METHOD AND DEVICE FOR FORMING FROM A FLAT SHEET MATERIAL A CORNER BOUNDED BY THREE SIDES

Abstract

A method and apparatus for forming and trimming an associated corner region formed from a flat plate. A die and a knife assembly includes a die that is movable in opposed reciprocating directions within a first plane. A support assembly for the corner region holds the corner region at oblique angle with respect to the plane.

Claims

1. A method of forming a corner region of a flat plate having side edges, comprising the steps of: (a) folding down the side edges of the flat plate by a predetermined height from a plane in which the flat plate extends to form first and second intersecting side walls having respective first and second free end faces and an excess projection in the corner region where the side walls intersect, (b) placing the first and second free end faces of the side walls respectively on first and second guide surfaces of respective first and second bearing elements for the first and second side walls, (c) placing the excess projection between two cooperating cutting elements having cutting edges in oblique relationship with the guide surfaces of the bearing elements, and (d) separating the excess projection by displacing one of the cutting elements against the other cutting element with the bearing elements fixedly held and the cutting elements are displaceable relative to the bearing elements in oblique relation to the side walls.

2. The method of claim 1, wherein the cutting elements are displaceable relative to the bearing elements at an angle that is greater than zero degrees and less than six degrees with respect to a virtual plane that is normal to the side walls.

3. The method as described in claim 1 wherein the cutting elements are displaceable relative to the bearing elements at an adjustable height relative to the bearing elements as well as at an adjustable angle relative to the surface of the side walls.

4. A system for forming a three-dimensional corner region of a flat plate, which comprises (a) a tool having a top face and shaping surfaces adapted to form two folded-down intersecting side walls of the flat plate in the corner region, (b) a clamping device for clamping the flat plate to the top face of the tool, (c) a roller system with a roll displaceable perpendicularly to the top face for folding down the side walls over a predetermined height from a plane in which the flat plate extends to form the two intersecting side walls having free end faces and an excess projection in the corner region where the side walls intersect, (d) first and second supports for the respective first and second side walls adapted to support the free end faces of the side walls, and (e) first and second cutting elements having cutting edges disposed in oblique relation with the guide surfaces of the bearing elements and arranged to receive the excess projection therebetween, one of the cutting elements being displaceable in a direction that is oblique to a virtual plane that is normal to the side walls against the other cutting element to separate the excess projection.

5. The system as described in claim 4 wherein said one of the cutting elements that is displaceable in a direction that is oblique to a virtual plane that is normal to the side walls is displaceable in a direction that is between more than zero and six degrees with respect to a plane that is normal to the side walls.

6. Apparatus for trimming an associated corner region having first and second side surfaces formed from a flat plate and each side surface having a free end referred to as a side edge wherein the apparatus comprises: a die and a knife assembly in which the die is movable in opposed reciprocating directions within a plane; a support assembly for holding the associated corner region by the first and second side edges, said support assembly positioning the associated corner region with respect to said plane; said support assembly including first and second elongated pivotally mounted rails each including respective first and second supports carried thereon that are each dimensioned and configured to hold the associated corner region physically oriented with respect to (1) said plane and (2) said die and knife assembly with the side surfaces disposed at an oblique angle with respect to said plane.

7. The apparatus as described in claim 6 wherein said oblique angle that is between more than zero and six degrees.

8. The apparatus as described in claim 6 wherein each of said supports is L-shaped.

9. The apparatus as described in claim 7 wherein each of said supports is dimensioned and configured for sliding movement along an axial part of a rail.

10. A system for forming a three-dimensional corner region of a flat plate as described in claim 4 wherein said first and second supports for the respective first and second side walls adapted to support the free end faces of the side walls are independently mounted whereby the angular relationship between the two cooperating cutting elements as well as the height of each sidewall relative to the two cooperating cutting elements are adjustable.

11. Apparatus for forming a three-dimensional corner region of a flat plate as described in claim 6 wherein said first and second supports for the respective first and second side walls adapted to support the free end faces of the side walls are independently mounted whereby the angular relationship between the two cooperating cutting elements as well as the height of each sidewall relative to the two cooperating cutting elements are adjustable.

12. A method of forming a corner region of a flat plate having side edges, comprising the steps of (a) folding down the side edges of the flat plate by a predetermined height from a plane in which the flat plate extends to form first and second intersecting side walls having respective first and second free end faces and an excess projection in the corner region where the side walls intersect, (b) placing the first and second free end faces of the side walls respectively on first and second guide surfaces of respective first and second bearing elements for the first and second side walls, (c) placing the excess projection between two cooperating cutting elements having cutting edges in oblique relationship with the guide surfaces of the bearing elements, and (d) separating the excess projection by displacing one of the cutting elements against the other cutting element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:

[0024] FIG. 1 is a perspective view of one embodiment of the apparatus in accordance with one form of the present invention;

[0025] FIG. 1A is a top view of the apparatus shown in FIG. 1;

[0026] FIG. 2 is a right side view of the apparatus shown in FIG. 1.

