Abstract:
A cutter system for cutting a larger sheet into individual photographic images includes a cutter for severing a transverse strip containing one or more printed images from a larger sheet. A transport table positioned to receive the strip from the cutter includes two sets of drivers, one set for moving the strip longitudinally and a second set for moving the strip laterally to a second cutter that in turn separates the strip into individual photographs. Sensors in both cutters acting in response to fiducial marks on the larger sheet cooperate with the drivers for positioning the larger sheet and the severed strip at the proper cutting locations.

Description:
CROSS REFERENCE TO RELATED CASES 
     The application is related to copending application Ser. No. 10/020,397 filed Dec. 12, 2001. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a method and apparatus for cutting a plurality of photographic prints from a larger sheet. 
     BACKGROUND OF THE INVENTION 
     It is conventional in photofinishing systems to use rolls of photographic paper that are the exact width of the finished print. Individual prints are cut from the roll with a single cross cut. Conventional systems also can produce prints of various lengths. This is done to accommodate modern cameras that include the capability of recording images of various selected lengths. For example the camera user can select any one of several lengths of images ranging from a wide-angle image to a much shorter image. However, each print produced by conventional photofinishing systems must be of the same width. 
     A change in the desired width of the print requires changing the width of the print medium. This has been done by manually changing the roll of photographic paper being used or by designing a photofinishing machine that has multiple feed units each stocked with a specific width of photographic paper. An alternative approach is to use multiple feed trays each stocked with single sheets for making a single print of a given size. This eliminates the need for cross cutting the print from a roll but still limits size selection to the exact size loaded into the selected feed tray. 
     Recent advances in photofinishing allow for the production of photographs by ink jet printers, laser printers and other photofinishing printer systems not dependent on traditional wet chemistry. Moreover, the use of computers in connection with these advancements allows for further improvement. For example, it is not necessary to use roll stock having the width of the desired photograph. A photofinishing printer can now generate photos of various sizes on a single sheet of print media. Also the images can be manipulated to arrange photos of different sizes on a single sheet. 
     The throughput speed of an ink jet printer, laser printer or the like is dependent upon the width of the printed page in that the use of a wider paper allows for an increase in the printed area per unit of time. When using such a printer, it is preferred as a matter of convenience to feed the printer with sheets of a single width. This presents the problem of severing multiple images of various widths from a single larger sheet. 
     Accordingly, it is an object of the present invention to provide a method and apparatus for cutting prints of various sizes from a larger sheet. 
     Another object is to provide a method and apparatus for orthogonally moving a sheet beneath cutters in order to sever prints of various widths from a larger sheet. 
     A further object of the present invention is to provide a method and apparatus for cutting prints of various sizes from a larger sheet including a transport mechanism for moving a sheet beneath orthogonally arranged cutters. 
     OBJECTS OF THE INVENTION 
     Briefly, the method and apparatus of the present invention operates on a sheet containing an array of smaller images. The sheet is provided by a photofinishing system that prints a set of images on a larger sheet having a defined length and width. The prints are arranged on the sheet in rows and the prints in each row share a common dimension, either width or length. Also the prints are aligned in the row such that the common dimension extends longitudinally. With this arrangement, the photographs in each row have leading and trailing edges that are aligned. The sheet is moved longitudinally into a cutter and as the sheet enters an inlet end of the cutter, the sheet is clamped and a transverse cut is made. The transverse cut severs a strip containing a row of photographs. The strip of photographs then is moved in a transverse direction towards an outlet end of the cutter and is advanced through the outlet end in a stepwise fashion. With each pause in the stepwise advance, the strip is clamped and a lateral cut is made to sever an individual print from the strip. The process then repeats for the next row of prints on the sheet. 
     Accordingly, the present invention may be characterized in one aspect thereof by a method for separating a sheet of photographic prints into individual prints comprising: 
     a) providing a sheet of photographic prints wherein the prints are arranged on the sheet in an orthogonal pattern composed of transverse rows, the prints defining each transverse row having aligned leading and trailing edges; 
     b) moving the sheet longitudinally along a first path of travel into a cutter inlet end; 
     c) cutting the sheet at the inlet end along a line perpendicular to the first path of travel to sever from the sheet a first strip containing a first row of prints; 
     d) moving the severed strip to a cutter outlet end along a second path of travel that is perpendicular to the first path of travel; 
     e) advancing the strip through the outlet end in a stepwise fashion that pauses the movement at a lateral edge of each print; and 
     f) cutting the strip at each pause in the movement along a line perpendicular to the second path of travel to sever individual prints from the strip. 
