U.S. patent application number 09/321674 was filed with the patent office on 2001-11-15 for dual mini-blind cutter.
Invention is credited to ANDERSON, ROGER L., DANIELS, JAMES L., GRAVES, DELBART B., JARECKI, DAVID J., PAHNKE, CARL, WALSH, MICHAEL J..
Application Number | 20010039868 09/321674 |
Document ID | / |
Family ID | 25413418 |
Filed Date | 2001-11-15 |
United States Patent
Application |
20010039868 |
Kind Code |
A1 |
GRAVES, DELBART B. ; et
al. |
November 15, 2001 |
DUAL MINI-BLIND CUTTER
Abstract
A mini-blind cutter for selective manual in-store sizing of a
first mini-blind product and a second mini-blind product. Each of
the mini-blind products include a head rail, a plurality of slats,
and a bottom rail having a different geometry and or material
composition. A die assembly is movable from a first position to a
second position includes a first and second region to receive the
first and second mini-blind products. A blade carrier assembly
includes at least two blade carriers and permits permit independent
translation of the blade carriers to accommodate the different
sized mini-blind products.
Inventors: |
GRAVES, DELBART B.; (NORA,
IL) ; PAHNKE, CARL; (FREEPORT, IL) ; DANIELS,
JAMES L.; (FREEPORT, IL) ; JARECKI, DAVID J.;
(ROCKFORD, IL) ; WALSH, MICHAEL J.; (ELM GROVE,
WI) ; ANDERSON, ROGER L.; (MCCONNELL, IL) |
Correspondence
Address: |
KEITH D LINDENBAUM
FOLEY & LARDNER
FIRSTAR CENTER
777 EAST WISCONSIN AVENUE
MILWAUKEE
WI
532025367
|
Family ID: |
25413418 |
Appl. No.: |
09/321674 |
Filed: |
May 31, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09321674 |
May 31, 1999 |
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08900987 |
Jul 25, 1997 |
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6167789 |
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Current U.S.
Class: |
83/553 ; 29/24.5;
83/633; 83/699.31; 83/699.51 |
Current CPC
Class: |
Y10T 83/949 20150401;
Y10T 83/412 20150401; Y10T 83/748 20150401; Y10T 83/8746 20150401;
Y10T 83/8733 20150401; E06B 9/266 20130101; Y10T 83/9483 20150401;
Y10T 83/04 20150401; Y10T 83/885 20150401; Y10T 83/9488 20150401;
Y10T 29/39 20150115 |
Class at
Publication: |
83/553 ;
83/699.31; 83/699.51; 83/633; 29/24.5 |
International
Class: |
B23D 023/00 |
Claims
What is claimed is:
1. A blind cutter for in-store sizing a mini-blind product
including a head rail, a plurality of slats, and a bottom rail, the
blind cutter comprising: a framework; a die assembly coupled to the
framework having a region for receiving a portion of each of the
head rail, plurality of slats, and bottom rail; a blade carrier
assembly attached to the framework, the blade carrier assembly
including a first blade carrier having a first blade member
attached thereto, and a second blade carrier having a second blade
member attached thereto; and a drive system being connected to the
framework and blade carrier assembly to provide independent linear
translation of the first blade carrier for a pre-determined first
distance, and simultaneous linear translation of the first and
second blade carriers for a pre-determined second distance.
2. The blind cutter of claim 1, wherein the first blade member
includes a first opening for receiving the portion of the bottom
rail to be sized, and a front blade portion for cutting the portion
of slats to be cut.
3. The blind cutter of claim 1, wherein the first blade carrier
includes a third blade, wherein the second blade is configured to
size the slats, and the third blade is configured to size the
bottom rail.
4. The blind cutter of claim 1 wherein the framework includes a
slat shear plate, the first blade carrier being movable
independently of the second blade carrier to compress a variable
number of slats between the second blade member and the slat shear
plate, such that a first of the plurality of slats is in contact
with the second blade and the last of the plurality of slats is in
contact with the slat shear plate.
5. The blind cutter of claim 1, wherein the die assembly includes a
second region for receiving a portion of a second head rail,
plurality of slats and bottom rail of a second mini-blind product,
the die assembly being movable from a position for cutting the
first mini-blind product and to a second position for cutting the
second mini-blind product.
6. The blind cutter of claim 5, wherein the die assembly is
slidable from a fixed first position to a fixed second position,
the first blind product being sized while the die assembly is in
the fixed first position, and the second blind product being sized
while the die assembly is in the second fixed position.
7. The blind cutter of claim 6, wherein the first region of the die
assembly is proximate the first and second blade members when the
die assembly is in the first position, and the second region of the
die assembly is proximate the first and second blade members when
the die assembly is in the second position.
8. The blind cutter of claim 1, wherein the blade carrier assembly
includes a latch mechanism for connecting the first and second
blade carriers to provide for simultaneous linear translation of
the first and second blade carriers throughout the translation of
the first blade carrier, when the die assembly is in the second
position.
9. The blind cutter of claim 1, wherein the first blade carrier
includes a handle, the first blade carrier being movable to a first
fixed extended position when the die assembly is the first
position, and the first blade carrier being moved to a second fixed
extended position when the die assembly is in the second
position.
10. The blind cutter of claim 1, wherein the drive system includes
a driving pawl and track; the first and second carriers being
movable from a first extended position in which the blind products
are loaded into the blind cutter for sizing and a second retracted
position in which the blind products have been sized; the drive
system including a switch for releasing the driving pawl from the
track to permit manual movement of the first blade carrier to the
extended position.
11. A blind cutter for selectively in-store sizing a first
mini-blind product and a different second mini-blind product, each
mini-blind product including a head rail, a plurality of slats, and
a bottom rail, the first and second mini-blind products having a
different geometry and or different material composition, the blind
cutter comprising: a framework; a die assembly coupled to the
framework, the die assembly including a first region for receiving
a portion of the head rail, plurality of slats and bottom rail of
the first mini-blind product, and a second region for receiving a
portion of the head rail, plurality of slats and bottom rail of the
second mini-blind product, the die assembly being movable from a
first position for cutting the first mini-blind product and to a
second position for cutting the second mini-blind product; a blade
carrier assembly attached to the framework, the blade carrier
assembly including a first blade carrier having a first blade
member attached thereto, and a second blade carrier having a second
blade member attached thereto; and a drive system being connected
to the framework and blade carrier assembly to provide linear
translation of the first and second blade carriers to size the
first mini-blind product when the die assembly is in the first
position, and to size the second mini-blind product when the die
assembly is in the second position.
12. The blind cutter of claim 11, wherein the drive system
translates the first blade carrier independent for a first
distance, and simultaneous linear translation of the first and
second blade carriers for a second distance, when the die assembly
is in the first position.
13. The blind cutter of claim 12, wherein the drive system
translates the first blade carrier and second blade carrier
simultaneously, when the die assembly is in the second
position.
14. The blind cutter of claim 12, wherein the blade carrier
assembly includes at least one connecting rod connecting the first
and second blade carriers, the connecting rod being fixedly secured
to the second blade carrier and slidably coupled to the second
blade carrier, to permit independent translation of the first blade
carrier for a predetermined distance when the die assembly is in
the first position.
15. The blind cutter of claim 12, wherein the blade carrier
assembly includes a catch to couple the first and second blade
carriers together for constant simultaneous translation when the
die assembly is in the second position.
16. The blind cutter of claim 15, wherein the catch is engaged as
the die assembly is moved from the first to the second position and
is disengaged as the die assembly is moved from the second to the
first position.
17. The blind cutter of claim 11 wherein the first blade carrier
includes a first blade member, the second region of the die
assembly including a head rail die block, a bottom rail die block,
and a safety block, the safety block prohibits the die assembly
from being moved from the first position to the second position
when the first blade carrier is a region that would allow for
contact of the cutting surface of the first blade member with the
bottom rail die block, such that the first blade member is
prevented from being damaged by the bottom rail die block.
18. A blind cutter for in-store sizing a mini-blind product
including a head rail, a plurality of slats, and a bottom rail, the
blind cutter comprising: a framework; a die assembly coupled to the
framework having a region for receiving a portion of each of the
head rail, plurality of slats, and bottom rail; a blade carrier
assembly attached to the framework, the blade carrier assembly
including at least one blade carrier movable from a first extended
position in which the mini-blind product is loaded into the blind
cutter for sizing and a second retracted position in which the
mini-blind product has been sized; and a drive system being
connected to the framework and blade carrier assembly to provide
linear translation of the at least one blade carrier to size the
mini-blind product, the drive system including a driving pawl and
track; the drive system including a switch for releasing the
driving pawl from the track to permit manual movement of the first
blade carrier from the retracted to the extended position.
