U.S. patent application number 11/182915 was filed with the patent office on 2006-03-02 for pattern cutter, its processing methods and moulds.
Invention is credited to Faye Angevine, Yeqing Deng.
Application Number | 20060042419 11/182915 |
Document ID | / |
Family ID | 34664149 |
Filed Date | 2006-03-02 |
United States Patent
Application |
20060042419 |
Kind Code |
A1 |
Deng; Yeqing ; et
al. |
March 2, 2006 |
Pattern cutter, its processing methods and moulds
Abstract
Disclosed here in the present invention is a pattern cutter,
including a base and cutting blade. The cutting blade is located on
the base. The blade forms the shape of pattern to be cut. The said
base and cutting blade are of one-piece structure, which is
machined to shape at one go through die-casting process. A method
for processing such a pattern cutter, which directly utilizes mould
to die cast the base and blade that are joined together. The said
cutting blade forms the pattern shape that requires to be cut. A
mould that is applied to the aforesaid processing method, inside
the mould there is arranged a cavity for blade forming purpose. The
said blade-forming cavity is of triangle or combination of triangle
and rectangle or combination of triangle and trapezoid. The depth
of blade-forming cavity is greater than or equal to 2.5 mm. The
included angle at the sharp end of the blade-forming cavity is
smaller than or equal to 60.degree.. The present invention is
characterized by simple and rational construction, easy to
manufacture, low cost, high product accuracy and good consistency,
with a wide range of adaptability and better market prospect.
Inventors: |
Deng; Yeqing; (Dongguan
City, CN) ; Angevine; Faye; (Taipei, TW) |
Correspondence
Address: |
MORRISS O'BRYANT COMPAGNI, P.C.
136 SOUTH MAIN STREET
SUITE 700
SALT LAKE CITY
UT
84101
US
|
Family ID: |
34664149 |
Appl. No.: |
11/182915 |
Filed: |
July 15, 2005 |
Current U.S.
Class: |
76/107.1 |
Current CPC
Class: |
B26F 1/44 20130101; B26D
5/10 20130101; B26D 7/2614 20130101; B26F 2001/4436 20130101; B26D
2007/2607 20130101; B22D 17/22 20130101; B23P 15/406 20130101 |
Class at
Publication: |
076/107.1 |
International
Class: |
B21K 5/20 20060101
B21K005/20 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 16, 2004 |
CN |
200410028111.X |
Claims
1. A pattern cutter, comprising: a base; and a cutting blade where
the cutting blade is integrally formed as a one piece structure
with the base and the cutting blade forms the shape of the pattern
to be cut, said base and cutting blade formed from die-cast
metal.
2. The pattern cutter of claim 1, wherein the height of cutting
blade is greater than or equal to 2.5 mm and the cutting edge of
the ea blade has an angle of less than or equal to approximately
60.degree..
3. The pattern cutter of claim 1, wherein the cross sectional shape
of the blade is of at least one of a triangle, a combination of a
triangle and a rectangle or combination of a triangle and a
trapezoid.
4. The pattern cutter of claim 1, wherein the surface of the base
is in parallel with that of the cutting blade and both of them are
of one of a plane or arc curved surface.
5. A method for forming a pattern cutter, comprising: providing a
die-casting machine; providing a mould having a desired blade
forming cavity and a base forming cavity formed therein and in
communication with each other; placing the mould in the die-casting
machine; using the die-casting machine to fill the blade forming
cavity and base forming cavity with a metal; and taking out a
pattern cutter after it has formed.
6. The method of claim 5 further comprising forming the mould by
machining the desired shape of the blade forming cavity and base
forming cavity therein.
7. The method of claim 5, further comprising, applying a surface
hardening treatment to the pattern cutter.
8. The method of claim 5, wherein the blade-forming cavity has a
cross-section which is of triangle or combination of triangle and
rectangle or combination of triangle and trapezoid.
9. The method of claim 8, wherein the blade-forming cavity is
formed from at least one of a combination of two mould pieces and
machining.
10. The method of claim 8, at least one of a cover die or ejector
die of the die-casting mould is joined together with a replaceable
core piece.
11. The pattern cutter of claim 1, wherein the die-cast metal is
comprised of one of a zinc alloy, an aluminum alloy and a metal
alloy.
12. The method of claim 7, wherein said applying the surface
hardening treatment includes applying at least one of chromium,
nickel and zinc.
13. The method of claim 7, wherein said applying the surface
hardening treatment comprises raising the hardness of a blade of
the pattern cutter from approximately HRC10 to at least
approximately HRC30.