     In another aspect the present invention may be characterized by an apparatus for separating a sheet of photographic prints into individual photographs comprising: 
     a) a cutter table having an inlet end and a distal outlet end, the outlet end being arranged orthogonally to the inlet end; 
     b) a sheet driver for moving a sheet of photographs longitudinally along a first path of travel into a cutter inlet end, the photographs being arranged on the sheet in an orthogonal pattern composed of transverse rows, the prints defining each transverse row having aligned leading and trailing edges; 
     c) a first cutter at the inlet end for cutting the sheet along a line perpendicular to the first path of travel to sever from the sheet a strip containing a first row of prints; 
     d) a first set of strip movers on the table for moving the severed strip in the direction of the first path of travel to an end of the table opposite the inlet end; 
     e) a second set of strip movers on the table for advancing the strip in a stepwise fashion to a cutter outlet end along a second path of travel that is perpendicular to the first path of travel, each stepwise advance being followed by a pause for locating a lateral edge of a print at the outlet end; and 
     f) a second cutter at the outlet end operable during a pause in the stepwise advance to cut the strip along a lateral edge of a print that is perpendicular to the second path of travel to separate individual prints from the strip. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIGS. 1-6 are schematic plan views showing a transport table and steps in the cutting of individual prints from a single sheet containing a plurality of photographic prints; 
     FIG. 7 is a front elevation view, partly broken away and in section showing a cutter at the inlet end of a transport table; 
     FIG. 8 is an isometric view showing a portion of the cutter at the inlet end from a reverse angle; 
     FIG. 9 is a view taken along lines  9 — 9  of FIG. 1 on an enlarged scale showing a schematic representation of additional components of the transport table not seen in FIG. 1; and 
     FIG. 10 is a view similar to FIG. 7 only showing a portion of a cutter at an exit end of the table. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings, FIGS. 1-6 shows a sequence of steps for severing individual prints from a sheet  11  containing a plurality of prints. In this respect the cutter and transporter of the present invention, portions of which is indicated at  10 , includes a transport table  12 . The table has an inlet end  14  at one side, an opposite end  16  and an exit end  18  disposed at the rear of the table orthogonal and adjacent to the inlet end. While not limited to size, an embodiment of the invention has a table that is of a size able to accommodate a web width of about 28 to 32 cm and a full web length of up to about 51 cm. 
     Incorporated into the transport table  12  is a driver system for moving a sheet first longitudinally from the inlet end  14  to the opposite end  16  and then transversely along the opposite end  16  to the table exit  18 . Portions of the driver system as shown in FIG. 1 include a plurality of longitudinally spaced driven rollers  20 . The rollers preferably are arranged in pairs and are disposed for moving a sheet along the table in a longitudinal path of travel indicated by arrow  22  that extends from the inlet end  14  and towards the opposite end  16 . These rollers  20  extend through openings in the table and are grouped generally towards the front of the table as viewed in FIG.  1 . 
     A second set of driven rollers  24 , also extending through openings in the table, are arranged for moving a sheet along a second path of travel indicated by arrow  26  that is perpendicular to the first path in a transverse direction across the table and towards the table exit  18 . As shown in FIGS. 1,  4  and  5 , the second set of driven rollers  24  is arranged along side the first set of driven rollers  20  and extend substantially the full length of the table from the inlet end  14  to the opposite end  16 . 
     As best seen in FIG. 9, a housing  19  is disposed over the table (the housing being removed from FIGS. 1-6 for viewing the table). Supported within the housing are first and second sets of idler pinch rollers  44 ,  46  respectively. The set of idler pinch rollers  44  is arranged for movement so as to create a nip with the driven rollers  20 . Forming the nip acts to drive a sheet caught in the nip in a longitudinal direction across the transport table (in the direction of arrow  22  in FIG.  1 ). The second set of idler pinch rollers  46  is arranged for movement so as to create a nip with the driven rollers  24 . This acts to drive a sheet caught in the nip in a transverse direction across the table and towards the exit  18  in the direction of arrow  26  (FIG.  1 ). The two sets of idler rollers  44 ,  46  are independently controlled so that there is selected movement in both the longitudinal and transverse directions. 