[0027] FIG. 3 is a front view of the apparatus shown in FIG. 1;

[0028] FIG. 4 is detailed view to an enlarged scale of the adjustment mechanism illustrated in FIG. 1 and the eccentric support surface at the front of the workpiece facilitating the overall height adjustment of the workpiece;

[0029] FIG. 5 is another detailed view to an enlarged scale of the pivot point OD, the adjustment mechanism illustrated in FIG. 1.

[0030] FIG. 6 is an illustration of corner formed from a sheet of metal and trimmed by the apparatus of the present invention;

[0031] FIGS. 7-8 are illustrations of corners formed from respective sheets of metal and trimmed by prior art trimming devices and which illustrates the deficiencies of the manufacture resulting from the prior art method and apparatus.

DETAILED DESCRIPTION

[0032] As previously described the present invention includes a method and apparatus that is (1) independent of other apparatus or (2) associated with known preprocessing apparatus such as the prior art apparatus described in the Harmenter patent as well as work pieces formed by other means such as an edge-folding press. For simplicity of description the following will refer specifically to the prior art apparatus described in the Harmenter patent. More specifically, the following description will refer to some of the specific drawings shown in the Harmenter patent to describe one possible application of the present invention.

[0033] One embodiment of the present invention includes a corner-shaping device to form a box-shaped component as well as a fixed element and a displaceable cutting element to trim the box-shaped component. Unlike the prior art such as Harmenter the present method and apparatus does not advance a displaceable cutting element toward the formed corner sides in a direction that is precisely perpendicular as shown in Harmenter FIG. 26. Furthermore, the present invention includes the method and apparatus for varying the angle between the direction of movement of the displaceable cutting element and a virtual plane that is perpendicular to the side walls of a corner bounded on three sides from a flat sheet material. The variation of this angular relationship is of course achieved by orientation of the work piece with respect to the displaceable cutting element. More particularly, the manner of holding the work piece in the present invention allows the user to vary the angle between the direction of movement of the displaceable cutting element and a virtual plane that is perpendicular to the side walls of a corner bounded on three sides from a flat sheet material as shown in FIG. 2.

[0034] As seen in FIGS. 1-5 the work piece in the illustrated embodiment of the present invention is supported on respective work piece supports 302 carried by respective rails 304. Each work piece support 302 is carried on a rail 304 in a manner that allows axial travel to facilitate cooperation with work pieces of different sizes. (For clarity elements of the structure shown in FIGS. 1-5 are identified by reference numerals 302 or higher to avoid confusion with structure that is described in descriptions that are incorporated by reference.) Each bolt 306 has a first axial part and a coaxial hexagonal head. The free end of the bolt 306 includes an eccentric cylindrical surface 307 having a geometric axis that is parallel to and spaced apart from the geometric axis of the first axial part. The rails 304 are each pivotally mounted for movement about the respective geometric axes of cylindrical surfaces 307. Thus, turning the hexagonal head of the bolt 306 causes the cylindrical surface 307 to move the rail 304 to move and thereby adjust the rail 304 to control both the height and angle of the workpiece relative to the displaceable cutting element. The angle ordinarily will be adjustable within the range of larger than zero degrees to 6 degrees. An angle of 1 degree works particularly well for many materials. Indicia on the respective rails 304 facilitates adjustment of the angle R. A support 310 is fixed to the housing 312 by a plate 320. The support 310 is provided with a slot 314 for engaging a pin 316 carried by the rail 304 to guide pivotal movement of that rail 304. A locking mechanism 320 cooperates with slot 322 to lock the rail 304 in a specific angular position. It will be understood that each rail 304 is individually adjustable. The normal and customary use and construction of the apparatus in accordance with the present invention will allow both rails to be pivotally adjustable and both will be ordinarily be adjusted to the same angle at all operational times. Although both rails will ordinarily be adjusted to the same angle different angles will be required for parts that are not symmetric.

[0035] The apparatus also includes a cylinder 324 for moving the displaceable cutting element or die 326 mounted on guides 328. The displaceable cutting element or die 326 moves with respect to a knife 330 carried in fixed relation to the housing 312. A sensor 332 is provided for work piece detection.

[0036] All publications and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[0037] Although the description above contains many specifics, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus, the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by the appended claims, in which reference to an element in the singular is not intended to mean one and only one unless explicitly so stated, but rather one or more. All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase means for.