19. The blind cutter of claim 18, wherein the die assembly includes
a first region for receiving a portion of the head rail, plurality
of slats and bottom rail of the mini-blind product, and a second
region for receiving a portion of the head rail, plurality of slats
and bottom rail of a second mini-blind product, the die assembly
being movable from a first position for sizing the first mini-blind
product and to a second position for sizing the second mini-blind
product includes a first and second.
20. The blind cutter of claim 19, wherein the drive system
translates the first blade carrier independent of the second blade
carrier for a first distance, and translates the first and second
blade carriers for a second distance, when the die assembly is in
the first position.
Description
[0001] This application is a continuation-in-part of U.S. patent
Ser. No. 08/900,987 filed Jul. 25, 1997.
FIELD OF THE INVENTION
[0002] This invention relates generally to the art of sizing window
coverings such as mini-blinds. more particularly the present
invention relates to a cutter for selective cutting of two
mini-blind products, wherein the blinds are made of different
material (e.g. vinyl and aluminum) and different geometric
characteristics.
BACKGROUND OF THE INVENTION
[0003] Numerous types of window coverings are now being sold in a
variety of outlets. Window coverings of the type with which the
present invention is concerned include mini-blinds, as opposed to
draperies and curtains which may be sold in the same outlets, but
which involve different sizing requirements. The type of outlets
that sell custom mini-blinds typically include custom specialty
shops and department stores which usually ask the customer for
window dimensions and then submit orders to factories or
distribution centers where the products are cut to a specific size.
Not only must the customer make two visits to these outlets to
obtain the product, but the custom mini-blinds are relatively
expensive.
[0004] Mass merchandisers also distribute mini-blinds. In many such
outlets only stock sizes are carried, because some windows,
especially in newer homes and offices are of standard dimensions.
These mini-blinds are usually much less expensive than those
obtained from custom outlets because of the economy realized from
carrying a limited stock of sizes and because there are no sizing
operations which must be performed on the products.
[0005] In recent years, a third option has been made available to
the customer. This option involves the in-store sizing of
mini-blinds and various other window coverings to customer
specifications. An example of how in-store sizing can be
accomplished is disclosed in commonly owned U.S. Pat. No. 5,339,716
issued Aug. 23, 1994 to Sands et al. and entitled "MINI BLIND
CUTTER" (the '716 patent). This patent discloses a mini-blind
cutter for cutting mini-blind slats, as well as mini-blind bottom
rails and headrails to a desired size. The mini-blind cutter may be
used to cut the mini-blind slats and rails on either end as a
readjustment of mounting mechanisms or ladders is not required.
[0006] The mini-blind cutter disclosed in the '716 patent includes
a framework having a receiving area for receiving the end of the
mini-blind to be cut. A cutter blade is attached to a bar which is
slidably mounted to the framework. This bar includes a rack engaged
with a pinion gear that is rotated by a ratchet handle. Movement of
the ratchet handle thus slides the bar along the framework and
forces the cutter blade through the end portion of the mini-blind.
The mini-blind cutter is used to cut the mini-blind slats, headrail
and bottom rail on either end, so readjustment of the mounting
mechanism or ladders is not required when sizing the
mini-blind.
[0007] Additionally, commonly owned U.S. Pat. No. 5,456,149 issued
Oct. 10, 1995 to Elsenheimer et al. and entitled "SIZING SYSTEMS
FOR WINDOW COVERINGS" (the '149 patent) discloses a system for
sizing various window products such as roller shades, mini-blinds,
pleated shades and vertical blinds. This system is used in
department stores and mass merchandising outlets. The '149 patent
discloses a system having four stations with a flip-top horizontal
surface containing sizing equipment on opposed sides. The system
includes fixed cutters, e.g. for roller shades and for cutting the
headrail of vertical blinds.
[0008] Another system for trimming a venetian blind assembly is
disclosed in U.S. Pat. No. 4,819,530 issued Apr. 11, 1989 to Huang
entitled "APPARATUS METHOD FOR TRIMMING A VENETIAN BLIND ASSEMBLY".
The device disclosed in this patent employs a hydraulic or
pneumatic cylinder or solenoid to drive the blade in order to cut
the various components of the mini-blind.
[0009] Other mini-blind cutters are available to manually cut
headrails manufactured from steel which include a drive mechanism
consisting of either an elongated lever arm or a rotary input
coupled with a cam driver device.
[0010] However, there are no mini-blind cutter mechanisms for use
in in-store sizing which can accommodate two blind configurations
having different shapes and wherein the blinds are made of
different materials such as vinyl and steel.
[0011] Accordingly, it would be advantageous to be able to provide
a mini-blind cutter which would be able to cut two different
mini-blind products having different geometric or material
characteristics, e.g. where the headrail and bottom rail components
are formed from either steel or vinyl. It would also be
advantageous if the system is compact and able to be used in
conjunction with sizing systems such as the one described in the
'149 patent referenced above.
SUMMARY OF THE PRESENT INVENTION
[0012] The present invention relates to a blind cutter for
selective, in-store sizing of a first mini-blind product and a
second mini-blind product having different geometric
configurations. Each mini-blind product to be sized includes a
headrail, a plurality of slats and a bottom rail. The blind cutter
includes a framework and a die assembly coupled to the framework.
The die assembly is moveable from a first position to a second
position with respect to the framework. The die assembly preferably
includes a first region for receiving a portion of the headrail, a
plurality of slats and the bottom rail of the first mini-blind
product, and a second region for receiving a portion of the
headrail, a plurality of slats and the bottom rail of the second
mini-blind product. The cutter further includes a blade carrier
assembly attached to the framework. The blade carrier assembly
includes a blade attached thereto. A drive system is connected to
the framework and blade carrier assembly to provide translation of
the blade. The blade is translated proximate the first region of
the die assembly to size the first mini-blind product when the die
assembly is in a first position. The blade is also translated
proximate the second region of the die assembly to size the second
mini-blind product when the die assembly is in a second
position.
[0013] In another aspect of the invention, the frame includes a
base plate having a bottom surface defining a base plane. The drive
system includes a handle assembly disposed to rotate in a plane
parallel to the base plane.
[0014] In yet another aspect of the invention the cutter also
includes a drive system having a second blade carrier provided with
a second blade. The two blade carriers are connected to the
framework and blade carrier assembly to provide independent linear
translation of a first blade carrier for a pre-determined first
distance. The drive system further provides simultaneous linear
translation of the first and second blade carriers for a
pre-determined second is distance.
[0015] In a further aspect of the invention a blind cutter for
in-store sizing a mini-blind product including a head rail, a
plurality of slats, and a bottom rail, the blind cutter includes a
framework and a die assembly. The die assembly is coupled to the
framework having a region for receiving a portion of each of the
head rail, plurality of slats, and bottom rail. A blade carrier
assembly is attached to the framework, and includes a first blade
carrier having a first blade member attached thereto, and a second
blade carrier having a second blade member attached thereto. A
drive system is connected to the framework and blade carrier
assembly to provide independent linear translation of the first
blade carrier for a pre-determined first distance, and simultaneous
linear translation of the first and second blade carriers for a
pre-determined second distance.
[0016] In another aspect of the invention a blind cutter is capable
of selectively in-store sizing a first mini-blind product and a
different second mini-blind product. The blind cutter includes a
framework and a die assembly coupled to the frame work. The die
assembly includes a first region for receiving a portion of the
head rail, plurality of slats and bottom rail of the first
mini-blind product, and a second region for receiving a portion of
the head rail, plurality of slats and bottom rail of the second
mini-blind product. The die assembly is movable from a first
position for cutting the first mini-blind product to a second
position for cutting the second mini-blind product. A blade carrier
assembly is attached to the framework and includes a first blade
carrier having a first blade member attached thereto, and a second
blade carrier having a second blade member attached thereto. A
drive is connected to the framework and blade carrier assembly to
provide linear translation of the first and second blade carriers
to size the first mini-blind product when the die assembly is in
the first position, and to size the second mini-blind product when
the die assembly is in the second position.