     Disposed adjacent both the table inlet and outlet ends  14 ,  18  are cutter mechanisms  28 ,  30  respectively. Located in advance of cutter  28  is a sensor  27  such as an LED emitter-detector. A similar sensor  29  is located in advance of cutter  30  (FIG.  1 ). Both sensors  27 ,  29  are connected to a controller  49  for purposes set out hereinbelow. The cutter mechanisms  28 ,  30  have substantially the same construction so only cutter mechanism  28  is described in detail. As seen in FIGS. 7, and  8 , cutter mechanism  28  at the inlet end includes a rotary knife  32  that is supported on a mandrel  34  extending perpendicular to the first path of travel  22 . The knife is movable along the mandrel and against an anvil  36  for shearing off a piece of the sheet  11 . Preceding the knife along the path of travel is a set of paper clamps  38 . 
     Clamps  38  are mounted for pivotal movement between open and a closed position. Each clamp includes a foot portion  39  that in the closed position (as shown in the Figures) bear against the anvil  36 . In the closed position the feet  39  operate to apply a force for holding the sheet  11  against the anvil  36  and in position during a cutting operation. Following the knife along the path of travel is a waste collector generally indicated at  40  (a similar waste collector  45  being associated with cutter  30 ). The waste collector is arranged to receive any portion of the sheet that is removed by the cutter mechanism. In this respect the waste collector is disposed generally below the anvil  36  and includes a pair of counter rotating augers  41 . These augers insure that any piece cut from the sheet by the rotating knife  32  is drawn downwards through an opening  42  and into a waste receptacle  43 . 
     To complete the construction, each cutter mechanism includes a registration roller  48  that nips with a pinch roller  50  for delivering a sheet  11  to the cutter as described hereinbelow. Preferably, a stepper motor (not shown) drives the registration roller. The stepper motor for driving the registration roller  48  is controlled in part by a controller  49  that receives an input from sensors  27  and  29 . 
     Operation will be described with reference to FIGS. 1 and 7 as beginning with a sheet  11  being delivered to the cutter mechanism. The sheet contains a plurality of individual photographic prints  52  applied by an ink jet printer or the like. As shown in FIG. 1, the sheet measures about 33×50.8 cm and contains an array of nine individual prints each measuring about 10.16×15.24 cm. The prints are arranged in an array that contains rows  53 A, B and C extending across the sheet and columns extending along the sheet. The prints in each row have aligned leading and trailing edges  54 ,  56  respectively and the prints in each column have aligned lateral edges  58 . It should be appreciated that while nine similar size prints are shown, prints of various sizes can be arranged on the sheet so long as the prints in each row have one dimension (either length or width) in common so as to present aligned leading and trailing edges  54 , 56 . The second dimension (length or width) of the prints in each row can vary. If all the prints are of equal size as shown, the columns will have aligned lateral edges  58 . However, each row can contain images of various sizes and where the prints do not have a second dimension in common the lateral edges  58  will not be aligned. For example, given a sheet  11  that is thirteen inches wide, a first row  53 A may be printed with two 4×6 images; or a 4×6 image and two 4×3 images; or a 4×9 image and a 4×3 image. A next row  53 B might contain two 5×7 images; or a single 8×10 or 5×12 image. It only is important that the images in each row have one dimension in common and that the sum of the second dimensions plus the trim waste does not exceed the width of sheet  11 . 
     Preferably each image is slightly oversize to allow for a non-precision cut location. Also, the array of prints on the sheet is surrounded by a fiducial mark. A first fiducial mark  60  comprises a dark transverse stripe located in advance of the leading edge  54  of the first row  53 A of prints. This fiducial mark provides for the detection of the first row of prints entering the transport table inlet end  14 . A second fiducial mark  61  comprising a dark longitudinal stripe extends the length of the sheet  11  adjacent at least one side of the sheet, preferably the side towards the rear of the transport table. The fiducial mark  61  lies between the sheet edge and the lateral edge  58  of the column of prints adjacent this sheet edge. 