14. The method of claim 5, wherein the blade forming cavity is
provided with a depth of at least 2.5 mm and an included angle at a
sharp end thereof of at approximately 60 degrees or less.
15. The method of claim 10, further comprising drilling the core
piece with a hole for fitting an insert block where an end face of
the insert block is provided with a blade-forming groove
corresponding to the shape of the blade of the pattern cutter.
16. A mould for forming a pattern cutter, comprising: a mould
having a desired blade-forming cavity and a base-forming cavity
formed therein and in communication with each other; the
blade-forming cavity having a cross-section which is of triangle or
combination of triangle and rectangle or combination of triangle
and trapezoid; and the blade-forming cavity having a depth of at
least 2.5 mm with an included angle at its sharp end smaller than
at least about 60.degree..
17. The mould of claim 16, wherein the blade-forming cavity is
formed from at least one of a combination of two mould pieces and
machining.
18. The mould of claim 16, wherein at least one of a cover die or
ejector die of the mould is joined together with a replaceable core
piece.
19. The method of claim 18, wherein the core piece has a hole for
fitting an insert block where an end face of the insert block is
provided with a blade-forming groove corresponding to the shape of
the blade of a pattern cutter.
Description
TECHNICAL FIELD
[0001] The present invention relates to the pattern cutting
technique and, more particularly, to a pattern cutter, its
processing methods and moulds.
BACKGROUND ART
[0002] The traditional paper-cutting handicrafts are a kind of work
of art gaining immense popular favor. With a large variety of
designs or patterns and high value of artistic appreciation, the
paper-cutting handicrafts are very suitable to the kindergarten
education of children. Abroad, these kind of paper-cutting products
are widely used for children education. In the United States, for
example, the paper-cutting products are very popularized. The
paper, plastic pieces, rubber pieces or similar materials are
generally cut into letters, cartoon, animals or human-shaped
patterns for cultivation of children's cognitive ability and
discrimination. But, the production efficiency is relatively low by
using traditional hand paper-cutting method to make paper-cutting
patterns, with a poor consistency in designs, hence it is not
suitable for mass production. To overcome this deficiency, a
process has' been adopted to suit the mass production, i.e. firstly
machining a pattern cutter for pattern cutting purpose. This
pattern cutter is designed to work in such a way that the thin
blade with a sharp cutting edge is bent to the pattern to be
processed and it is embedded and fixed into a flat plate. Then,
this pattern cutter is used to cut paper or similar flat sheet
material. The material that is cut has an individual artistic
pattern identical to that of the thin cutting blade, i.e. the
products that are required. If the products of different shapes are
to be made, what to do is only to change the pattern cutter with
different shapes. In producing such pattern cutter, the thin
cutting blade needs to be bent to pattern shape that is required.
The existing method to form such blades is generally to bend them
by hand, leading to extremely low production efficiency and poor
processing accuracy. However, by use of the Forming Method and Its
Equipment for Pattern Cutting Blade, which is disclosed in China
Invention Patent Registration No. 01 127727.0, to machine the
cutting blades that are required, the blade forming speed will be
greatly increased and production cost reduced. But, the
technological process, through which the cutting blades are firstly
machined and then assembled to a pattern cutter, will inevitably
increase the processing and assembling steps, thereby the required
materials and labor cost are still relatively high.
DESCRIPTION OF THE INVENTION
[0003] The object of the present invention is to solve those
problems occurring in the prior art and provide a pattern cutter
that is simple and rational in construction, easy to produce and
convenient to use, low in manufacturing cost and good in product
consistency.
[0004] Another object of the present invention is to provide a
technological method for processing the aforesaid pattern
cutter.
[0005] Still another object of the present invention is to provide
a forming mould, which can materialize the aforesaid processing
method.
[0006] The objects of the present invention can be accomplished
through the following technical solutions. This pattern cutter
includes a base and cutting blade. The cutting blade is located on
the base. The cutting blade forms the pattern shape to be cut. The
said base and cutting blade are of one-piece structure and machined
into shape at one go through die-casting process.
[0007] On the base, the height of the said cutting blade is greater
than or equal to 2.5 mm. The angle of the cutting edge of the said
blade is smaller than or equal to 60.degree..
[0008] The cross sectional shape of the said blade is of triangle
or combination of triangle and rectangle or combination of triangle
and trapezoid.
[0009] The surface of the said base is in parallel with the face of
cutting blade, and both of them can be either plane or arc curved
surface.
[0010] The holding legs are integrally made on the said base at the
other side opposite to the surface where the cutting blade is
located. The said holding legs are used for connection with other
fittings or allow an operator to directly hand hold the pattern
cutter in operation.
