System for deflecting an intermediate item in a folding unit

Abstract

A mechanism (100a or 100b) for preventing the folding of an intermediate item (300) in a knife folder (200) is disclosed. The mechanism (100a or 100b) includes a deflector (50) that is movable between a non-operating position (50a) and an operating position (50b). When the intermediate item is moving on the folding rollers (230a and 230b) of the knife folder (200), the deflector (50) is moved to the operating position (50b) for deflecting the received intermediate item towards a roller gap (232) of the folding rollers by the deflector end (20) of the deflector. Upon rotating the folding rollers, the intermediate item (300) moves away from the knife folder (200) through the roller gap (232) preventing folding of the intermediate item (300).

Claims

1. A mechanism (100 a or 100 b) for preventing folding of an intermediate item (300) in a knife folder (200), the intermediate item (300) is a sheet having one or more folds (302, 304) thereon, the knife folder (200) includes a knife blade (210), a stopper (220) and one or more pairs folding rollers (230 a and 230 b), the knife blade (210) is movable between a non-operating knife position (210 a) and an operating knife position (210 b); and for folding the intermediate item (300) by the knife folder (200), the intermediate item (300) is moved on the folding rollers (230 a and 230 b), the knife blade (210) is moved to the operating knife position (210 b) to press on a fold line (303) of the received intermediate item (300), the stopper (220) restricts a linear movement of the intermediate item (300) on the folding rollers (230 a and 230 b) in an entry direction (303) of the intermediate item (300) and the folding rollers (230 a and 230 b) are rotated to fold the intermediate item (300) and moves the folded intermediate item (300 a) through a roller gap (232) between the folding rollers (230 a and 230 b), the non-operating knife position (210 a) is a position of the knife blade (210) at which the knife blade (210) is not in a physical contact with the intermediate item (300), the mechanism (100 a or 100 b) comprises: a deflector (50) movably arranged on a frame (201) of the knife folder (200), the deflector (50) is movable between a non-operating position (50 a) and an operating position (50 b), the non-operating position (50 a) is a position of the deflector (50) at which a deflector end (20 or 30) of the deflector (50) is not in a physical contact with the intermediate item (300) received at the knife folder (200), the operating position (50 b) is a position where the deflector end (20) of the deflector (50) is physically in contact with the intermediate item (300); wherein for preventing the folding of the intermediate item (300) by the knife folder (200), when the intermediate item (300) is moving on the folding rollers (230 a and 230 b), the deflector (50) is moved to the operating position (50 b) for deflecting the received intermediate item (300) towards the roller gap (232) by the deflector end (20) of the deflector (50); and upon rotation of the folding rollers (230 a and 230 b), the intermediate item (300) moves away from the knife folder (200) through the roller gap (232).

2. The mechanism (100 a) as claimed in claim 1, wherein the deflector (50) is moved to the operating position (50 b) when the knife blade (210) is at the non-operating knife position (210 a).

3. The mechanism (100 a or 100 b) as claimed in claim 1, wherein the deflector end (20) has a concave surface face (22), the concave surface face (22) is projected away from the deflector (50), the concave surface face (22) includes: a centre concave portion (22 a) adapted to stop the linear movement of the intermediate item (300) in the entry direction (303) when the moving intermediate item (300) touches the centre concave portion (22 a); and a lower concave surface (22 b) adapted to deviate the movement of the intermediate item (300) towards the roller gap (232).

4. The mechanism (100 a or 100 b) as claimed in claim 1, wherein the deflector end (30) has a straight-line surface face (32), the straight-line surface face (32) is projected away from the deflector (30), the straight-line surface face (32) includes: a centre portion (32 a) adapted to stop the linear movement of the intermediate item (300) in the entry direction (303) when the moving intermediate item (300) touches the centre portion (32 a); and a lower straight surface (32 b) adapted to deviate the movement of the intermediate item (300) towards the roller gap (232).