[0017] Still a further aspect of the invention is a blind cutter
for in-store sizing a mini-blind product including a head rail, a
plurality of slats, and a bottom rail. The blind cutter includes a
framework and a die assembly coupled to the framework. The die
assembly has a region for receiving a portion of each of the head
rail, plurality of slats, and bottom rail. A blade carrier assembly
is attached to the framework and includes at least one blade
carrier movable from a first extended position in which the
mini-blind product is loaded into the blind cutter for sizing and a
second retracted position in which the mini-blind product has been
sized. A drive system includes a driving pawl and track and is
connected to the framework and blade carrier assembly to provide
linear translation of the at least one blade carrier to size the
mini-blind product. The drive system further includes a switch for
releasing the driving pawl from the track to permit manual movement
of the first blade carrier from the retracted to the extended
position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will hereafter be described with reference to
the accompanying drawings, wherein like reference numerals denote
like elements, and:
[0019] FIG. 1 is a perspective view of the right or exit side of
the mini-blind cutter of the present invention;
[0020] FIG. 2 is a perspective view of the left or loading side of
the mini-blind cutter of FIG. 1;
[0021] FIG. 3 is a top plan view of the cutter shown in FIG. 1;
[0022] FIG. 4 is a rear elevation view of the mini-blind cutter of
FIG. 1;
[0023] FIG. 5 is a front elevation view of the mini-blind cutter of
FIG. 1;
[0024] FIG. 6 is an elevation view of the right side of the
mini-blind cutter of FIG. 1;
[0025] FIG. 7 is an elevation view of the mini-blind cutter of FIG.
1 in a first engaged position;
[0026] FIG. 8 is an elevation view of the mini-blind cutter of FIG.
1 in the fully extended position;
[0027] FIG. 9 is an elevation view of the mini-blind cutter of FIG.
1 in the loading position where the die assembly is in the first or
lower position;
[0028] FIG. 10 is an isometric view of the die assembly of the
mini-blind cutter of FIG. 1;
[0029] FIG. 11 is a right elevation view of the die assembly of
FIG. 10;
[0030] FIG. 12 is a cross-sectional view taken generally along line
12-12 of FIG. 11;
[0031] FIG. 13 is a cross-sectional view taken generally along line
13-13 of FIG. 6;
[0032] FIG. 14 is a cross-sectional view taken generally along line
14-14 of FIG. 6.
[0033] FIG. 15 is an exploded view of the rear end plate, slide
mechanism and a partial fragmentary view of the die assembly of the
mini-blind system of FIG. 1;
[0034] FIG. 16 is a cross-sectional view taken generally along line
16-16 of FIG. 6 in the starting position;
[0035] FIG. 17 is a cross-sectional view taken generally along line
16-16 of FIG. 6 in the fully extended position;
[0036] FIG. 18 is a cross-sectional view taken generally along
lines 18-18 of FIG. 6;
[0037] FIG. 19 is a cross-sectional view taken generally along
lines 18-18 of FIG. 6 with the headrail, bottom rail and slats in
loaded in the cutter;
[0038] FIG. 20 is a cross-sectional view taken generally along
lines 18-18 of FIG. 6 with the slat blade having extended through
the bottom rail;
[0039] FIG. 21 is a cross-sectional view taken generally along
lines 18-18 of FIG. 6 with the slat carrier engaged with the slats
and the headrail blade engaged with the head rail;
[0040] FIG. 22 is a cross-sectional taken generally along lines
18-18 of FIG. 6 with the slat carrier, head rail carrier in the
fully extended position;
[0041] FIG. 23 is a perspective view of the right or exit side of a
second embodiment of the mini-blind cutter;
[0042] FIG. 24 is a plan view of the right side of the mini-blind
cutter of FIG. 23;
[0043] FIG. 25 is a plan view of the left side of the mini-blind
cutter of FIG. 23;
[0044] FIG. 26 is a plan view of the right side of the mini-blind
cutter of FIG. 23 with the pawls disengaged from the rack;
[0045] FIG. 27 is a partial plan view of the right side of the
mini-blind cutter of FIG. 23 with the die assembly in the first
position;
[0046] FIG. 28 is cross-sectional view taken generally along line
28-28 of FIG. 27;
[0047] FIG. 29 is cross-sectional view taken generally along line
29-29 of FIG. 27;
[0048] FIG. 30 is a partial plan view of the left side of the
mini-blind cutter of FIG. 23 with the die assembly in the first
position;
[0049] FIG. 31 is cross-sectional view taken generally along line
31-31 of FIG. 30;
[0050] FIG. 32 is a partial plan view of the right side of the
mini-blind cutter of FIG. 23 with the die assembly in the second
position;
[0051] FIG. 33 is cross-sectional view taken generally along line
33-33 of FIG. 32;
[0052] FIG. 34 is cross-sectional view taken generally along line
34-34 of FIG. 32;
[0053] FIG. 35 is a partial plan view of the left side of the
mini-blind cutter of FIG. 23 with the die assembly in the second
position; and
[0054] FIG. 36 is cross-sectional view taken generally along line
35-35 of FIG. 35;
DETAILED DESCRIPTION
[0055] Referring generally to FIG. 1 a mini-blind cutter 10 will be
described. Cutter 10 is used to cut one or both ends of a
mini-blind product 12 having a headrail 14, a plurality of slats 16
and a bottom rail 18. In the preferred embodiment both ends of the
mini-blind product 12 is cut. All of these components may be
downsized with cutter 10 to properly size the mini-blind for a
given window opening. Cutter 10 may be used to cut two different
mini-blind configurations. One exemplary first configuration
includes a vinyl headrail, vinyl bottom rail and either aluminum or
vinyl slats. A second exemplary configuration includes a steel
headrail and bottom rail and aluminum slats. Cutter 10 could also
be configured to cut steel slats.
[0056] In the preferred embodiment the geometric shape of the
cross-section of the mini-blind components of the first and second
configurations to be sized are also different. Cutter 10 could also
be adapted to cut a wide variety of other combinations of
mini-blind components or other components of pleated, cellular,
venetian or vertical blinds.
[0057] Referring generally to FIG. 1, mini-blind cutter 10,
according to the present invention, includes a framework or frame
20 supporting a movable die assembly 22 that works in cooperation
with a carrier assembly 24. Die assembly 22 is movable from a first
or lowered position to cut a mini-blind having the first
configuration to a second or raised position to cut a mini-blind
having the second configuration. Die assembly is shown in the first
lowered position in FIG. 9 and in the second raised position in
FIGS. 1 and 6.
[0058] A drive system 28 is supported on frame 20 to drive a
portion of carrier assembly 24 relative to die assembly 22 to
effectuate the cutting of the mini-blind components in either the
first or second positions.
[0059] Referring generally to FIGS. 1-5, frame 20 includes a bottom
plate 30 having a front side 30a, a rear side 30b, a loading side
30c, an exit side 30d, a top surface 30e and a bottom surface 30f.
Bottom plate 30 further includes a front channel 32 proximate front
side 30a and a center channel 34 located a set distance from front
channel 32 in a direction toward rear side 30b. Front and center
channels 32, 34 are parallel to one another and to front side 30a.
Channels 32, 34 extend from loading side 30c to exit side 30d of
bottom plate 30.
[0060] Frame 20 further includes a front plate 36 located in front
channel 32, and a rear plate 38 located in center channel 34. Front
plate and rear plate 36, 38 include an upper aperture 40, 42 and a
lower aperture 44, 46 configured to receive an upper and lower
shaft 48, 50 respectively. Upper and lower shafts 48, 50 are used
in conjunction with carrier assembly 24. Each of front plate and
rear plate 36, 38 includes a pair of threaded apertures 52
extending through an exit side edge 36e, 38e to upper apertures 40,
42 and lower apertures 44, 46 to receive a set screw 58 for setting
the position of upper and lower shafts 48, 50.
[0061] Each of front plate 36 and rear plate 38, includes an
internal side 36a, 38a and an external side 36b, 38b. Internal
sides 36a and 38a face one another while external sides 36b, 38b
face away from one another. Each internal side 36a, 38a includes a
channel 64, 66 formed therein. (See FIGS. 14 and 15). Each channel
64, 66 has an orientation of eighty five (85) degrees relative to a
bottom edge 36c, 38c of each front and rear plate 36, 38
respectively. Each channel 64, 66 further includes a pair of slots
68, 70 centrally located in the channel and having an axis which is
also orientated at eighty five (85) degrees relative to bottom edge
36c, 38c.
[0062] Frame 20 further includes a pair of slide blocks 72, 74.
Each slide block has a width narrower than the width of each
channel 64, 66 to permit each slide block, 72, 74 to slidably move
within each respective channel 64, 66. Each slide block 72, 74
includes a groove 76, 78 which has an orientation of five (5)
degrees relative to an outer edge 72a, 74a of slide block 72, 74
respectively. Each slide block 72, 74 is slidably located in
channel 64, 66 of front and rear plates 36, 38 respectively. In
this orientation each groove 76, 78 is perpendicular to bottom
plate 30 regardless of the location of slide block 72, 74 within
channels 64, 66.
