutout extending toward a concave surface of the substrate opposite the convex surface, the method further including fixing the lever within the notch such that the lever is rotatable relative to the substrate about an axis of rotation, the axis of rotation being positioned within the notch between the convex and concave surfaces.

[0017]

[0017] Additional embodiments described herein provide a die board including a substrate and a lever. The substrate includes a first major surface having a convex shape, a second major surface opposite the first major surface having a concave shape, a base surface positioned between the first and second major surfaces and opposite the second major surface, and a notch extending from an opening in the first major surface toward the second major surface to terminate at the base surface. The lever is supported by the substrate such that relative movement between the lever and the substrate is prevented in all degrees of freedom other than rotation about an axis of rotation between the first and second major surfaces.

[0018]

[0018] Additional embodiments described herein provide a scrap ejection device including a lever, a shaft fixed to the lever such that relative movement between the lever and the shaft is prevented, a bearing block having a recess, the bearing block positioned in the recess such that the shaft is rotatable relative to the bearing block about an axis of rotation, a biasing member positioned to exert a biasing force on the lever, and a bracket having at least one through hole. The shaft is positioned in the recess, and the bearing block is positioned in a cutout in a substrate, the notch extending through an opening in the convex surface of the substrate toward the concave surface of the substrate, and at least one fastener is inserted into the convex surface through the at least one through hole when the bracket is positioned to block a portion of the opening such that movement of the bearing block from the notch through the opening is prevented.

[0019] Brief description of each figure in the drawing

[0019] In the drawings, similar elements or acts are identified by the same reference numbers. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to make the drawings easier to read. Furthermore, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements, but may simply be selected for ease of recognition in the drawings. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is a cross-sectional side view of a rotary cutting system according to one embodiment, the system facing a first orientation. [Figure 2]

[0021] FIG. 2 is a top view of the rotary cutting system shown in FIG. 1, with the system facing a first orientation. [Figure 3]

[0022] FIG. 2 is a cross-sectional side view of the rotary cutting system shown in FIG. 1, with the system facing a second orientation. [Figure 4]

[0023] FIG. 2 is a top view of the rotary cutting system shown in FIG. 1, with the system facing a second orientation. [Figure 5]

[0024] FIG. 2 is a cross-sectional side view of the rotary cutting system shown in FIG. 1, with the system facing a third orientation. [Figure 6]

[0025] FIG. 2 is a top view of the rotary cutting system shown in FIG. 1, with the system facing a third orientation. [Figure 7]

[0026] FIG. 1 is a plan view of a known die board, according to one embodiment. [Figure 8]

[0027] 8 is a cross-sectional side view of the known die board shown in FIG. 7, the die board being attached to the die drum and the die drum in a first stage of assembly. [Figure 9]

[0028] 9 is a cross-sectional side view of a known die board attached to the die drum shown in FIG. 8, the die board in a second stage of assembly. [Figure 10]

[0029] 9 is a cross-sectional side view of a known die board attached to the die drum shown in FIG. 8, the die board in a third stage of assembly. [Figure 11]

[0030] FIG. 2 is a plan view of a die board substrate according to one embodiment. [Figure 12]

[0031] 12 is a cross-sectional side view of a die board according to one embodiment, the die board including the substrate shown in FIG. 11 attached to the die drum during the first stage of assembly. [Figure 13]

[0032] FIG. 13 is a cross-sectional side view of the die board shown in FIG. 12 attached to the die drum during the second stage of assembly. [Figure 14]

[0033] FIG. 13 is another cross-sectional side view of the die board shown in FIG. 12. [Figure 15]

[0034] FIG. 1 is an exploded isometric view of a die board according to one embodiment. [Figure 16]

[0035] FIG. 16 is an isometric view of the die board shown in FIG. 15 in an assembled configuration, according to one embodiment. [Figure 17]

[0036] FIG. 17 is a cross-sectional side view of the die board shown in FIG. 16. DETAILED DESCRIPTION OF THE INVENTION

[0021] Detailed explanation

[0037] In the following description, certain specific details are set forth to provide a thorough understanding of various disclosed embodiments. However, those skilled in the art will recognize that the embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with rotary cutting systems are not shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

[0022]

[0038] Unless the context requires otherwise, throughout this specification and the claims that follow, the term "comprise" and variations thereof, such as "comprises" and "comprising," are to be interpreted in their open and inclusive sense, i.e., "including but not limited to."

[0023]

[0039] Throughout this specification, a reference to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, the appearances of the phrase "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. For example, certain features of the disclosure that are described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features of the disclosure that are described in the context of a single embodiment may be provided individually or in any subcombination.

[0024]

[0040] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. It should also be noted that the term "or" is generally employed in its broadest sense, i.e., to mean "and / or," unless the context clearly dictates otherwise. As used herein, references to two elements "facing" or "facing toward" each other indicate that a straight line can be drawn from one of the elements to the other of the elements without contacting any intervening solid structure.