5. The mechanism (100 a or 100 b) as claimed in claim 1, wherein the mechanism (100 a or 100 b) includes a guiding member (60) connected to the frame (201) of the knife folder (200), the guiding member (60) is extending towards the roller gap (232) with a distal end (62) of the guiding member (60) at a predefined first distance (64) from the roller gap (232), the deflector (50) is slidably moved on the guiding member (60) from the non-operating position (50 a) to the operating position (50 b) by applying an external force thereon.

6. The mechanism (100 a or 100 b) as claimed in claim 5, wherein the external force can be applied manually or by a first force applying unit (68) connected to the deflector (50).

7. The mechanism (100 a or 100 b) as claimed in claim 5, wherein the guiding member (60) is angularly oriented with reference to the entry direction (303).

8. The mechanism (100 a or 100 b) as claimed in claim 5, wherein an angle (67) between a direction of extension (63) of the guiding member (60) and a direction of extension of the knife blade (211) is in a range of 20 to 160 degree in an anti-clockwise direction (69).

9. The mechanism (100 a or 100 b) as claimed in claim 1, wherein the mechanism (100 a or 100 b) includes a fulcrum lever (70) pivotally connected to the frame (201) of the knife folder (200) at a pivotal pin (71), the deflector (50) is mounted on a first end bar (72) of the fulcrum lever (70), the fulcrum lever (70) enables revolving movements of the deflector (50) between the non-operating position (50 a) and the operating position (50 b) around the pivotal pin (71) when an external force applied on the fulcrum lever (70) accordingly; and when the deflector (50) is at the operating position (50 b), the first bar end (72) is at a predefined second distance (74) from the roller gap (232).

10. The mechanism (100 a or 100 b) as claimed in claim 9, wherein the external force can be applied manually or by a second force applying unit (78) connected to the fulcrum lever (70).

11. The mechanism (100 b) as claimed in claim 1, wherein the when the deflector (50) is at the operating position (50 b) if the knife blade (210) is moving towards the operating knife position (210 b), the knife blade (210) is moved backwards from an interference position (90) towards the non-operating knife position (210 a), the interference position (90) is a position where the deflector (50) and the knife blade (210) has a physical contact therebetween.

12. The mechanism (100 b) as claimed in claim 11, wherein the mechanism (100 b) having: a first controller (82) connected to the deflector (50) for controlling movements of the deflector (50) between the non-operating position (50 a) and the operating position (50 b); a second controller (84) connected to the knife blade (210) for controlling movements of the knife blade (210) between the non-operation knife position (210 a) and the operation knife position (210 b); a detecting unit (86) connected to the second controller (84) to provide information about the position of the knife blade (210) at the interference position (90) to the second controller (84), and the second controller (84) is adapted to move the knife blade (210) backwards from the interference position (90) towards the non-operating knife position (210 a).

13. The mechanism (100 a or 100 b) as claimed in claim 1, wherein the deflector end (20 or 30) is angularly oriented from a direction of extension (23 or 33) of the deflector (20 or 30).

14. The mechanism (100 a or 100 b) as claimed in claim 1, wherein the mechanism (100 a or 100 b) includes a latching unit (95) for latching the deflector (50) at a position between the operating position (50 b) and the non-operating position (50 b).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The advantages and features of the present invention will be understood better with reference to the following detailed description of some embodiments of the and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which;

(2) FIGS. 1a, 1b and 1c shows schematic views of an existing knife folder with a knife blade of the knife folder at various positions;

(3) FIGS. 2a, 2b, 2c shows schematic views of a mechanism for preventing folding of an intermediate in the knife folder shown in FIGS. 1a, 1b and 1c in accordance with the present invention;

(4) FIG. 2d shows an enlarged view of folding rollers of the knife folder shown in FIGS. 1a, 1b and 1c;

(5) FIGS. 3a and 3b shows schematic views of one more embodiment of a mechanism for preventing folding of an intermediate in the knife folder shown in FIGS. 1a, 1b and 1c in accordance with the present invention;

(6) FIGS. 3c, 3d, 3e, 3f, and 3g shows schematic views of various embodiments a guiding member of the mechanism shown in FIGS. 3a and 3b;