[0063] Each slide block 72, 74 further includes a pair of threaded
apertures 81. Each slide block 72, 74 is removably secured to front
and rear plate 36, 38 respectively by a pair of screws 83 which are
located through slots 68, 70 and threaded into apertures 81 of
slide blocks 72, 74. By loosening screws 83 it is possible to move
each slide block along channel 64, 66 to effectively move groove
76, 78 closer to or further from the exit side of cutter 10. This
adjustment of slide blocks 72, 74 allows for optimal operation of
cutter 10 as will be described below.
[0064] Frame 20 also includes a top plate 86 attached to front
plate 36 and rear plate 38. Top plate 86 includes a plurality of
through holes which are aligned with a plurality of threaded holes
in a top portion 36d, 38d of front and rear plates 36, 38. Top
plate 86 is attached to front and rear plates 36, 38 with a
plurality of screws 88. Each screw 88 extends through a respective
through hole and is threaded into a respective threaded hole.
[0065] Additionally, frame 20 includes a first support plate 90
located between front plate 36 and rear plate 38 proximate loading
side 30c of bottom plate 30. A second support plate 92 is located
parallel to first support plate 90 a set distance from the left or
loading side 30c of bottom plate 30. A shelf plate 94 is located
parallel to bottom plate 30 and is supported atop first and second
support plates 90, 92. (See FIGS. 2 and 13). Shelf plate 94 is
attached to first and second support plates 90, 92 with a plurality
of screws 96. Additionally shelf plate 94 is attached to front
plate 36 and rear plate 38 with a pair of screws 98.
[0066] Shelf plate 94 supports a slat shear plate 100 that is used
in conjunction with die assembly 22 and carrier assembly 24 which
will be described in greater detail below. Slat shear plate 100 is
attached to shelf plate 94 with a pair of screws 102. (See FIG.
2).
[0067] Frame 20 also includes a spring tower 104 attached to bottom
plate 30 in a slot 106 proximate the rear side 30b of bottom plate
30. Bottom plate 30 further includes a through slot 108 extending
from rear side 30b of bottom plate 30 a set distance toward front
side 30a. (See FIGS. 1 and 4).
[0068] Referring generally to FIGS. 10-12, die assembly 22 will now
be described in greater detail. As noted above die assembly 22
cooperates with frame 20 to permit die assembly 22 to be moved from
a first lowered position for cutting a first mini-blind product
having a first configuration to a second raised position for
cutting a second mini-blind product having a second configuration.
Die assembly 22 includes a first region 110 for receiving a portion
of each of the headrail, plurality of slats, and bottom rail of the
first mini-blind product, and a second region 112 for receiving a
portion of each of the headrail, plurality of slats, and bottom
rail of the second mini-blind product.
[0069] Die assembly 22 includes a bottom die plate 114 and an
opposing top die plate 116. Die assembly 22 further includes a
support side plate 118 located intermediate top die plate 116 and
bottom die plate 114. Support side plate 118 is attached to top die
plate 116 and bottom die plate 114 with screws 120. Support side
plate 118 has a front side 118a, a rear side 118b, a top side 118c,
a bottom side 118d, a loading side surface 118e and a cutting side
surface 118f.
[0070] Die assembly 22 further includes a headrail die block 122
attached intermediate top die plate 116 and bottom die plate 114
distal support side plate 118. Headrail die block 122 includes a
front side 122a, a rear side 122b, a top side 122c, a bottom side
122d, a loading side surface 122e and a cutting side surface
122f.
[0071] Headrail die block 122 and support side plate 118 each
include a guide flange 124, 126 extending from front side 122a and
rear side 118b respectively. Guide flanges 124, 126 are employed to
guide die assembly 22 within grooves 76, 78 as it is moved from the
first position to the second position. Each flange 124, 126 extends
from top side 122c, 118c to bottom side 122d, 118d
respectively.
[0072] In the preferred embodiment each flange 124, 126 is
rectangular and extends outward from headrail die block 122 and
support side plate 118. (See FIG. 10). Of course other geometric
configurations that cooperate with grooves 76, 78 may also be
used.
[0073] Headrail die block 122 includes a first slot 128 having the
shape of the cross-section of the first headrail and a second slot
130 having the shape of the a cross-section of the second headrail.
The first slot 128 is located proximate top die plate 116 and
second slot 130 is located proximate bottom die plate 114.
[0074] Die assembly 22 further includes a bottom rail die 132
having a bottom surface 132a and a rear surface 132b. Bottom rail
die 132 includes a slot 133 having the configuration of the
cross-section of the bottom rail of the second configuration.
Bottom surface 132a of bottom rail die 132 is located adjacent
bottom die plate 30. Rear surface 132b of bottom rail die 132 is
located adjacent support side plate 118. In this manner die
assembly 22 includes a first opening or receiving area 134 defined
by the open space intermediate headrail die block 122 and support
side plate 118, and a second opening 136 defined by the space
intermediate headrail die block 122 to bottom rail die 132.
[0075] Bottom rail die 132 also includes a cutting side surface
132c having a curved form configured to match the curved form of a
cutting blade 138 of the carrier assembly 24. Similarly, slat shear
plate 100 includes a cutting side surface 100a having a curved form
configured to match the curved form of cutting blade 138.
[0076] Die assembly 22 further includes a catch lever 140
manufactured or formed from a nylon material. Catch lever 140
includes a beveled catch portion 142 configured to secure die
assembly in the second position. Catch lever 140 also includes a
lift lever 144 to aid in the raising and lowering of die assembly
22 from the first lowered position to the second or raised
position. Catch lever 140 must have sufficient resiliency to permit
beveled catch portion 142 to engage and disengage top plate 116 by
an operator without excessive force. Additionally, catch lever 140
must have sufficient strength to maintain die assembly in the
raised second position. Although nylon is the preferred material,
other materials having similar characteristics could be used.
[0077] Referring again to FIG. 1, carrier assembly 24 will now be
described in greater detail. Carrier assembly 24 includes a
slat/bottom rail blade carrier 146 (hereinafter slat carrier) and a
headrail blade carrier 148 (hereinafter headrail carrier). Each of
the slat carrier 146 and headrail carrier 148 is independently and
slidably attached to upper shaft 48 and lower shaft 50. As
described above, upper shaft 48 and lower shaft 50 are located
within an upper aperture 40, 42 and a lower aperture 44, 46 of
front plate 36 and rear plate 38 respectively.
[0078] Upper shaft 48 and lower shaft 50 are fixed relative to
front plate 36 and rear plate 38 by set screws 58.
[0079] Slat carrier 146 includes an upper section 150 having a
bearing aperture 152 extending therethrough and a lower section 154
having a bearing aperture 156 extending therethrough. A pair of
bearings 158 are press fit within bearing apertures 152, 156. Slat
carrier 146 slidably moves on upper and lower shafts 48, 50 by
means of pair of press fit bearings 158. A center region 162 is
integrally formed with and connects upper section 150 and lower
section 154 together.
[0080] Similarly, headrail carrier 148 is slidably located on upper
shaft 48 and lower shaft 50 by a pair of bearings 164. While in the
preferred embodiment the pair of bearings 164 is not press fit, it
is possible to employ press fit bearings in the headrail carrier as
well as the slat carrier. The use of press fit bearings allows for
greater stability of the carriers during the cutting operation.
[0081] Slat carrier 146 is movably connected to headrail carrier
148 by means of at least one connecting rod 166. However, in the
preferred embodiment three connecting rods 166 are utilized. Each
connecting rod 166 includes a first bolt 167 extending through a
respective aperture 170 in headrail carrier 148 and threadably
secured to a spacer 172. In this manner spacer 172 is fixed
relative to headrail carrier 148. A cap screw 174 having a head 176
extends through a non-threaded aperture 178 in the slat carrier 146
and is threadably secured to spacer 172. Each aperture 170 includes
a counter bore 180 having a depth equal to the length of head 176.
This permits the top of head 176 to be flush with an external or
rear surface 146a of slat carrier 146.
[0082] Connecting rods 166 establish a maximum and minimum distance
between slat carrier 146 and headrail carrier 148. The maximum
distance is achieved when head 176 is seated within the base of
counter bore 180. (See FIGS. 1 and 16). The minimum distance is
achieved when an internal or front surface 146b, of slat carrier
146 is adjacent spacer 172. (See FIG. 17). In the minimum distance
position, head 176 of cap screw 174 is a set distance from slat
carrier 146.
[0083] Slat carrier 146 further includes blade 138 secured to the
center region 162 by means of two screws extending therethrough.
(See FIG. 1). The geometry of blade 138 is described in the '716
patent referred to above and is incorporated herein by reference.