[0011] A technological process to form the aforesaid pattern
cutter, wherein the features are that a mould is directly utilized
to die cast the base and blade which are joined together. The said
cutting blade forms the pattern shape that requires to be cut.
[0012] The said technological process can include the following
concrete procedures: (1) Machine the die casting mould according to
the shape of the required product; (2) Place the die casting mould
on the die-casting machine, and use the die-casting machine to fill
the alloy solution into the cavity of die-casting mould. Take out
the die casting product after it is cooled and formed; (3) Conduct
surface hardening treatment to the die casting product.
[0013] The object of the said surface hardening treatment is to
raise the hardness of cutting blade of pattern cutter and extend
its operating life. Specifically, the surface of the die casting
blade is plated with a metal material of higher hardness, e.g.
chromium, nickel, zinc, etc. For chromium plating, the
technological conditions are as follows: the concentration-of
chromium solution is 150.about.250 g/L, operating temperature is
generally 50.about.60.degree. C. and current density is generally
40.about.60 A/dm.sup.2. Through surface hardening treatment, the
hardness of die casting blade can generally be raised from around
HRC10 to HRC30 and above.
[0014] The said alloy comprises the aluminum alloy, zinc alloy or
other alloys, with the preference of zinc alloy.
[0015] In order to achieve the aforesaid process, the die casting
mould has a blade-forming cavity, which is of triangle or
combination of triangle and rectangle or combination of triangle
and trapezoid. The depth of blade-forming cavity is greater than or
equal to 2.5 mm, with an included angle at its sharp end being
smaller than or equal to 60.degree..
[0016] The sharp wall of the said blade-forming cavity can be
formed either by combination of two mould pieces or through the
machining on either of moulds. As to one mould piece, the
blade-forming cavity should have a vent hole, which is used to
discharge air when the alloy solution is filled into the cavity so
as to avoid producing any air-trapped die casting product or any
such item as produced due to insufficient solution in the
cavity.
[0017] The cover die or ejector die of the said die-casting mould
is joined together with a replaceable core piece. The said core
piece is drilled with a hole for fitting an insert block. On the
end face-of the insert block is machined a blade-forming-groove
corresponding to the blade shape of pattern cutter. By use of the
mould of this structure, the insert block can be freely changed
according to the different processing patterns, having a good
adaptability.
[0018] In comparison to the prior art, the present invention has
the following advantageous effects. (1) Simple and rational
construction. This pattern cutter comprises a base and cutting
blade of one-piece structure. The construction has been further
simplified, whereas the existing pattern cutter that needs the base
and cutting blade to be machined separately, then embedded and
assembled. And as compared with the prior art, it is more rational
and there will be no such accidents that the blade breaks loose
from the base due to improper installation. So, it is safer in
operation. (2) Easy to make and low in cost. The present invention
utilizes die-casting process to produce pattern cutter, with a high
production rate. Generally the output is 240 pieces per hour per
unit. The use of the present invention can greatly increase work
efficiency, reduce product cost and improve economy efficiency. (3)
High product accuracy and good consistency. The present invention
adopts a mould in production. So long as the machining accuracy of
the mould and corresponding production conditions are guaranteed,
the products that are turned out can have rather high processing
quality, with less product errors and good consistency. (4) Good
adaptability. According to the present invention, the pattern
cutters for cutting the different shapes of patterns can be formed
only by changing the shape of core seat in the mould, with a wide
range of adaptability.
DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is the schematic view showing the construction of
pattern cutter of the present invention.
[0020] FIG. 2 is the schematic view showing the back construction
of the pattern cutter as shown in FIG. 1.
[0021] FIG. 3 is the schematic view showing the construction of the
die casting mould for forming the pattern cutter as shown in FIG.
1.
[0022] FIG. 4 is the schematic view showing the construction of the
A core piece of the die casting mould as shown in FIG. 3.
[0023] FIG. 5 is the top view of A core piece as shown in FIG.
4.
[0024] FIG. 6 is the schematic view showing another construction of
the pattern cutter of the present invention;
DESCRIPTION OF THE PARTICULAR EMBODIMENTS
[0025] A detailed description of the present invention is given
below in conjunction with the working examples and accompanying
drawings, but the implementation modes of the present invention are
not limited to those.