(7) FIGS. 4a and 4b shows schematic views of one more embodiment of a mechanism for preventing folding of an intermediate in the knife folder shown in FIGS. 1a, 1b and 1c in accordance with the present invention;

(8) FIGS. 4c and 4d show schematic views of various embodiments a fulcrum lever of the mechanism shown in FIGS. 4a and 4b;

(9) FIGS. 5a and 5b shows schematic views of one embodiment of a deflector end of the mechanism shown in FIGS. 2a, 2b, 2c, 3a, 3b, 4a & 4b;

(10) FIGS. 6a & 6b show schematic views of one more embodiment of a deflector end of the mechanism shown in FIGS. 2a, 2b, 2c, 3a, 3b, 4a &4b;

(11) FIGS. 7a, 7b & 7c show schematic views of one more embodiment of a deflector end of the mechanism shown in FIGS. 2a, 2b, 2c, 3a, 3b, 4a & 4b;

(12) FIGS. 8a & 8b shows schematic views of a mechanism for preventing folding of an intermediate in the knife folder shown in FIGS. 1a, 1b and 1c in accordance with the present invention;

(13) FIGS. 9a & 9b shows schematic views of one more embodiment of a mechanism for preventing folding of an intermediate in the knife folder shown in FIGS. 1a, 1b and 1c in accordance with the present invention; and

(14) FIGS. 10a & 10b shows schematic views of one more embodiment of a mechanism for preventing folding of an intermediate in the knife folder shown in FIGS. 1a, 1b and 1c in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(15) An embodiment of this invention, illustrating its features, will now be described in detail. The words comprising, having, containing, and including, and other forms thereof, are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items.

(16) The terms first, second, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms an and a herein do not denote a limitation of quantity, but rather denote the presence of one or more one of the referenced items.

(17) The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.

(18) The present invention provides a mechanism (100a or 100b) for preventing the folding of an intermediate item (300) in a knife folder (200) (refer to FIGS. 1a, 1b & 1c). The intermediate item (300) is a sheet having one or more folds (302, 304) thereon. The knife folder (200) (refer to FIG. 1a) is a folding device. The knife folder (200) includes a knife blade (210), a stopper (220) and one or more pairs of folding rollers (230a and 230b). The knife blade (210) is movable between a non-operating knife position (210a) and an operating knife position (210b). The knife folder (200) folds an intermediate item (300). The intermediate item (300) is a sheet having one or more folds thereon. The intermediate item (300) is moved on (over) the folding rollers (230a and 230b) for folding the intermediate item (300) by the knife folder (200). The intermediate item (300) is transferred to the knife folder (200) by feeding rollers (205a and 205b). The knife folder (200) receives the intermediate item (300) through a conveyor (203) at an inlet (203a) (FIG. 1a) with a linear movement in an entry direction (303). The stopper (220) restricts a linear movement of the intermediate item (300) on the folding rollers (230a and 230b) in the entry direction (302). The knife blade (210) is moved to the operating knife position (210b) to press on a fold line (303b) (FIG. 1b) of the received intermediate item (300).

(19) Further, the folding rollers (230a and 230b) are rotated to fold the intermediate item (300) and move the folded intermediate item (300a) through a roller gap (232) (FIG. 1c) between the folding rollers (230a and 230b). The non-operating knife position (210a) (FIG. 1a) is a position of the knife blade (210) at which the knife blade (210) is not in physical contact with the intermediate item (300).

(20) Referring now to FIGS. 2a, 2b and 2c, schematic diagrams of a mechanism (100a or 100b) for preventing folding of an intermediate item (300) in the knife folder (200) in accordance with the present invention is illustrated.

(21) The mechanism (100a or 100b) includes a deflector (50). The deflector (50) is movably arranged on a frame (201) of a knife folder (200). The frame (201) is any one of the body members of the knife folder (200). The deflector (50) is movable between a non-operating position (50a) (FIG. 1a) and an operating position (50b). The non-operating position (50a) (FIG. 1a) is a position of the deflector (50) at which a deflector end (20 or 30) of the deflector (50) is not in a physical contact with an intermediate item (300) received at the knife folder (200).