[0025]

[0041] The term "aligned," as used herein in reference to two elements along a direction, means that a line passing through one of the elements and parallel to that direction also passes through the other of the two elements. The term "between," as used herein in reference to a first element being between a second element and a third element relative to a direction, means that the first element is closer to the second element when measured along that direction than the third element is to the second element when measured along that direction. The term "between" includes, but does not require, that the first, second, and third elements be aligned along that direction.

[0026]

[0042] The recitation of ranges of values ​​herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, including the recited endpoints of the range, unless otherwise indicated herein, and each separate value is incorporated herein as if it were individually recited herein.

[0027]

[0043] Aspects of the present disclosure will now be described in detail with reference to the drawings, wherein like reference numerals refer to like elements throughout unless otherwise specified. Certain terminology is used in the following description for convenience and not as a limitation. As used herein, the term "plurality" means two or more. The term "at least a portion" of a structure includes the entire structure.

[0028]

[0044] The headings and abstracts provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

[0029]

[0045] 1-6 , the rotary cutting system 20 includes a die drum 22 and an anvil drum 24. The die drum 22 may include a die drum body 26 (e.g., an elongated cylinder) rotatable in a first rotational direction R1 about a rotation axis 28. According to one embodiment, the die drum 22 may be elongated along the rotation axis 28. The die drum 22 may include a plurality of recesses 30 extending into the die drum body 26 from an opening 32 in an outer surface 34 of the die drum body 26. According to one embodiment, the recesses 30 may include anchor points 31 (e.g., in the form of a through hole extending through the entire thickness of the die drum body 26, a blind hole terminating within the die drum body 26, or a combination of a through hole and a blind hole). For example, one or more of the anchor points 31 may be in the form of a bolt hole.

[0030]

[0046] According to one embodiment, the recesses 30 may be arranged in rows (e.g., extending along a direction parallel to the rotation axis 28) such that the holes in each row are spaced an equal distance from adjacent recesses 30 in the same row. Each of the rows may be spaced an equal distance circumferentially around the outer surface 34 of the die drum 22 (e.g., along the first rotation direction R1 of the die drum 22) from adjacent rows. Thus, the recesses 30 may be arranged in a grid pattern as shown in the illustrated embodiment. Alternatively, the recesses 30 may have other arrangements (regular or irregular) to accommodate the needs of the particular operation in which the rotary cutting system 20 is being used. For example, the recesses 30 within a row may be evenly spaced, while the rows are positioned with different distances between them (or vice versa).

[0031]

[0047] The plurality of recesses 30 may be arranged to respectively receive fasteners for securing a component (e.g., a die board) to the die drum 22. According to one embodiment, at least some of the plurality of recesses 30 (e.g., at least some, up to all, of the anchor points 31) may be at least partially internally threaded to accommodate external threads of a fastener (e.g., for bolting).

[0032]

[0048] The anvil drum 24 may include an anvil drum body 36 (e.g., an elongated cylinder) that is rotatable in a second rotational direction R2 about a rotational axis 38. According to one embodiment, the anvil drum 24 may be elongated along the rotational axis 38. During operation of the rotary cutting system 20, the first rotational direction R1 may be opposite the second rotational direction R2. Furthermore, the die drum 22 and the anvil drum 24 may rotate at the same angular velocity.

[0033]

[0049] The rotary cutting system 20 may include a die board 40 having a substrate 42. According to one embodiment, the substrate 42 is made from wood. The substrate 42 may include a first major surface 44 that is convex and a second major surface 46 that is concave. The second major surface 46 may be shaped to correspond to the outer surface 34 of the die drum 22. According to one embodiment, the second major surface 46 forms a portion of a cylinder having a diameter that is approximately equal (e.g., equal to within a tolerance) to the diameter of the outer surface 34.

[0034]

[0050] The die board 40 may include a plurality of through-holes. At least some of the plurality of through-holes may be fastener-receiving holes 48 that receive fasteners to secure the die board 40 to the die drum 22. The plurality of through-holes in the die board 40 may further include holes 50 (i.e., holes that do not function during operation of the rotary cutting system 20) that are sized to facilitate transportation of the die board 40 by a user. In addition to securing the die board 40 to the die drum 22 (i.e., fasteners), the through-holes in the die board 40 may also include holes to receive other components of the rotary cutting system 20 (e.g., plungers, described in detail below).

[0035]

[0051] The rotary cutting system 20 may include a blade 60 supported by the die board 40 such that the cutting edge of the blade 60 extends (e.g., radially) away from the first major surface 44. The blade 60 may form the periphery of a closed shape (e.g., an oval, a slot, etc.) as shown. The blade 60 may include an interior volume within the closed shape.

[0036]

[0052] The rotary cutting system 20 (e.g., die board 40) may include a scrap ejector 62. The scrap ejector 62 may include a lever 64, which may be supported by the substrate 42 such that the lever 64 is rotatable relative to the substrate 42 about one axis of rotation while all other relative movement is prevented. As shown, the lever 64 may be in the form of a plate or plate-like member.