WORKING EXAMPLE 1
[0026] FIG. 1 and FIG. 2 show the concrete construction of the
pattern cutter of the present invention. As shown in FIG. 1, the
pattern cutter is composed of the base 1 and cutting blade 2. The
base 1 is an arc plate with a certain radian. The cutting blade 2
is located on the base 1, with the surface of its cutting edge
being in parallel to that of base 1 (both being of arc curved
surface). The cutting blade 2 forms a penguin pattern shape to be
cut. The said base 1 and cutting blade 2 are of one-piece
construction. The specific cross sectional structure is shown in
E-E view of FIG. 1. The cutting blade 2 has a cross sectional shape
similar to triangle (the exact shape is the combination of triangle
and trapezoid). The height of cutting blade 2 is 3 mm on the base
1. The cutting blade 2 has an angle of 30.degree. at the cutting
edge. On the surface of cutting blade 2 there is a plating coat 15.
The holding legs 3 are integrally made on the said base 1 at the
other side opposite to the surface where the cutting blade 2 is
located, as shown in FIG. 2. The said holding legs 3 are used for
connection with other fittings or for hand held purpose in
operation.
[0027] FIG. 3.about.FIG. 5 show the concrete structure of the die
casting mould for processing the aforesaid penguin pattern cutter.
As shown in FIG. 3, the die casting mould comprises the ejector die
4 and cover die 5. On the ejector die 4 is fitted a B core piece 6.
On the B core piece 6, there are two protruding arc surfaces 6-1,
which are symmetrical to each other. On the arc surfaces 6-1, there
are concave holes 6-2 for forming the holding legs 3 on the back of
pattern cutter. On the cover die 5, A core piece 7 is fitted. In
the two square throughholes of the A core piece 7, the identical
square insert blocks 8 are fitted respectively. On one end of each
square insert block 8 is machined a blade-forming groove 9 of
penguin shape, as shown in FIG. 5. The blade-forming groove 9 close
to the edge of square throughhole is mated with that-of the square
throughhole of A core piece 7 by means of the insert block 8, as
shown in FIG. 4. The rest of the blade-forming groove 9 is machined
to shape on the end face of the insert block 8 separately. The
whole cross sectional dimensions and shape of the blade-forming
groove 9 are the same as the blade that is to be formed. The said A
core piece 7 is mated with B core piece 6 as to form an integral
mould cavity. The mould cavity comprises the blade-forming cavity
and base cavity which are communicated to each other. The push rod
10 is connected to the mould cavity so as to push out the die
casting product after it is formed. The lateral cavity has also a
vent hole used to discharge air when the alloy solution is being
filled into the cavity. The base cavity is through with the pouring
opening 12 by way of pouring passage 11. The said pouring openings
12 are symmetrically arranged on the symmetrical spindles in the
central round throughholes of A core piece 7. The said pouring
passage 11 is almost of conical construction, which is formed by
mating the pouring head piece 13 and C core piece 14 symmetrically
arranged via a shaft. The technological processes by using the
aforesaid mould to form pattern cutter comprise the following
specific procedures. After the mould is assembled, it is installed
on the die-casting machine. The die-casting machine pours the
400.degree. C. zinc alloy solution into the cavity of the mould
through the pouring opening under the pressure of 25.about.40 MPa.
The die casting product can then be taken out after the pressure
has been maintained and cooled to shape. Then the die casting piece
can be chromium plated. The concentration of chromium plating
solution is 200 g/L, at the operating temperature of 55.degree. C.
and the current density of 50 A/dm.sup.2. After chromium plating,
the hardness of the blade of pattern cutter can be raised to HRC 30
and above.
WORKING EXAMPLE 2
[0028] FIG. 6 shows another construction of the pattern cutter as
set forth in the present invention. As shown in FIG. 6, this
pattern cutter comprises a base 1 and cutting blade 2. The base 1
is a flat plate, with the cutting blade 2 located on the base 1.
The surface for the cutting edge of the blade is in parallel to
that of the base 1 (both of them being of plane). The cutting blade
2 forms the circular pattern shape that is to be cut. The said base
1 and the cutting blade 2 are of one-piece structure. The specific
cross sectional structure is as shown in G-G view of FIG. 6. The
cross sectional shape of the cutting blade 2 is of triangle. The
height of the cutting blade 2 is 4 mm on the base 1. The blade 2
has an angle of 40.degree. at the cutting edge. The cutting blade 2
is surfaced with a chromium-plating coat 15.
[0029] The methods for manufacturing the pattern cutter as set
forth in the present working example are the same as those in the
working example 1 in addition to the following features. The alloy
material that is used is the aluminum alloy. The cutting blade is
surface treated with chromium plating after the die-casting product
is taken out from the mould. The concentration of chromium plating
solution is 250 g/L, the operating temperature is 60.degree. C.,
and the current density is 60 A/dm2. After chromium plating
treatment, the hardness of cutting blade of the pattern cutter is
raised to HRC 30 and above.
* * * * *