(22) The operating position (50b) (FIG. 2b) is a position where the deflector end (20) of the deflector (50) is physically in contact with the intermediate item (300).

(23) For preventing the folding of the intermediate item (300) by the knife folder (200), when the intermediate item (300) is moving on the folding rollers (230a and 230b), the deflector (50) is moved to the operating position (50b) for deflecting the received intermediate item (300) towards a roller gap (232) of the folding rollers (230a and 230b) by the deflector end (20) of the deflector (50). The deflector (50) is moved on a movement facilitator (206). The movement facilitator (206) can be linear bearing or slide rollers and the like. The roller gap (232) (refer to FIG. 2d) is a parallel distance between tangents (234a and 234b) of the folding rollers (230a and 230b). Upon rotation of the folding rollers (230a and 230b), the intermediate item (300) moves away from the knife folder (200) through the roller gap (232). Due to the cumulative moving forces applied by feeding rollers (205a and 205b) and the folding rollers (230a and 230b), the unfolded intermediate item (300) moves away from the knife folder (200). The unfolded intermediate item (300) can be transferred to a predefined destination.

(24) In one of the embodiments of the mechanism (100a or 100b), as shown in FIGS. 3a and 3b, the mechanism (100a or 100b) include a guiding member (60) connected to the frame (201) of the knife folder (200). The guiding member (60) is extending towards the roller gap (232) with a distal end (62) of the guiding member (60) at a predefined first distance (64) (FIG. 3a) from the roller gap (232). The deflector (50) is slidably moved on the guiding member (60) from the non-operating position (50a) (FIG. 3a) to the operating position (50b) (FIG. 3b) by applying an external force thereon the deflector (50). More specifically, the guiding member (60) has a track (not shown). The deflector (50) is slidably moving on the surface of the track. The deflector (50) is arranged on the track in such a way that the deflector (50) always has surface contact with the track but is movable between the non-operating positions (50a) to the operating position (50b).

(25) The external force on the deflector (50) can be applied manually. In one more embodiment (FIG. 3c and FIG. 3d), a first force applying unit (68) connected to the deflector (50). The first force applying unit (68) is a motor or a plunger or a spring or any obvious functional elements capable of applying force on the deflector (50) for moving the deflector (50) between the non-operating position (50a) and the operating position (50b).

(26) In one of the embodiments of the mechanism (100a or 100b), the guiding member (60) is angularly oriented with reference to the entry direction (303). The guiding member (60) can be angularly oriented with reference to the entry direction (303) in various angular orientations, as shown in FIGS. 3e and 3f.

(27) In one more embodiment of the mechanism (100a or 100b) (FIG. 3g), an angle (67) between a direction of extension (63) of the guiding member (60) and a direction of extension of the knife blade (211) is in a range of 20 to 160 degree in an anti-clock wise direction (69).

(28) In one more embodiment of the mechanism (100a or 100b) (FIGS. 4a and 4b), the mechanism (100a or 100b) includes a fulcrum lever (70) pivotally connected to the frame (201) of the knife folder (200) at a pivotal pin (71). The deflector (50) is mounted on a first bar end (72) of the fulcrum lever (70). The first bar end (72) is a non-pivoted end of the fulcrum lever (70). The fulcrum lever (70) enables revolving movements of the deflector (50) between the non-operating position (50a) and the operating position (50b) around the pivotal pin (71) when an external force applied on the fulcrum lever (70) accordingly. When the deflector (50) is at the operating position (50b), the first bar end (72) is at a predefined second distance (74) from the roller gap (232). The external force can be applied manually.

(29) In an embodiment of the fulcrum lever (70a) (as shown in FIG. 4c), the fulcrum lever (70a) has a handle (73) extending from the first bar end (72) away from the first bar end (72). The handle (73) is accessible to a user to apply force on the fulcrum lever (70a) to revolving the deflector (50) between the non-operating position (50a) and the operating position (50b).