[0037]

[0053] During operation of the rotary cutting system 20, a blank (e.g., a corrugated packaging blank 10) may be moved toward a nip 66 between the die drum 22 and the anvil drum 24, as shown in Figures 1 and 2. The die drum 22 may rotate in a first rotational direction R1 about an axis of rotation 28, while the anvil drum 24 rotates in a second rotational direction R2 about an axis of rotation 38. The die board 40 may be secured to the die drum 22 such that the die board 40 and the anvil drum 24 are in rolling contact with the corrugated packaging blank 10 as it passes through the nip 66.

[0038]

[0054] As the corrugated packaging blank 10 passes through the nip 66, the blade 60 may separate a portion 12 of the corrugated packaging blank 10 from a remaining portion 14 of the corrugated packaging blank 10, as shown in Figures 3 and 4. According to one embodiment, the portion 12 may have the same enclosed shape formed by the blade 60.

[0039]

[0055] As the corrugated packaging blank 10 exits the nip 66, the portion 12 may remain captured within the internal volume of the blade 60, while the remaining portion 14 leaves the rotary cutting system 20. The rotary cutting system 20 may include a plunger 68 and an actuator 70, each positioned within the die drum 22. As shown, the plunger 68 may be positioned within one of the plurality of recesses 30. The recess 30 in which the plunger 68 is positioned may be one of the anchor points 31 (i.e., all of the plurality of recesses 30 are identical and serve as anchor points to secure the component to the die drum 22). Additionally, the plurality of recesses 30 may be of different sizes, shapes, etc. For example, the recess in which the plunger 68 is positioned may be smoothly drilled (i.e., lacking threads).

[0040]

[0056] The plunger 68 and actuator 70 may be arranged such that when the die board 40 and plunger 68 are within a particular portion of a full rotation of the die drum 22 about the axis of rotation 28, the actuator 70 translates the plunger 68 radially (away from the axis of rotation 28) into contact with the scrap ejector 62, thereby rotating the lever 64 about the axis of rotation of the scrap ejector 62 relative to the substrate 42. This rotation of the lever 64 pushes the captured portion 12 of the corrugated packaging blank 10 out of the interior volume of the blade 60 (e.g., toward a scrap collector 72), as shown in FIGS.

[0041]

[0057] As shown, the actuator 70 may include a cam positioned so that the plunger 68 travels along the cam and remains within the die drum 22 until it reaches a particular portion of the rotation of the die drum 22 (e.g., 90°-180° from the nip 66). Once the particular portion of the rotation of the die drum 22 is reached, the shape and / or position of the cam causes the plunger 68 to translate away from the axis of rotation 28 and contact the lever 64. The cam may be fixed such that the die drum 22 rotates relative to the cam during operation of the rotary cutting system 20.

[0042]

[0058] 7-10, a known rotary cutting system 200 is shown that includes a complex assembly process prior to operation. As shown, the rotary cutting system 200 includes a known die board 202 that includes a known substrate 203 and a known scrap ejector 204. To assemble the rotary cutting system 200, the die board 202 is secured to a die drum 206 via a plurality of fasteners 208 (e.g., externally threaded members such as bolts), each fastener being inserted through a fastener-receiving hole 210 in the die board 202 and into a fastener-receiving hole (e.g., an internally threaded hole) in the die drum 206.

[0043]

[0059] Securing the die board 202 to the die drum 206 aligns a plunger hole 212 in a lever 214 of the scrap ejector 204 with a through hole 216 in the substrate 203 and a plunger receiving hole 218 in the die drum 206. A plunger 220 is inserted through the plunger hole 212, through the through hole 216, and into the plunger receiving hole 218, as shown in FIG. 8 . The plunger hole 212 in the lever 214 is then blocked (e.g., with a clip 222, described below) to provide a surface against which the plunger 220 strikes upon radial translation away from the axis of rotation of the die drum 206. The impact of the plunger 220 on the lever 214 rotates the lever 214, which in turn pushes scrap out of the interior volume of a blade 224 supported by the substrate 203.

[0044]

[0060] The scrap ejector 204 includes a clip 222 that is removable / attachable to the lever 214 to block the plunger hole 212 after the plunger 220 is positioned within the die drum 206. To attach the clip 222, the lever 214 is rotated away from the die board 202, as shown in FIG. 9. To facilitate this rotation of the lever 214, a finger recess 226 may be provided in the substrate 203 adjacent the lever 214. This finger recess 226 can collect scrap or other debris during operation of the rotary cutting system 200, thus resulting in more frequent maintenance to prevent clogging or other problems resulting from scrap / debris accumulation.

[0045]

[0061] An operator of the rotary cutting system 200 can place their finger in the finger recess 226 to apply force to the underside of the lever 214, rotating the lever 214 upward and away from the substrate 203 and at least partially out of the notch that receives the lever 214. When the lever 214 is rotated away from the die board 202, the clip 222 can be positioned to attach to the lever 214 and block at least a portion of the plunger hole 212, as shown in FIG. 10 . The clip 222 is small and includes a biasing force that is overcome during attachment of the clip 222 to the lever 214. The size and biasing force of the clip 222 can result in the clip 222 falling off or getting lost during attachment, which increases the assembly time of the rotary cutting system 200.