Slat carrier 146 also includes a chute region 184 located proximate
blade 138 and is defined by the open region intermediate upper
section 150 and lower section 154. Lower section 154 includes a top
beveled surface 155 having a sloped region extending downward
toward the cutting side 30d of base 30. Chute region 184 permits
the cut portions of the bottom rail and slats to easily exit cutter
10 to a waste receptacle for example. (See FIG. 1).
[0084] An indicator 188 is attached to cutting side surface 146c of
upper section 150 of slat carrier 146. Indicator 188 includes a
pointer 190 that extends over top plate 86 to indicate the position
of slat carrier 146 during the cutting process. Top plate 86 may
additionally include indicia indicating the position of slat
carrier 146 during the cutting process.
[0085] Slat carrier 146 further includes a pair of spring
attachment bosses 192 attached to rear surface 146a of slat carrier
146. Each boss 192 includes an aperture for receiving an end of a
return coil extension spring 194. In the preferred embodiment two
springs 194 are employed. (See FIG. 6).
[0086] Also attached to slat carrier 146 is an arm 196 which
communicates with drive system 28. Arm 196 is attached to rear
surface 146a of slat carrier 146 with screws. As illustrated in
FIG. 1, the screws attaching arm 196 extend through center region
162. In the preferred embodiment center region 162 includes through
holes and arm 196 includes a pair of threaded holes to securably
receive the screws.
[0087] Turning to headrail carrier 148, a piercing blade 198 is
attached to a center portion 199 of headrail carrier 148. Piercing
blade 198 has a "W" shaped configuration, including a center
piercing section 198a and two side sections 198b, extending from
center piercing section 198a. Piercing blade 198 has a
substantially uniform thickness. However, piercing blade 198 may
also have a beveled region proximate the cutting portions of the
center and side sections 198a, 198b. The uniform thickness provides
for a more uniform cut and longer blade life.
[0088] Referring to FIGS. 1, 2 and 8 drive system 28 will now be
described. Drive system 28 includes a handle assembly 200 having a
handle 202 pivotally attached to a handle arm 204. A clutch bearing
205 is attached to arm 204 distal handle 202 to limit movement of
handle arm 204 in a single rotary direction. In the preferred
embodiment the handle assembly is supplied by Reid Tool Supply
located in Muskegon Michigan and identified by part number
KHQ-20.
[0089] Handle assembly 200 is operated in a plane parallel to the
plane defined by top plate 86. Further, handle arm 204 is operable
in a plane parallel to the plane in which the mini-blind to be
sized is located during the sizing operation. Handle 202 includes a
longitudinal axis which is transverse to the plane of operation of
the handle assembly 200. Handle 202 may be pivoted for storage such
that the longitudinal axis of handle 204 is substantially parallel
to handle arm 204. This feature allows cutter 10 to be more compact
for shipping, as well as during use with the device described in
the '149 patent.
[0090] Handle arm 204 is further attached to a shaft 206 having a
worm 208 attached thereto. (See FIG. 8 in dashed lines). A worm
gear 210 is driven by worm 208. A second output shaft 212 is
coupled to worm gear 210. (See FIGS. 16-18). In the preferred
embodiment, the worm and worm gear are selected to provide a thirty
to one ratio. That is thirty rotations of handle assembly 200
results in one rotation of output shaft 212. However other ratios
may be employed as well. Preferably a ratio of between ten to one
and forty to one may be employed. Depending on the material of the
blinds to be cut the ratio may vary to provide the requisite
mechanical advantage required for operation by an operator for
in-store sizing.
[0091] Shaft 206 is secured to a drive system housing 216 by means
of a sleeve bearing 214 that is attached thereto. Drive system
housing 216 includes a load side plate 218 and an exit side plate
220. Load side plate 218 and exit side plate 220 are positively
located in channels 222, 224 respectively in bottom plate 30 (See
FIGS. 1, 2 and 14). Drive system housing 216 further includes a
housing cover 217 which is attached to exit side plate 220.
[0092] Sleeve bearing 214 is attached to load side plate 218. Shaft
206 is positively located relative to the sleeve bearing by a pair
of collars attached to shaft 206 proximate the top and bottom of
the sleeve bearing.
[0093] Output shaft 212 is rotatably attached to load side plate
218 and exit side plate 220 by a pair of bearings 226. Output shaft
212 includes a first end 228 located proximate load side plate 218
and an opposing second end 230. Additionally, output shaft 212
includes an elongated tab or key extending a set distance along the
longitudinal axis of the output shaft proximate second end 230. A
cam 232 having a keyway 234 is located on output shaft 212 having a
key such that keyway 234 is positively located by key 236. (See
FIG. 6). A cam attachment plate 238 is attached to cam 232 with two
screws 240. Cam attachment plate 238 is further secured to output
shaft 212 with a single screw 242.
[0094] Referring to FIGS. 1 and 6 cam 232 includes an operating
edge 244. A follower 246 is pivotally attached to arm 196. Follower
246 is maintained in contact with operating edge 244 of cam 232 by
means of extension springs 194. In the preferred embodiment each
extension spring 194 is formed from a 0.072 diameter wire, five
inches long and rated at 8.4 pounds per inch. Of course other
springs may be utilized that are able to retract headrail carrier
and slat carrier, by biasing follower 246 against cam operating
edge 244. Each extension spring 194 is attached at a first end 248
to a boss 250 on spring tower 104 and at a second end 252 to boss
192 on slat carrier 146. Extension springs 194 are always in
tension thereby biasing follower 246 against cam operating edge
244.
[0095] As noted above it is important for optimal cutting
performance that blades 138, 198 of headrail and slat carriers 146,
148 respectively be in close proximity to bottom rail die 132, slat
shear plate 100 and headrail die 122. In order to maximize
dimensional integrity of slat carrier 146 relative to die assembly
22, press fit bearings are utilized to minimize potential
deflection of the slat carrier blade 138 during the cutting.
[0096] By design, the cutting surface of blades 138, 198 are
proximate the bottom rail die 132, shear plate 100 and head rail
die 122 respectively. However, as a result of component variability
and resulting tolerance stack up, as well as wear of the blades, it
is desirable to be able to adjust the position die assembly 22
relative to the cutting surface of blades 138, 148.
[0097] As discussed above frame 20 includes slide blocks 72, 74
which are adjustably located in channels 64, 66 of front and rear
plates 36, 38 respectively. Each slide block 72, 74 is adjusted
upwardly or downwardly within channels 64, 66. Movement of slide
block 72, 74 upward toward the top the plates 36, 38 results in
movement of die assembly 22 toward the exit side of cutter 10.
Similarly, downward movement of slide blocks 72, 74 results in
movement of die assembly 22 toward the loading side of cutter
10.
[0098] Since slide blocks 72, 74 are independently adjustable it is
possible to independently adjust each end of die assembly 22. By
independent adjustment of the slide blocks, it is possible to
compensate for relative wear of blades 138, 198 if the blades do
not wear at the same rate.
[0099] The operation of cutter 10 and the interaction of the
various components detailed above will now be described. For
purposes of describing the various components of mini-blind cutter
10, the front of cutter 10 is the portion that faces the operator
when utilizing cutter 10. Specifically, the operator faces front
end plate 36 when operating cutter 10. (See FIG. 5). The rear of
cutter 10 is opposite the front and includes the rear side 30b of
base plate 30. (See FIG. 4). A longitudinal axis of cutter 10
extends down the center of cutter 10 from the front of the cutter
10 to the rear of cutter 10. The loading side of cutter 10 is the
side in which the headrail components are loaded into cutter 10 to
be cut. The loading side corresponds to the left side of cutter 10
when the operator is facing the front of cutter 10. (See FIG. 2).
Similarly, the right side, the side opposite the loading side, is
referred to as the exit side. This is the side from which the cut
portions of the mini-blind are expelled after they are cut. The
transverse direction of cutter 10 is the direction perpendicular or
normal to the longitudinal axis toward the loading or exit sides.
Finally, a base plane is defined by the bottom surface 30f of base
plate 30.
[0100] Turning now to the operation of cutter 10 itself, the two
modes of operation as discussed above will be addressed. In the
first mode of operation, as illustrated in FIG. 9, die assembly 22
is in a first or lower position such that first slot 128 of
headrail die 112 and first receiving area 134 are located proximate
shelf plate 94. In this first mode of operation a mini-blind
product having a first configuration is sized. As discussed above,
for purposes of illustration the first configuration will include a
headrail and bottom rail formed from vinyl and a plurality of slats
formed of vinyl or aluminum.
