DIE CUTTER ASSEMBLY AND METHODS OF MINIMIZING DEFLECTION

Abstract

A cutting apparatus for cutting a web within a frame includes a die cutter assembly including a cutting blade projecting from a cylindrical surface and a counter anvil including first and second ends journaled into the frame. The counter anvil is positioned below the die cutter assembly for receiving the web fed therebetween across a width of the frame. The cutting apparatus includes first and second outboard bearing assemblies positioned on the die cutter near the first and second opposing ends, respectively, and one or more inboard bearing assemblies positioned about the die cutter assembly and spaced inwardly from the outboard bearing assemblies. Each outboard bearing assembly is configured to control a spacing between the die cutter assembly and the counter anvil along the width of the frame. The cutting apparatus also includes one or more actuators positioned atop the frame in connection with the one or more inboard bearing.

Claims

1. A cutting apparatus for cutting a web within a frame, comprising: a die cutter assembly including a cutting blade projecting from a cylindrical surface, wherein the die cutter includes first and second opposing ends journaled into the frame; a counter anvil including first and second ends journaled into the frame, wherein the counter anvil is positioned below the die cutter assembly for receiving the web fed therebetween across a width of the frame such that the web is cut as the cutting blade strikes against the counter anvil; first and second outboard bearing assemblies positioned on the die cutter near the first and second opposing ends, respectively, wherein each outboard bearing assembly is vertically movable and configured to control a spacing between the die cutter assembly and the counter anvil along the width of the frame; one or more inboard bearing assemblies positioned about the die cutter assembly and spaced inwardly from the outboard bearing assemblies; and one or more actuators positioned atop the frame, wherein each actuator includes a piston rod in connection with the one or more inboard bearing adjacent to the cutting blade that applies downward pressure to the die cutter assembly.

2. The cutting apparatus of claim 1, wherein the cutting blade is located centrally along a width of the die cutter assembly.

3. The cutting apparatus of claim 2, wherein the die cutter assembly includes a die sleeve secured around a die shaft, wherein first and second ends of the die shaft are journaled into the frame, wherein the cutting blade projects from the die sleeve, and wherein the one or more inboard bearing assemblies are positioned about the die shaft adjacent to the cutting blade of the die sleeve.

4. The cutting apparatus according to claim 3, wherein the first and second outboard bearing assemblies include first and second outboard bearings, respectively, that rotate within first and second outboard bearing housings, respectively.

5. The cutting apparatus according to claim 4, wherein first and second inner races of the first and second outboard bearings assemblies, respectively, are mounted to the die shaft.

6. The cutting apparatus of claim 1, wherein each of the one or more actuators is positioned atop the frame.

7. The cutting apparatus of claim 1, wherein each of the one or more actuators comprises one of an air cylinder, a pneumatic cylinder, and a hydraulic cylinder.

8. A method of cutting a web comprising the steps of: providing a cutting apparatus within a frame including: a die cutter assembly including a cutting blade projecting from a cylindrical surface, wherein the die cutter includes first and second opposing ends journaled into the frame; a counter anvil including first and second ends journaled into the frame, wherein the counter anvil is positioned below the die cutter assembly for receiving the web fed therebetween across a width of the frame such that the web is cut as the cutting blade strikes against the counter anvil; first and second outboard bearing assemblies positioned on the die cutter near the first and second opposing ends, respectively, wherein each outboard bearing assembly is vertically movable; one or more inboard bearing assemblies positioned about the die cutter assembly and spaced inwardly from the outboard bearing assemblies; and one or more actuators positioned atop the frame, wherein each actuator includes a piston rod in connection with the one or more inboard bearing adjacent to the cutting blade; adjusting the spacing between the die cutter assembly and the counter anvil by adjusting first and second heights of the first and second outboard bearing assemblies within the frame; and applying downward pressure to the die cutter assembly through the one or more inboard bearing assemblies by activating the one or more actuators.

9. The method of claim 8, wherein the cutting apparatus includes first and second actuators positioned adjacent to the cutting blade.