[0046]

[0062] Although only one scrap ejector 204 is shown, some die boards 202 include many scrap ejectors 204. Furthermore, the rotary cutting system 200 may include more than one die board 202, with each die board 202 having multiple scrap ejectors 204. As the number of scrap ejectors 204 increases, the assembly time of the rotary cutting system 200 also increases. Furthermore, some of the scrap ejectors 204 may be angularly (i.e., circumferentially) offset from one another along the die board 202. Because the plungers are held in place only by gravity prior to attachment of the clips 222, each plunger 220 is inserted with the plunger bore 212 facing “up” (i.e., away from the direction of gravity). After all of the "up" facing plungers 220 have been inserted and all of the "up" facing plunger holes 212 have been blocked with respective ones of the clips 222, the die board 202 and the die drum 206 to which the die board 202 is secured may be rotated until the next plunger hole 212 faces "up".

[0047]

[0063] 11-14 , the die board 40 of the pending disclosure may include elements that reduce assembly time for the rotary cutting system 20. According to one embodiment, at least some of the fastener-receiving holes 48 of the die board 40 are oblong (e.g., one-dimensionally elongated squares or circles, slots, etc.). As shown, the oblong fastener-receiving holes 17 may be elongated in the first rotational direction R1. Similarly, the die board 40 may include one or more plunger-receiving holes 19 that are also oblong (e.g., elongated in the first rotational direction R1). The oblong fastener-receiving holes 17 and the oblong plunger-receiving holes 19 enable a method of assembling a rotary cutting system (e.g., rotary cutting system 20), as described below.

[0048]

[0064] According to one embodiment, a method of assembling a rotary cutting system (e.g., rotary cutting system 20) includes aligning one of the through holes 48 (e.g., oblong fastener-receiving hole 17) of the die board 40 with one of the recesses 30 (e.g., first anchor point 31 a) of the die drum 22 with respect to a radial direction extending perpendicularly away from the axis of rotation 28 of the die drum 22 (i.e., such that a radial ray 52 extending away from the axis of rotation 28 passes through both the oblong fastener-receiving hole 17 and the aligned recess 30). The method includes aligning the plunger hole 212 of the lever 214 with the recess 30 of the die drum 22. The method may further include aligning another of the through holes 48 (e.g., plunger receiving holes 19) of the die board 40 with the first recess 30a of the die drum 22. As noted above, the first anchor point 31a and the first recess 30a may be the same, or in another configuration (i.e., with another die board 40 secured to the die drum 22), the first anchor point 31a may receive a plunger (e.g., plunger 220) and the first recess 30a may receive a fastener (e.g., fastener 208).

[0049]

[0065] As shown, plunger receiving hole 19 may be located within a cutout in die drum 22 that receives a scrap ejector (e.g., scrap ejector 204). Thus, according to one embodiment, plunger receiving hole 19 may have a height (measured along another radial ray extending perpendicularly from rotation axis 28 and extending through plunger receiving hole 19) that is less than the height of oblong fastener receiving hole 17 (measured along a radial ray extending perpendicularly from rotation axis 28 and extending through plunger receiving hole 19).

[0050]

[0066] The method may further include inserting a portion of a fastener (e.g., fastener 208) through the oblong fastener-receiving hole 17 and into the first anchor point 31 a such that the fastener 208 is secured relative to the die drum 22, as shown in FIG. 12. According to one embodiment, the inserted fastener may be the first fastener, and the method may further include inserting additional fasteners (e.g., second, third, fourth, fifth, etc.) into additional corresponding anchor points similar to the illustrated first fastener. Thus, the die drum 22 may include a plurality of oblong fastener-receiving holes 17, each aligned (e.g., aligned in a row) with a corresponding anchor point 31.

[0051]

[0067] The method may include inserting an actuator (eg, plunger 220) through plunger-receiving hole 19 and into first recess 30a, as shown in FIG.

[0052]

[0068] The method may further include rotating the substrate 42 and the scrap ejector 204 supported by the substrate 42 relative to the die drum 22 and the plunger 220 positioned within the first recess 30a until the plunger bore 212 of the scrap ejector 204 and the plunger 220 are misaligned such that the exit of the plunger 220 from the first recess 30a is blocked by the scrap ejector 204. According to one embodiment, the plunger 220 exits the first recess 30a along a radial direction extending perpendicularly from the rotation axis 28. As shown in FIG. 13 , the exit of the plunger 220 may be blocked by the lever 214 (e.g., a portion of the lever 214 through which the plunger bore 212 passes).

[0053]

[0069] The die board 40 may include an additional scrap ejector (e.g., a second scrap ejector), which may be aligned with the die drum 22 similarly to the scrap ejector 204 described above. According to one embodiment, the method may include aligning a through-hole of the second scrap ejector supported by the die board 40 with one of the recesses 30 of the die drum 22 (e.g., one of the anchor points 31). Similar to the first plunger 220 described above, the second plunger 220 may be inserted through the through-hole of the second scrap ejector, through the through-hole of the die board 40, and into the corresponding recess 30 of the die drum 22. Rotating the die board 40 relative to the die drum 22 may include rotating the second scrap ejector relative to the second plunger until the through-hole of the second scrap ejector and the second plunger are misaligned such that the exit of the second plunger from the recess 30 is blocked by the second scrap ejector.