[0101] In the second mode of operation as illustrated in FIGS. 1
and 6, die assembly 22 is in the second or raised position such
that second slot 130 of headrail die 112, second receiving area 136
and bottom die 132 are located proximate shelf plate 94. In this
second mode of operation a mini-blind product having a second
configuration is sized. The exemplary mini-blind product of the
second configuration includes a headrail and bottom rail formed
from steel and a plurality of slats formed of aluminum or steel. It
should also be noted that the first and second blind configurations
also have different geometric shapes.
[0102] Die assembly 22 is moved from the first position to the
second position by lifting lever 144 in the upward direction until
catch 142 engages top plate 86. (See FIG. 1). In a similar manner
die assembly 22 may be moved from the second position back to the
first position by depressing catch 142 toward the loading side of
cutter 10 thereby releasing lever catch from top plate 86. Once
catch 142 is released, die assembly 22 may be lowered to the first
position by the operator with lever 144.
[0103] While die assembly 22 is movable in an up/down direction
transverse to the base plane, die assembly 22 is positively located
in frame 20 in the other directions. This is accomplished by
engagement of flanges 124, 126 within grooves 76, 78 of slide
blocks 72, 74 which are secured within channels 64, 66 of front and
rear plates 36, 38.
[0104] For both modes of operation the starting position of the
drive system and carrier assembly is the same. As shown in FIGS. 6
and 9 drive system and carrier assembly is in the start position.
In this start position, follower 246 is located adjacent point A on
cam 232 which represents the point of minimum radius of cam 232.
Slat carrier 146 is at a point closest to rear plate 38. In the
start position the distance between slat carrier 146 and headrail
carrier 148 is maximized. Additionally, in this position the heads
176 of connecting rods 166 are located within counter bores
180.
[0105] For illustrative purposes the operation of cutter 10 in the
second mode of operation will be described first. With die assembly
22 in the second or raised position, headrail 14, slats 16, and
bottom rail 18 of the first mini-blind configuration are loaded
into cutter 10 for sizing. Facing the front plate 36 of cutter 10
the operator loads the blind into cutter 10 from the left or
loading side of cutter 10. (See FIGS. 1 and 18).
[0106] As illustrated in FIGS. 1 and 18 headrail 14 is slid through
second slot 130 of headrail die 122. Similarly slats 16 are slid
into second receiving area 136 proximate slat shear plate 100.
Finally, bottom rail 18 is slid into bottom die slot 133. Headrail
14, slats 16 and bottom rail 18 are positioned such that the
portion of each component to be cut extends beyond exit surface
122f of headrail die, exit surface of slat shear plate 100 and exit
surface 132c respectively.
[0107] Once the blind components are loaded into cutter 10 and
positioned relative to the exit side of die assembly 22, the
operator begins the cut cycle by manually rotating handle assembly
200 in a clockwise direction. Rotation of handle assembly 200 and
handle arm 204 specifically occurs in a plane parallel to the base
plane. It is also possible to design handle assembly 200 for
counter-clockwise rotation. Counter-clockwise rotation of handle
assembly 200 may be desirable to allow greater leverage for the
right handed operator.
[0108] Rotation of handle assembly 200 results in the rotation of
shaft 206 and worm 208, which in turn rotates worm gear 210 and
output shaft 212, which in turn rotates cam 232 in a clockwise
position. The clockwise rotation of cam 232 is defined by viewing
cam 232 from the exit side of cutter 10.
[0109] In the preferred embodiment, handle assembly 200 is rotated
thirty times to complete a single rotation of cam 232. The complete
rotation of cam 232 represents one complete cutting cycle of cutter
10. A complete cutting cycle includes translation of blades 138,
198 from a starting position to a fully extended position in which
the mini-blind components are cut and return the blades 138, 198
are returned to the starting position.
[0110] As cam 232 is rotated, follower 246 is translated toward the
front of cutter 10 which results in the forward movement of slat
carrier 146. The cam profile is configured such that the rate of
forward translation of follower 246 varies for a given rotation of
output shaft 212.
[0111] In the preferred embodiment, the greatest rate of forward
translation of the follower per unit of rotation of the output
shaft occurs proximate the starting point A. During this initial
stage of the cutting cycle, slat carrier 146 moves from the
starting position to a point proximate where blade 138 engages
bottom rail 16. The force required to move the slat carrier from
the start position to a position proximate bottom rail 18 is less
than the force required to cut the components. The mechanical
advantage required initially is less than that required during the
actual cutting of the components. Accordingly, the rate of
translation per degree of rotation is greater for the initial
period in which blade carrier 146 moves from the start position to
the position in which blade 138 engages bottom rail 18.
[0112] Continued translation of slat carrier 146 and blade 138
results in the cutting of bottom rail 18. The curvature of blade
138 as discussed above is preferably flush against the curved
surface 132c of bottom rail die 132. Once a portion of bottom rail
16 has been cut it exits cutter 10 via chute region 184 of slat
carrier 146. Further translation of slat carrier 146 results in the
engagement of blade 138 with slats 16. Slats 16 are first forced
forward within second opening 136 against slat shear plate 100
thereby removing any slack between the slats 16. The force of blade
138 further minimizes the curvature of slats 16 during the cutting
operation. Each slat 16 is then sheared by blade 138 in seriatim
and exits cutter 10 through chute 184.
[0113] During the cutting of slats 16 front surface 146b of slat
carrier 146 abuts spacer 172 and results in forward translation of
headrail carrier 148. As a result slat carrier 146 and headrail
carrier 148 move forward in unison. As the remainder of uncut slats
16 are cut headrail 14 is cut by blade 198. (See FIG. 21).
[0114] In this manner, drive system 28 provides independent linear
translation of the first blade carrier for a pre-determined first
distance, and simultaneous linear translation of the first and
second blade carriers for a pre-determined second distance. The
predetermined first distance being sufficient to cut the bottom
rail and portions of the slats. The pre-determined second distance
being sufficient to complete the cutting of the slats and headrail.
This approach permits the overall length of cutter 10 along the
longitudinal axis to be reduced. It is possible to include a
separate third blade carrier, such that a unique blade cuts the
three separate components. However this adds additional cost.
[0115] Depending on the increased load required by simultaneously
cutting the uncut slats and headrail it is possible to alter the
cam profile configuration to reduce the rate of translation per
unit of rotation of handle assembly 200. The variation in the cam
profile allows for a constant input force on behalf of the
operator. However, a constant rate of translation can be employed
for the entire portion of the cycle in which the blades are engaged
with the components.
[0116] The carriers 146, 148 are farthest from the starting
position or in the fully extended position when follower 246 is
adjacent point C on cam 232. At this point head rail 14, slats 16,
and bottom rail 18 are fully cut. (See FIGS. 8 and 22). Continued
rotation of handle assembly 200, results in the rotation of cam 232
from point C to starting point A. The rate of reduction in radius
from point C to point A allows carriers 146, 148 to return quickly
to the starting position.
[0117] In the preferred embodiment, the return of carriers 146, 148
from the fully extended position to the starting position is
accomplished with rotation of approximately 30 to 36 degrees of cam
232. Based upon a thirty to one ratio of rotation of handle
assembly 200 to rotation of cam 232, return of the carriers is
accomplished with approximately two and one half to three turns of
handle assembly 200.
[0118] Extension springs 194 are in tension when carriers 146, 148
are in the fully extended position and bias the carriers back to
the starting position as cam 232 is rotated from point C to point
A. While it would be possible to incorporate a step reduction in
the radius from point C to point A this would result in the
carriers "slamming" back under the tension of springs 194. The
sloped non-step reduction in the radius allows for a smoother
return of carriers 146, 148.
[0119] Turning to the operation of cutter 10 in the first mode of
operation, die assembly 22 is moved to the first or lower position
such that first slot 130 of headrail die 122 and first opening 134
are located adjacent shelf plate 94. (See FIG. 9).
[0120] Similar to the process described above for sizing the
mini-blind product having the second configuration, the mini-blind
having the first configuration is loaded into blind cutter from the
left or loading side of cutter 10. (See FIG. 18).
[0121] While, the headrail of the first configuration is slid
through first slot 128 in the manner described above for the
headrail of the second embodiment, the slats and bottom rail 18 of
the first configuration are slid into first opening region 134.
Although a separate die is not used in the preferred embodiment for
cutting the vinyl bottom rail, a die could be used to cut the
bottom rail of the first configuration as well. The use of bottom
die 132 for cutting the steel bottom rail increases the dimensional
integrity of the bottom rail during the cutting process.
[0122] As described above with respect to the second configuration,
the headrail, slats and bottom rail of the first position are
positioned such that the portions to be cut extend beyond the exit
surface of headrail die 122, slat shear plate 100, and bottom rail
die 132.