(30) In one more embodiment (as shown in FIG. 4d), the fulcrum lever (70) is connected to a second force applying unit (78). The second force applying unit (78) is a motor or a plunger or a spring or any obvious functional elements capable of applying force on the fulcrum lever (70) for moving the deflector (50) between the non-operating position (50a) and the operating position (50b). Further, the mechanism (100a and 100b) has two or more stoppers (76a and 76b) (FIGS. 4a and 4b) extending from the frame (201) for restricting revolving movements of the deflector (50) beyond the non-operating position (50a) and the operating position (50b). The stoppers (76a and 76b) are mechanical.

(31) In one more embodiment of the mechanism (100a or 100b) (FIG. 5a), the deflector end (20) has a concave surface face (22). The concave surface face (22) is projected away from the deflector (50). The concave surface face (22) includes a centre concave portion (22a) and a lower concave surface (22b). The centre concave portion (22a) is adapted to stop the linear movement of the intermediate item (300) in the entry direction (303) when the moving intermediate item (300) touches the centre concave portion (22a) (FIG. 5a). The lower concave surface (22b) is adapted to deviate the movement of the intermediate item (300) towards the roller gap (232) (FIG. 5b).

(32) In one more embodiment of the mechanism (100a or 100b), the deflector end (30) has a straight-line surface face (32) (FIGS. 6a and 6b). The straight-line surface face (32) is projected away from the deflector (30). The straight-line surface face (32) includes a centre portion (32a) and a lower straight surface (32b). The centre portion (32a) (FIG. 6a) is adapted to stop the linear movement of the intermediate item (300) in the entry direction (303) when the moving intermediate item (300) touches the centre portion (32a). The lower straight surface (32b) adapted to deviate the movement of the intermediate item (300) (FIG. 6b) towards the roller gap (232).

(33) In one more embodiment of the mechanism (100a or 100b), the deflector end (20 or 30) is angularly oriented from a direction of extension (23 or 33) of the deflector (20 or 30). The deflector end (20 or 30) is angularly oriented from the direction of extension (23 or 33) of the deflector (20 or 30) in various angular orientations, as shown in FIGS. 7a, 7b & 7c.

(34) The deflector (50) is moved between the non-operating position (50a) and the operating position (50b) with various types of movements (sliding, revolving) various possible functional elements such as the guiding member (60), the fulcrum lever (70) and the deflector end (20 and 30) as shown in FIGS. 3a, 3b, 3c, 3d, 3e, 3f, 3g, 4a, 4b, 4c, 4d, 5a, 5b, 6a, 6b, 7a, 7b & 7c based on the availability of space in the knife folder (200) and other deterministic factors.

(35) In one more embodiment of the mechanism (100a or 100b), the mechanism (100a or 100b) includes a latching unit (95) (FIGS. 8a and 8b) for latching the deflector (50) at a position between the operating position (50b) (FIG. 8b) or the non-operating position (50a) (FIG. 8a). The latching unit (95) can be a grub screw or a plunger lock, or any other latching unit adapted to latch the mechanism (100a or 100b) at the position between the operating position (50b) and the non-operating position (50b). The position can be at the operating position (50b) or the non-operating position (50b).

(36) Referring now to FIGS. 9a & 9b, schematic views of one of the embodiments of the mechanism (100a) in accordance with the present invention are illustrated. In the mechanism (100a), the deflector (50) is moved to the operating position (50b) when the knife blade (210) is at the non-operating knife position (210a) (FIG. 9a). The deflector (50) is moved to a non-operating position (50a) when the knife blade (210) is at the operating knife position (210b) (FIG. 9b). In the existing knife folder (200), the knife blade (210) is connected to a slider-crank mechanism (250) for moving the knife blade (210) between the non-operating knife position (210a) and the operating knife position (210b). A rotating member (252) of the slider-crank mechanism (250) is connected to a motor (254) for providing rotational motions to the slider-crank mechanism (250). In an alternate embodiment, the slider mechanism (250) can also be driven by a Pneumatic or a hydraulic or an electric actuator.