[0054]

[0070] The oblong shape of the oblong fastener receiving hole 17 may be elongated along a central axis (e.g., extending along the first rotational direction R1), and the oblong fastener receiving hole 17 may be symmetrical about the central axis. Rotating the die board 40 relative to the die drum 22 and plunger 220 may include moving the die board 40 relative to the fastener 208 so that the fastener 208 follows a path that is coincident with the central axis of the oblong fastener receiving hole 17.

[0055]

[0071] After rotating the die board 40 relative to the die drum 22 until the plunger hole 212 of the scrap ejector 204 is misaligned with the plunger 220, the die board 40 may be fixed relative to the die drum 22 so that relative movement between the die board 40 and the die drum 22 is blocked in all degrees of freedom. According to one embodiment, the fasteners 208 may be further tightened within the oblong fastener-receiving holes 17 to secure the die board 40 relative to the die drum 22. Additional fasteners (e.g., similar to the fasteners 208) may be inserted through additional respective through holes 48 in the die board 40 and into respective recesses 30 (e.g., anchor points 31) in the die drum 22 to secure the die board 40 relative to the die drum 22.

[0056]

[0072] As shown, a fastener (e.g., fastener 208) may be inserted through fastener-receiving hole 15 in die board 40 and into a third recess 30 (e.g., second anchor point 31b) of the plurality of recesses 30 in die drum 22. According to one embodiment, fastener-receiving hole 15 may have a shape different from the shape of fastener-receiving hole 17, which is oblong. For example, fastener-receiving hole 15 may have a shape (e.g., circular) corresponding to fastener 208. As shown, fastener-receiving hole 15 does not have to have an oblong shape. Prior to rotation of die board 40 relative to die drum 22, fastener-receiving hole 15 and second anchor point 31b may be misaligned (as shown in FIG. 12 ) and are aligned after rotation of die board 40 relative to die drum 22 (as shown in FIG. 13 ).

[0057]

[0073] The method may include rotating the die drum 22 in a first rotational direction R1 about the rotation axis 28 after the die board 40 is secured to the die drum 22 (e.g., as described above). According to one embodiment, adjacent recesses 30 (with respect to the first rotational direction R1) of the plurality of recesses 30 of the die drum 22 may be spaced apart from one another by an angle α. As shown, the angle α may be measured along the first rotational direction R1 from the center of the first anchor point 31 a to the center of an adjacent recess (e.g., the third anchor point 31 c) of the plurality of recesses. The oblong fastener-receiving holes 17 of the die board 40 may have an arc length β (e.g., measured along the first rotational direction R1). The angle α of the die drum 22 may be greater than the arc length β. Thus, the method may include rotating the die board 40 relative to the die drum 22 by an angle less than the angle α (e.g., by the arc length β).

[0058]

[0074] The scrap ejector 204 may be supported by the substrate 42 such that the lever 214 is rotatable relative to the die board 40 about an axis of rotation 230. As shown, the axis of rotation 230 may be parallel to and radially spaced from the axis of rotation 28 of the die drum 22. The method may include securing the scrap ejector 204 to the die board 40 such that the lever 214 is rotatable relative to the die board about the axis of rotation 230.

[0059]

[0075] As described above, the rotary cutting system 20 may include a known scrap ejector 204 that is secured to the die board 40 such that the clip 222 is not required to block the plunger bore 212. With reference to Figures 15-17, the rotary cutting system 20 (e.g., the die board 40) may include a scrap ejector 100. The scrap ejector 100 may include a lever 102, a shaft 104, one or more bearing blocks 106, a biasing member 108, and a bracket 110.

[0060]

[0076] The lever 102 may be similar to the lever 214 described above. As shown, the lever 102 may include a first portion 112 that is substantially planar. The first portion 112 may be completely planar (e.g., having a first major surface 114 and a second major surface 116 that are both flat) or may have a curvature (e.g., having a convex first major surface 114 and a concave second major surface 116). The curvature of the first portion 112 may match the curvature of a substrate (e.g., substrate 42) to which the scrap ejection device 100 is secured. The scrap ejection device 100 (e.g., the lever 102) may include a plunger-receiving hole 118 formed by the first portion 112 such that the plunger-receiving hole 118 extends through both the first major surface 114 and the second major surface 116.

[0061]

[0077] The shaft 104 may be secured (e.g., welded) to the lever 102. As shown, the shaft 104 may be secured to one of the major surfaces (e.g., the first major surface 114 or the second major surface 116) of the lever 102 at a location proximate the first end 120. The first end 120 may have a width W1 measured across the first major surface 114 that is greater than a width W2 of the second end 122 of the lever 102. The lever 102 may include a second portion 124 extending from the second end 122 of the lever 102. The second portion 124 may extend out of plane with respect to the first major surface 114 of the lever 102. As shown, the second portion 124 may include one or more extension portions 126.