[0123] The cutting operation is substantially similar to that
described above with the noted exception that slats are forced
against shear plate 100 initially upon contact of bottom rail by
blade 138.
[0124] Referring now to FIG. 23 a second preferred cutter mechanism
300 will be described. Cutter 300 is similar to cutter 10 in a
number of respects. First, cutter 300 includes a frame 302 similar
to frame 20 of cutter 10. Accordingly, every element of frame 302
will not be described again. However, the differences between frame
302 and frame 20 will be outlined below as required to support the
description of the various modified systems. For example, since
cutter 300 includes a different drive system, frame 302 does not
include a spring tower. Components that are similar in both cutter
10 and cutter 300 will be identified with a separate reference
numeral for clarity.
[0125] Similarly, cutter 300 includes a die assembly 304 that is
similar to die assembly 22 of cutter 10, and a blade carrier
assembly 306 and supporting structure similar to carrier assembly
24. The differences in these systems and assemblies will be
described below as required.
[0126] As discussed above with respect to cutter 10, cutter 300 may
be used to cut two different mini-blind configurations, in two
different modes of operation. The first mode of operation involves
sizing a mini-blind having a vinyl head rail, vinyl bottom rail and
either aluminum or vinyl slats. This mini-blind configuration will
be referred to as the vinyl blind. The second mode of operation
involves sizing a mini-blind having a steel head rail and bottom
rail and aluminum slats. This mini-blind configuration will be
referred to as the aluminum blind. Of course other materials and
combinations could also be sized.
[0127] The framework or frame 302 supports the movable die assembly
304 that works in cooperation with the carrier assembly 306. Die
assembly 304 is movable from a first or lowered position to cut a
mini-blind having the first configuration (vinyl blind) to a second
or raised position to cut a mini-blind having the second
configuration (aluminum blind).
[0128] Referring to FIGS. 23-26, cutter 300 includes a drive
assembly 308 having a rack and pawl mechanism. The rack 310 is
driven forward by a driving pawl 312 coupled to an actuation handle
314 by means of a four bar linkage 316. The rack 310 is attached to
the rear side 318 of a rear blade carrier 320, such that
translation of the rack 310 results in translation of the rear
blade carrier 320.
[0129] A roller 322 supported in a drive cradle 324 supports the
rack 310 as it drives the rear blade carrier 320 forward.
Additionally, the rack 310 is supported laterally by a pair of
supports 326 secured to the drive cradle 324 and positioned on
opposite sides of the rack 310. The drive cradle 324 is secured to
the base plate 328 of the frame 302. The drive assembly is further
includes a top bar 330 supported by the front plate 332 of the
frame 302 and a rear support member 334 extending from the base
plate 328 at the rear (R) of the cutter 300. The base plate 328 and
the top bar 330 of the frame 302 are fixed relative to one another
and serve as the ground of the four bar linkage 316.
[0130] As illustrated in FIGS. 23-26, the handle 314 is secured to
the four bar linkage 316 at a first link 336. The first link 336 is
pivotally attached to the drive cradle 324 at a first pivot 338. A
second link 340 is pivotally attached to the first link 336 at a
second pivot 342 a predetermined distance from the first pivot 338.
The second link 340 in turn is pivotally attached to a third link
344 at a third pivot 346. The third link 344 is pivotally attached
to the top bar 330 at a fourth pivot 348. In this manner the four
bar linkage 316 is completed. The driving pawl 312 is pivotally
attached to the third link 344 at a fifth pivot 352. Movement of
the handle 314 toward the front (F) of the cutter 300 results in
forward movement of the driving pawl 312 which in turn engages and
drives the rack 310 and rear blade carrier 320 forward.
[0131] The driving pawl 312 includes a driving pawl release bar 354
attached thereto. The release bar 354 extends from the driving pawl
312 to a point above the top bar 330. Rearward movement of the
driving pawl release bar 354 pivots the driving pawl 312 about the
fifth pivot 352 thereby disengaging the teeth of the driving pawl
312 from the rack 310.
[0132] The driving mechanism further includes a holding pawl 356 to
prevent the rack 310 from moving rearward during the cutting of the
blind components. An extension bar 358 is secured to and extends
downward from the top bar 330. The holding pawl 356 is pivotally
attached to the extension bar 358 at a sixth pivot 360. A holding
pawl release bar 362 extends from the holding pawl 356 to a point
above the top bar 330. Similar to the release bar 354 of the
driving pawl 312, movement of the holding pawl release bar 362
toward the rear of the cutter disengages the holding pawl 356 from
the rack 310 thereby permitting the rack 310 to be moved
rearward.
[0133] A cutter engagement/release switch 364 is slidably attached
to the top bar 330. The switch 364 includes a first end 366 having
a knob 368 attached thereto, and a second opposing end 370.
Movement of the knob 368 in a direction rearward, causes the second
end 370 of the switch 364 to contact and push rearward the holding
pawl release bar 362. Continued movement of the switch 364, results
in the holding pawl release bar 362 which in turn contacts the
driving pawl release bar 354 thereby releasing the driving pawl
312. In this manner the switch 364 can be moved rearward to release
the driving and holding pawls 312, 356 from the rack 310. Once the
driving and holding pawls 312, 356 have been released from the rack
310, the rack 310 may be manually moved rearward or forward.
[0134] Similarly, movement of the switch 364 toward the front of
the cutter, results in the engagement of the driving and holding
pawls 312, 356 with the rack 310. While the switch 364 does not
directly pull the driving and holding pawls 312, 356 into
engagement with the rack 310, the driving and holding pawls 312,
356 are pivotally attached to the four bar linkage 316 and top bar
330 respectively such that gravity acts to pivot the pawls into
engagement with the rack 310.
[0135] Referring to FIGS. 24 and 28 the blade carrier assembly 306
includes a head rail blade carrier 372, a bottom rail blade carrier
320, and a latch mechanism 374 for coupling the head rail blade
carrier 372 and bottom rail blade carrier 320 together. The bottom
rail blade carrier 320 includes a blade member 376 (see FIG. 37)
having a first opening 378 for receiving a metal bottom rail of the
second configuration as outlined above. The first opening 378 has a
predetermined profile similar to the outer shape of the metal
bottom rail. The front edge 380 of the blade member 376 includes an
arcuate blade portion 382 for cutting the slats independently of
the metal bottom rail in the second mode of operation. The front
edge 380 of the blade 376 is also employed for cutting both the
bottom rail and slats of the vinyl blind in the first mode of
operation.
[0136] Referring to FIGS. 28 and 29, a latch 384 is secured to the
top 386 of the head rail blade carrier 372 and extends rearward.
The latch 384 includes a notch 388 proximate the rearward end. The
bottom rail blade carrier 320 includes a pivotal catch 390 that can
be rotated from a first disengaged position (see FIG. 28) to a
second engaged position (see FIG. 33). The catch 390 includes a tab
portion 392 that is received within the notch 388 when the catch
390 is in the first position. When the head rail and bottom rail
blade carriers are adjacent one another and the die assembly is
raised to the second position, movement of the catch 390 to the
second position engages the tab 392 within the notch 388, thereby
coupling the two blade carriers together.
[0137] Similarly, when the catch 390 is pivoted to the first
position, the tab 392 is disengaged from the notch 388 and the
blade carriers are free to move independent of one another. Of
course the movement of the blade carriers are still linked through
the connectors as described above with respect to cutter 10.
[0138] The catch 390 is automatically pivoted by engagement of the
top plate 394 of the die assembly 304 as the die is moved to or
from the first position. When the die assembly 304 is raised from
its first or lower position to its second or upper position, the
upper surface 396 of the top plate 394 of the die assembly contacts
the underside 398 of the tab 392 thereby rotating the catch 390
such that the tab 392 is located within the notch 388. In this
manner, the head rail and bottom rail blade carriers are coupled
together.
[0139] Similarly, when the die assembly 304 is moved from the upper
or second position to the first or lower position, the under side
400 of the top plate 394 engages an extension portion 402 on the
catch 390 thereby pivoting the catch 390 to the disengaged
position.
[0140] Additionally, the bottom rail blade carrier 320 includes a
handle 404 for manually moving the blade carriers either to a first
fully extended position to receive the components of a blind to be
sized or to a second retracted position in which the blades have
moved past the corresponding die portions toward the front plate
332.
[0141] Die assembly 304 includes a safety block 406 attached to the
exit side of the support side plate 408 of the die assembly. In
this manner the safety block is proximate the carrier assembly 306.
The safety block 406 prohibits the die assembly 304 from being
moved from the lower position to the upper position, when the
bottom rail blade carrier 320 is in the fully extended position.