(37) The functioning of the motor (254) is stopped accordingly to stop the knife blade (210) at the non-operating knife position (210a) (FIG. 9a). A person ordinarily skilled in the art is aware to stop functioning of the motor (254) accordingly stop the knife blade (210) at the non-operating knife position (210a).

(38) Also, when the deflector (50) is at the operating position (50b), a connection (254b) between the motor (254) and the rotating member (252) can be decoupled for restricting the movements of the knife blade (210) towards the operating knife position (210b). The connection (254b) can be decoupled when the knife blade (210) is at the non-operating knife position (210a).

(39) Referring now to FIGS. 10a, 10b & 10C, schematic views of one of the embodiments of the mechanism (100b) in accordance with the present invention are illustrated. In the mechanism (100b), when the deflector (50) is at the operating position (50b) if the knife blade (210) is moving towards the operating knife position (210b) (FIGS. 10a and 10b), the knife blade (210) is moved backwards from an interference position (90) (FIG. 10b) towards the non-operating knife position (210a) (FIG. 10a). The interference position (90) is a position where the deflector (50) and the knife blade (210) have a physical contact therebetween.

(40) More specifically, the mechanism (100b) includes a first controller (82), a second controller (84) and a detecting unit (86). The first controller (82) is connected to the deflector (50) for controlling movements of the deflector (50) between the non-operating position (50a) and the operating position (50b). The first controller (82) can be a mechanical controller such as a brake, a stopper and the like. The second controller (84) is connected to the knife blade (210) for controlling movements of the knife blade (210) between the non-operation knife position (210a) and the operation knife position (210b). In the existing knife folder (200), the knife blade (210) is connected to a slider-crank mechanism (250) for moving the knife blade (210) between the non-operating knife position (210a) and the operating knife position (210b) and a rotating member (252) of the slider-crank mechanism (250) is connected to a motor (254) for providing rotational motions to the slider-crank mechanism (250); then the second controller (84) is a controlling unit which controls the rotation of the motor (254). The second controller can be an electronic controller having a set of hardware and a set of software to control the rotation of the motor.

(41) The detecting unit (86) can be a position sensor or an interference detection sensor. The detecting unit (86) is connected to the second controller (84) to provide information about the position of the knife blade (210) at the interference position (90) to the second controller (84). The second controller (84) is adapted to move the knife blade (210) backwards from the interference position (90) towards the non-operating knife position (210a). The position of the interference position (90) with respect to a reference (90a) depends on various parameters such as the geometry of the deflector (50) and the knife blade (210), the speed of the movements of the deflector (50) and the knife blade (210) and the like. The reference (90a) is any member of the knife folder (200), which is not having a relative motion with respect to any other links of the knife folder (200).

(42) Hence, the position of the interference position (90) with respect to the reference (90a) is obtained by performing operation trails of the mechanism (100a or 100b) by moving the configured deflector (50) between the non-operating position (50a) and the operating position (50b), and the knife blade (210) is movable between a non-operating knife position (210a) and an operating knife position (210b) at predefined speeds.

(43) Therefore, the present invention has the advantage of providing the mechanism (100a or 100b) for preventing the folding of the intermediate item (300) in the knife folder (200). As the deflector (50) moves the received intermediate (300) away from the knife folder (200) without allowing a folding operation by the knife blade (210), the unfolded intermediate item (300) moves away from the knife folder (200). The mechanism (100a or 100b) prevents the folding of the intermediate item (300) in the knife folder (200) even if the intermediate item (300) is transferred to the knife folder (200). Therefore, the mechanism (100a or 100b) avoids the need of removing the knife folder (200) from machinery (not shown) between two other machines of the machinery when there is a need to prevent folding of the intermediate item in the knife folder, thereby reduces the duration of the machine set up time.

(44) The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to explain best the principles of the present invention and its practical application and enable others skilled in the art to utilise best the present invention and various embodiments with various modifications suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.