[0062]

[0078] The shaft 104 may be received within one or more bearing blocks 106 such that the shaft 104 and attached lever 102 are rotatable relative to the one or more bearing blocks 106 about an axis of rotation 128. As shown, the shaft 104 may have a circular cross-sectional shape, and the axis of rotation 128 may be the center of the circular cross-sectional shape. The one or more bearing blocks 106 may include a recess 130 (e.g., a through-hole) that receives a portion of the shaft 104. The recess 130 may have a shape that corresponds to the shaft 104 such that the shaft 104 is rotatable within the recess 130.

[0063]

[0079] The bearing block 106 may be monolithic and may be formed from a plastic (e.g., nylon). According to one embodiment, the bearing block 106 may include an outer portion 132 made from a first material surrounding an inner portion 134 made from a second material, the inner portion 134 forming the recess 130. According to one embodiment, the outer portion 132 may be made from a softer material (e.g., a plastic such as nylon) and the inner portion 134 may be made from a harder material (e.g., a metal such as brass).

[0064]

[0080] The shaft 104 may be positioned within the bearing block 106 to form a hinge point, which may be fully recessed within the substrate 42 (as shown). Alternatively, the hinge point may be positioned such that it is above the first major surface 114. The bearing block 106 may be indirectly fixed to the substrate 42 (e.g., via a bracket 110) or may be directly fastened to the substrate 42 (e.g., via one or more fasteners).

[0065]

[0081] The biasing member 108 may be in the form of a spring clip 136. The spring clip 136 may be positioned relative to the lever 102 such that a portion of the spring clip 136 extends over the first end 120 of the lever 102 and exerts a biasing force "downward" on the first major surface 114 toward the second major surface 116. Alternatively, the biasing member 108 may be a spring positioned below the lever 102 such that the biasing member 108 exerts a biasing force "upward" on the second major surface 116. The spring may be positioned on the opposite side of the pivot point 128 from the extension 126.

[0066]

[0082] Bracket 110 may be completely planar (similar to the description of lever first portion 112 provided above) or may have a curvature. Bracket 110 may include one or more fastener-receiving holes 140 extending therethrough.

[0067]

[0083] A method of assembling a die board (e.g., die board 40) includes positioning lever 102 within notch 150 in substrate 42. Notch 150 may include an opening 152 in a convex surface 154 of the substrate, and notch 150 may extend toward a concave surface 156 of substrate 42 opposite convex surface 154. The method may include securing lever 102 within notch 150 such that lever 102 is rotatable relative to substrate 42 about an axis of rotation 128, and such that axis of rotation 128 is positioned within notch 150 and between convex surface 154 and concave surface 156.

[0068]

[0084] The method may include positioning the shaft 104 secured to the lever 102 within one or more recesses 130 of the bearing blocks 106 such that the shaft 104 and lever 102 are rotatable relative to the one or more bearing blocks 106 about the axis of rotation 128. According to one embodiment, securing the lever 102 within the notch 150 includes securing the one or more bearing blocks 106 within the notch 150 such that the shaft 104 and recesses 130 are positioned within the notch 150.

[0069]

[0085] According to one embodiment, the method includes securing spring clip 136 to die board 40 such that spring clip 136 exerts a biasing force on lever 102 that biases lever 102 toward die board 40. Securing spring clip 136 to die board 40 may include inserting one or more fasteners 162 (e.g., screws) through respective holes in spring clip 136 and into surface 158 of die board 40. As shown, surface 158 may be a base surface 160 that partially forms notch 150 and is positioned between convex surface 154 and concave surface 156.

[0070]

[0086] A bracket 110 may be used to secure the lever 102 within the cutout 150. According to one embodiment, the method includes securing the bracket 110 to the die board 40 such that the bracket 110 blocks a portion of the opening 152. As shown, the portion of the opening blocked by the bracket 110 is aligned with one or more bearing blocks 106 such that movement of the one or more bearing blocks 106 out of the cutout 150 is prevented. The bracket 110 may be secured to the die board 40 by inserting one or more fasteners 162 through one or more respective through holes 164 in the bracket 110. The one or more fasteners 162 may be inserted through the convex surface 154.

[0071]

[0087] The fasteners 162 may be of different sizes. For example, the fasteners 162 used to secure the spring clips 136 in the notches 150 may be smaller (e.g., shorter, smaller diameter) than the fasteners 162 used to secure the bracket 110 to the convex surface 154.

[0072]

[0088] Inserting the fastener(s) 162 through the convex surface 154 may provide a more durable connection of the scrap ejection apparatus 100 to the die board 40. The die board 40 may have a thickness of less than 1 inch (e.g., 0.5 inch, 5 / 8 inch), and therefore, inserting the fastener(s) 162 into the surface of the die board 40 within the cutout 150 may result in a weaker connection because it limits the amount of die board 40 available to secure the fastener(s) 162 therein.