10. The method of claim 9, wherein first and second pressures are applied to the die cutter assembly through the first and second actuators, respectively, and wherein the first and second pressures are different.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0017] FIG. 1 is a schematic of a conventional rotary die cutting machine.

[0018] FIG. 2 is a perspective view of a rotary die cutter machine of the present application.

[0019] FIG. 3 is cross sectional view of the die cutter machine generally taken along lines 3-3 of FIG. 2.

[0020] FIG. 4 is a perspective view of a die cutter assembly of the present application.

[0021] FIG. 5 is cross sectional view of the die cutter assembly generally taken along lines 5-5 of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

[0022] Referring to FIGS. 2 and 3, the rotary die cutting machine 100 of the present application includes a die cutter assembly 102 and a counter anvil 104 mounted within a frame 106. A die cutter 108 of the die cutter assembly 102 includes a cutting blade 110 located centrally along the width of the die cutter 108, although the positioning of the cutting blade 110 may extend further along the width as necessary or desired.

[0023] As shown in FIGS. 3 and 5, the die cutter 108 includes a die sleeve 112 mounted or otherwise secured to a die shaft 114. First and second ends 116, 118 of the die shaft 114 are journaled into the frame 106 as shown in FIGS. 2 and 3. The die shaft 114 is connected to a motor (not shown) that causes rotation of the die cutter assembly 102.

[0024] Referring to FIGS. 3 and 5, first and second outboard bearing assemblies 120, 122 of the die cutter assembly 102 including first and second outboard bearings 124, 126, respectively, that rotate within first and second outboard bearing housings 128, 130, respectively. The inner races 132, 134 of the outboard bearings 124, 126 are mounted to the die shaft 114, and the outer races 136, 138 of the outboard bearings 124, 126 are mounted to the outboard bearing housings 128, 130.

[0025] The elevation of the die cutter assembly 102 is controlled by adjusting the elevation of the outboard bearing housings 128, 130. Best seen in FIG. 3, the outboard bearing assemblies 120, 122 control the vertical spacing 139 of the die cutter assembly 102 and the counter anvil 104, and are adjusted based on the blade height and the amount of deflection to be countered.

[0026] Referring to FIGS. 3-5, first and second inboard bearing assemblies 140, 142 positioned along the width of the die cutter 108 are spaced inwardly from the first and second ends 114, 116, respectively, of the die cutter 108. First and second actuators 144, 146 positioned atop the frame 106 apply pressure to the die cutter 108 through the first and second inboard bearing assemblies 140, 142. First and second inner bearings 148, 150, respectively, rotate within first and second inboard bearing housings 152, 154, respectively, of the first and second inboard bearing assemblies 140, 142. The inner races 156, 158 of the inboard bearings 148, 150 are mounted to the die shaft 114, and the outer races 160, 162 of the inboard bearings 148, 150 are mounted to the inboard bearing housings 152, 154.

[0027] As shown in FIGS. 2 and 3, the first and second actuators 144, 146 include first and second piston rods 145, 147, respectively, that contact the first and second inboard bearing housings 152, 154, respectively. Activation of each actuator 144, 146 applies downward pressure through the first and second piston rods 145, 147 to the inboard bearing housings 152, 154. In some embodiments, the first and second inboard bearing assemblies 140, 142 are positioned immediately adjacent to the cutting blade 110. While the outboard bearing assemblies 120, 122 control the spacing 139 between the die cutter assembly 102 and the counter anvil 104, the profile of deflection may vary along the width of the frame 102, particularly at the cutting blade 110. Use of the actuators 144, 146 through the inboard bearing assemblies 140, 142 directs the pressure to the area experiencing the most deflectionthe cutting blade 110. The actuators 144, 146 may be any suitable mechanical device for applying pressure to the first and second inboard bearing assemblies, such as air cylinders, hydraulic cylinders, and/or pneumatic cylinders.

[0028] The pressure applied through each of the first and second actuators 144, 146 may be equal or different, depending on the profile of deflection, the cutting forces along the width of the die cutter assembly 102, and other such variables. Further, the die cutter assembly 102 may include any number of inboard air cylinder(s) 144, 146 as required by the application, the shape of the cutting blade, the strength of the material to be cut, and other variables.

[0029] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.