This prevents the bottom rail blade member 376 from being damaged
by ensuring that the bottom rail die block 410 does not hit the
cutting edge 380 of the bottom rail blade as the die 304 is being
raised. The safety block 406 is positioned such that if a user
attempts to move the die assembly 304 when the bottom rail blade
carrier 320 is in the extended position, the safety block 406
safely contacts the under side of the bottom rail blade member 376
where no damage to the cutting blade 380 can occur.
[0142] The operation of the cutter 300 will now be described,
including the steps required to operate the cutter 300 in both the
first and second mode of operation.
[0143] The first step required to use cutter 300 is to move the die
assembly 304 to the first or second position depending on the blind
configuration to be sized. Movement of the die assembly 304 is
accomplished by pushing the switch 364 in a rearward direction
thereby disengaging the driving and holding pawls 312, 356 from the
rack 310. With the rack 310 free to move, the handle 404 attached
to the rear blade carrier 320 is manually pulled in a forward
direction until the blade member 376 of the rear blade carrier 320
clears both the safety block 406 and the bottom rail die block
412.
[0144] With the rear blade carrier 320 clear of the safety block
406 and bottom rail die block 412, the die assembly 304 can be
either raised or lowered by activation of a lever 414 pivotally
attached to the top plate of the frame at a pivot 416. The lever
414 in turn is pivotally attached to a spring biased link 418 that
retains the lever 414 in a first or second position representing
the lower and upper positions of the die assembly 304. In the
embodiment disclosed in the figures, when the lever 414 is pivoted
toward the rear of the cutter, the die assembly 304 is lowered to
the first die position. Similarly when the lever 414 is pivoted
toward the front of the cutter 300, the die assembly 304 is raised
to the second position.
[0145] FIGS. 27-31 illustrate the die assembly 304 in the lower
position, while FIGS. 32-36 illustrate the die assembly 304 in the
raised position. As discussed above, the raising and lowering of
the die assembly 304 engages or disengages respectively the tab 392
within the notch 388. As shown in FIGS. 28 and 29 the tab 392 is
disengaged from the notch 388 when the die assembly 304 is in the
first or lower position. In contrast, FIGS. 33 and 34 illustrate
the tab 392 engaged with the notch 388 when the die assembly 304 is
in the second or raised position.
[0146] The sizing of a vinyl blind will be described first. The die
assembly 304 is moved to the first or lower position as discussed
above. Once the die assembly 304 has been lowered, the rear die
assembly 304 is manually moved rearward utilizing the rear blade
carrier handle 404. Since, the rear blade carrier 320 and the front
blade carrier 372 are not coupled with the tab and notch 388, the
rear blade carrier 320 will travel a predetermined distance
independently of the front blade carrier 372. Connecting rods 420
operate as connecting rods 166 in cutter 10 described above, such
that once the rear blade carrier 320 has traveled rearward a
predetermined distance, the connecting rods 420 act to move the
front and rear blade carriers 320, 372 rearward together beyond the
predetermined distance.
[0147] Once the rear blade carrier 320 has been fully extended
rearward, the bottom rail, slats and head rail of the vinyl blind
are placed within the die assembly as described above with respect
to cutter 10. The rear blade carrier is 320 may then be moved
forward via the rear carrier handle 404 until the rail and slats
are pressed against the slat shear plate 422. In this manner the
bottom rail and slats are located securely between the blade member
and the slat shear plate 422. Since cutter 300 may be used to size
a mini-blind having a variety of number of slats, movement of the
rear blade carrier 320 acts to take up excess space between the
blade member 376 and the slat shear plate 422.
[0148] Once, the bottom rail and slats are secured, the switch 364
is then moved forwardly to disengage the end of switch from the
holding and driving pawl release bars 362, 354. In this manner the
holding and driving pawls 356, 350 are engaged with the rack
310.
[0149] The handle 314 is then moved in a forward direction via
pivot 338, resulting in forward translation of the driving pawl 350
via the four bar linkage 316. The handle 314 can only move as far
forward as the first link 336 will permit. After the handle 314 has
traveled as far as it can, the handle 314 is rotated back to its
starting position, and as a result the driving pawl 350 is also
returned rearwards. Of course an operator need not pivot the handle
as far as it can before returning it rearwards. The angle of the
teeth in the rack and the driving pawl, permit the driving pawl 350
to move rearward independently of the rack 310. However, due to the
pressure that builds up in the bottom rail, slats being cut, the
holding pawl 356 is required to prevent the rack 210 from moving in
a rearward direction while the driving pawl 350 is returned
rearwards.
[0150] The handle 314 is pivoted forward and back until the bottom
rail, slats and head rail are sized. As discussed above with
respect to cutter 10 after a predetermined distance, the rear blade
carrier 320 and the head rail blade carrier 372 move together
thereby sizing the remaining uncut components.
[0151] Once all of the components have been sized, the rear blade
carrier 320 and the front blade carrier 372 are in the forward
position. Accordingly, the die assembly 304 can be raised for
cutting the second blind configuration. Raising the die assembly
304 automatically pivots the catch 390 such that the tab 392 is
engaged within the notch 388. (See FIGS. 33 and 34).
[0152] After the die assembly 304 has been raised, the switch 364
is moved rearward to release the driving and holding pawls 350, 356
as discussed above. The rear blind carrier 320 and the front blind
carrier 372 are moved manually rearward via the rear blind carrier
handle 404. Since the rear blade carrier 320 and the front blade
carrier 372 are coupled with the catch 390 and latch 384 they move
together. A stop located on the frame positively locates the blade
carriers relative to the die assembly.
[0153] Unlike cutter 10, the bottom rail of the aluminum blind is
located within the aperture 378 of the blade member 372, and the
slats are located between the cutting surface 382 and the shear
slat plate. In this manner, the bottom rail is sized by the rear
edge of the aperture in a shearing motion while the slats are sized
by the cutting surface 382 of the blade member.
[0154] Once the aluminum blind components have been located within
the die assembly and blade carriers, the switch 364 is moved
forward to permit engagement of the driving and holding pawls 350,
356 with the rack 310. Similar to the sizing of the vinyl blind,
the handle 314 is pivoted forward and back a number of times to
size the bottom rail, slats and head rail.
[0155] Cutter 300 provides a method for cutting two different blind
products on the same piece of equipment, utilizing the same drive
system. As discussed above, cutter 300 accommodates two mini-blind
products of different geometry and or different material
composition. Additionally, the number of slats may also vary for a
given blind type. Since the vinyl slats are thicker than an
aluminum slat, the region of the die assembly 304 to receive the
vinyl slats must be wider than the region to receive a similar
number of aluminum slats.
[0156] Additionally, the rear blade carrier 320 must be able to
move further rearward in the extended direction in order to
accommodate the greater thickness of the vinyl slats. In the
preferred embodiment of cutter 300 the front edge 380 of the blade
member 376 also is used to size the vinyl bottom rail. Accordingly,
the rear blade carrier 320 must move further rearward than when the
metal bottom rail of the aluminum blind is located within the
aperture 378 of the blade member 376.
[0157] The cooperation of the drive system 308 and blade carrier
assembly 306 permits the rear blade carrier 320 to move to two
different extended positions for sizing the first vinyl blind
product and for sizing the second metal blind product. As discussed
above the rear blade carrier 320 is moved further rearward for the
sizing the vinyl product, since the front edge 380 of the rear
blade member 376 cuts both the bottom rail and slats. Additionally,
the width of the compressed vinyl slats is greater than compressed
aluminum slats.
[0158] The location of the front blade carrier 372 in the extended
position is the same for both the first and second modes of
operation. However, in the first mode of operation for sizing the
vinyl blind, the location of the rear blade carrier 320 is set by
the connecting rods 420 while, in the second mode of operation for
sizing the aluminum blind, the rear blade carrier 320 is set by the
catch 390 and latch 384. The connecting rods 420 permit independent
travel of the rear blade carrier 320, while the catch 390 and latch
384 allow for simultaneous translation throughout the translation
of the blade carriers.
[0159] The first region of the die assembly 304 may also include a
bottom rail die block (not shown), such that the portion of the
bottom rail of the vinyl mini-blind would be located within the
opening in the rear blade member. However, in order to accommodate
the thickness of the vinyl slats the rear blade carrier 320 would
be located further rearward in the extended position.
[0160] Although the invention has been described in conjunction
with specific embodiments thereof, it is evident that alternatives,
modifications and variations will be apparent to those skilled in
the art. It is intended that the claims embrace all such
alternatives, modifications and variations that fall within the
spirit and broad scope of the appended claims.
* * * * *