[0073]

[0089] Known scrap ejectors (such as the known scrap ejector 204 shown in FIGS. 7-10 ) include a fastener that is inserted through a surface within a cutout that receives a lever 214. Due to the rotation of the lever 214 relative to the substrate of the die board 202 during scrap ejection, as well as the rotation of the die drum 206 and attached die board 202, the connection of the lever 214 to the substrate can have "play," resulting in vibration within the system. This vibration can cause premature wear on the components of the die board 202. In particular, the point where the fastener 217 is driven into the substrate is susceptible to spalling.

[0074]

[0090] These smaller screws may be more reliable when the rotary cutting system 20 operates with smaller gauge / thickness corrugated packaging blanks 10. However, as the thickness of the corrugated packaging blank 10 increases, the wear on the rotary cutting system 20 also increases. Thus, a more secure connection between the scrap ejectors and their substrates, as discussed herein, can result in a more robust die board that is less susceptible to failure at the connection point between the scrap ejector and the substrate.

[0075]

[0091] The bracket 110 may have a shape that corresponds to the first end 120 of the lever 102. As shown, the bracket 110 may have a "C" shape with a central recess 166 that provides a path for the first end 120 of the lever 102 and the spring clip 136 to rotate along during operation of the rotary cutting system 20. When the lever 102 rotates about the axis of rotation 128 away from the die board 40, a portion of the first end 120 and the spring clip 136 can enter the central recess 166.

[0076]

[0092] The above description of illustrated embodiments, including those described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. However, while specific and example embodiments are described herein for illustrative purposes, various equivalent modifications can be made by those skilled in the art without departing from the spirit and scope of the present disclosure. The various embodiments described above can be combined to provide further embodiments.

[0077]

[0093] Many of the methods described herein can be practiced with variations. For example, many of the methods may include additional acts, omit some acts, and / or perform acts in a different order than illustrated or described.

[0078]

[0094] These and other changes can be made to the embodiments in light of the above detailed description. Generally, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments, along with the full range of equivalents to which such claims are entitled. Accordingly, the claims are not limited by this disclosure.

Claims

1. 1. A method of assembling a rotary cutting system, comprising: aligning a first through hole of a die board with a first anchor point of a die drum, wherein the die drum is rotatable in a first rotational direction about a rotation axis, and the first through hole has an elongated oblong shape along the first rotational direction; Aligning a through hole of a scrap discharge device supported by the die board with a recess of the die drum; Aligning a second through hole of the die board with the recess of the die drum; inserting a portion of the fastener through the first through hole and into the anchor point such that the fastener is secured relative to the die drum; Inserting a plunger into the recess through the through hole of the scrap discharge device and the second through hole of the die board; rotating the die board and the scrap discharge device relative to the die drum and the plunger until the through hole of the scrap discharge device and the plunger are misaligned so that an exit of the plunger from the recess is blocked by the scrap discharge device; A method comprising:

2. the scrap ejector is a first scrap ejector, the recess is a first recess, the plunger is a first plunger, and the method further comprises: aligning a through-hole of a second scrap discharge device supported by the die board with a second recess of the die drum; Aligning a third through hole of the die board with the second recess of the die drum; inserting a second plunger into the second recess through the through hole of the second scrap discharge device and through the third through hole of the die board; further comprising rotating the die board and the scrap discharge device relative to the die drum and the plunger includes rotating the through hole of the second scrap discharge device so that the through hole is misaligned with the second plunger so that an outlet of the second plunger from the second recess is blocked by the second scrap discharge device. The method of claim 1.

3. the oblong shape is elongated along a central axis, the oblong shape is symmetrical with respect to the central axis, and the method further comprises: moving the die board relative to the fastener so that the fastener follows a path coincident with the central axis during rotation of the die board and the scrap ejector relative to the die drum and plunger. The method of claim 1 or 2, further comprising:

4. When the through hole of the scrap discharge device and the plunger are misaligned, the die board and the scrap discharge device are fixed to the die drum and the plunger. The method of claim 3 further comprising:

5. After fixing the die board and the scrap discharge device to the die drum and the plunger, rotating the die drum around the rotation axis in the first rotation direction. The method of claim 4 further comprising:

6. 6. The method of claim 5, wherein the die drum includes an adjacent anchor point adjacent to the first anchor point relative to the first rotational direction, the adjacent anchor point being spaced apart from the first anchor point by a first length measured along the first rotational direction, and the oblong shape has a second length measured along the central axis in the first rotational direction, the first length being greater than the second length.

7. the rotation axis is a first rotation axis, fixing the scrap discharge device to the die board so that the scrap discharge device is rotatable relative to the die board about a second rotation axis; The method of claim 5 further comprising:

8. The method of claim 7 , wherein the first axis of rotation is parallel to the second axis of rotation.

9. The method according to any one of claims 1 to 8, wherein the second through-hole of the die board has an oblong shape that is elongated along the first rotation direction.

10. the fastener is a first fastener, and the method comprises: aligning a second through hole of the die board with a second anchor point of the die drum before rotating the die board and the scrap discharge device, wherein the second through hole has an oblong shape that is elongated along the first rotation direction; inserting a portion of a second fastener through the second through hole and into the second anchor point so that the second fastener is secured relative to the die drum; The method of claim 1 further comprising:

11. The method of claim 1 , wherein the first anchor point and the recess are identical in size and shape.

12. A method for assembling a die board, comprising: positioning a lever within a notch in a substrate, the notch including an opening in a convex surface of the substrate, the notch extending toward a concave surface of the substrate opposite the convex surface; fixing the lever within the notch such that the lever is rotatable relative to the base about a rotation axis, the rotation axis being positioned within the notch between the convex surface and the concave surface; A method comprising:

13. Positioning the shaft fixed relative to the lever within a recess in the bearing block so that the shaft and the lever are rotatable relative to the bearing block about the axis of rotation. The method of claim 12 further comprising:

14. The method of claim 13 , wherein fixing the lever within the notch includes fixing the bearing block within the notch such that the shaft and the recess are positioned within the notch.

15. securing the spring clip to the substrate such that the spring clip exerts a biasing force on the lever that biases the lever toward the substrate; The method of any one of claims 12 to 14, further comprising:

16. 16. The method of claim 15, wherein securing the spring clip to the substrate comprises inserting a fastener through a through hole in the spring clip and into a surface of the substrate that forms the notch, the surface being positioned between the convex surface and the concave surface.

17. 17. The method of any one of claims 12 to 16, wherein fixing the lever in the cutout comprises fixing a bracket to the base material, thereby blocking at least a portion of the opening in the convex surface to prevent the bearing block from exiting the cutout.

18. The method of claim 17 , wherein securing the bracket to the substrate comprises inserting a fastener through a through hole in the bracket and into the convex surface of the substrate.

19. a first main surface having a convex shape; a second major surface opposite the first major surface, the second major surface having a concave shape; a base surface positioned between the first major surface and the second major surface and opposite the second major surface; and a notch extending from the opening in the first major surface toward the second major surface to terminate at the base surface; A substrate comprising: a lever supported by the substrate such that relative movement between the lever and the substrate is prevented in all degrees of freedom except for rotation about an axis of rotation between the first major surface and the second major surface; A die board.

20. a bracket secured to the base such that at least a portion of the opening is blocked by the bracket, thereby preventing movement of the lever through the opening and out of the notch; 20. The die board of claim 19 further comprising:

21. 21. The die board of claim 20, wherein the bracket is secured to the first major surface.

22. 22. The die board of claim 21, wherein the bracket is secured to the first major surface via at least one fastener inserted through a through hole in the bracket and into the first major surface.

23. a biasing member secured to the substrate such that the biasing member exerts a biasing force on the lever that biases the lever toward the substrate; The die board according to any one of claims 19 to 22, further comprising:

24. 24. The die board of claim 23, wherein the biasing member is a spring clip.

25. 25. The die board of claim 23 or 24, wherein the biasing member is secured to the substrate such that at least a portion of the biasing member is positioned within the notch.

26. 26. The die board of claim 25, wherein the biasing member is secured to the substrate via at least one fastener inserted through a through hole in the biasing member and into the base surface.

27. 27. The die board of claim 19, further comprising a blade coupled to the substrate such that relative movement between the blade and the substrate is prevented, the blade extending away from the first major surface and terminating in a sharp cutting edge, the sharp cutting edge forming an enclosed shape that encloses an interior volume.

28. 28. The die board of claim 27, wherein the blade includes a body, the body forming a gateway providing a passageway through the body to the interior volume.

29. 30. The die board of claim 28, wherein a portion of the lever extends through the gateway into the interior volume.

30. Lever and a shaft fixed to the lever such that relative movement between the lever and the shaft is prevented; a bearing block having a recess, the shaft being positioned within the recess so as to be rotatable relative to the bearing block about an axis of rotation; a biasing member positioned to exert a biasing force on the lever; a bracket having at least one through hole; Equipped with when the shaft is positioned within the recess and the bearing block is positioned within a notch in a base material, the notch extending through an opening in a convex surface of the base material toward a concave surface of the base material, and the bracket is positioned to block a portion of the opening such that movement of the bearing block from the notch through the opening is prevented, at least one fastener is inserted through the at least one through hole into the convex surface. Scrap ejector.

31. 31. The scrap ejection device of claim 30, wherein the lever includes a through hole, and the lever is positioned within the notch such that the through hole in the lever is aligned with the through hole in the substrate positioned within the notch.

32. 32. The scrap ejection device of claim 30 or 31, wherein the biasing member is a spring clip.

33. 33. The scrap ejection device of claim 32, wherein the spring clip includes a through hole, and the spring clip is secured within the notch via a fastener inserted through the through hole in the spring clip and into the substrate.

34. 34. The scrap ejection device of claim 33, wherein the fastener inserted into the substrate through the through hole of the spring clip is inserted through a base surface of the substrate, the base surface forming a portion of the notch and positioned between the convex surface and the concave surface.

35. The scrap discharge device according to any one of claims 30 to 34, wherein the lever is rotatable relative to the substrate about the axis of rotation.

Images