     The sheet is delivered to the cutter mechanism  28  by a carrier, a portion of which is shown at  25  that is operated by the controller  49  (FIG.  1 ). It should be noted that as part of the operation for printing the images on the sheet, the controller is provided with a memory of the print layout. This memory, for example, includes information as to the distance between the leading and trailing edges  54 ,  56  of each row  53 A, B and C as well as the length in the transverse direction of each print in each row. 
     As the sheet approaches the cutter, the sensor  27  first detects the leading edge of the sheet and then the fiducial mark  60 . The distance between the sheet leading edge and the fiducial mark is communicated to the controller. The carrier  25 , continuing its operation, delivers the sheet to the nip between the registration roller  48  and pinch roller  50 . When the leading edge of the sheet butts the nip at the registration roller  48 , the carrier  25  is slightly overdriven. This creates a slight buckle near the leading edge to insure that it is seated properly in the nip. The registration roller then is driven, preferably by a stepper motor (not shown) under the control of controller  49  to draw the sheet  11  into cutter mechanism  28 . Since the distance between the leading edge of the sheet and the fiducial mark  60  has been communicated to the controller  49 , the stepper motor is operated by the controller to drive the registration roller  48  and advance the sheet into the cutter to a first cut position (FIG.  2 ). At the first cut position, the leading edge of the first row  53 A of prints is disposed at the edge of the anvil and below the knife  32 . The clamps  38  then are pivoted to a closed position, which clamps the sheet to the anvil. After clamping, the knife  32  is drawn along the support mandrel  34  to make an initial cut. 
     The initial cut removes a strip from the sheet including the fiducial mark  60  and a small portion of the over printing to the trailing side of the fiducial mark. The cut off strip drops into the waste collector  40  aided by augers  41  (FIG. 7) that pull the waste through the opening  42  and into the receptacle  43 . 
     After the initial cut is made, the clamps are pivoted to an open position to release the sheet. The stepper motor for driving the registration roller is again activated. The controller  49  next causes the registration roller to draw the sheet to a position for making a second cut and stops. As noted above, the length of the first row  53 A (distance between leading edge  54  and trailing edge  56 ) is a known dimension. Accordingly the registration roller  48  is operated by the stepper motor under the control of the controller  49  so as to index the sheet a distance sufficient to locate the trailing edge of the first row at the cutting location. The clamps  38  again are pivoted into a clamping position to hold the sheet for the second cut. The second cut is performed as before. In making the second cut, the knife cuts into the overprinted area at the trailing edge of the row so the first row  53 A of prints is severed from the sheet. At this point the registration roller operates to move the strip comprising the first row of prints  53 A onto the cutter transport table  12  (FIG.  3 ). 
     As the strip is moved onto the cutter table  12 , the idler rollers  44  are lowered and the driven rollers  20  (also under the control of controller  49 ) are powered for moving the strip longitudinally across the transport table to the opposite end  16  (FIG.  4 ). The translation longitudinally across the transport table stops when the strip contacts a stop  51  at the opposite end  16  or a sensor (not shown) detects the leading edge  54  of the strip (FIG.  3 ). Either event triggers the lifting of the longitudinal idler rollers  44  and stops the rotation of the driven rollers  20 . 
     The lateral idler pinch rollers  46  (FIG. 9) then are lowered to press against the strip and power is applied to the driven lateral rollers  24  to move the strip in a transverse direction across the transport table as shown by arrow  26  and into the cutter  30  (FIG.  4 ). As the strip approaches the cutter  30 , the sensor  29  first detects the lateral edge of the sheet and then the fiducial mark  61 . The distance between the lateral edge and the fiducial mark is communicated to the controller  49 . The lateral rollers  24  continue to move the strip into the cutter until the edge is driven into the registration nip between the registration roller  48 ′ and the pinch roller  50 ′ in cutter  30  (FIG.  10 ). At this point the registration roller is stationary and the lateral drive rollers  24  are over driven to create a small buckle or loop  62  in the strip as shown in FIG.  10 . 
     Overdriving the lateral roller  24  to create the buckle insures that the edge of the strip is well referenced to the registration roller  48 ′ and insures a proper orthogonal orientation of the strip prior to being drawn into the cutter. After the buckle is created, the lateral roller  24  is stopped and the registration roller  48 ′ is activated. The idler pinch rollers  46  are kept in contact with the driven roller  24  until after the edge of the strip has been pulled in to the nip with the registration roller  48 ′. This insures no loss of location. The pinch idler rollers  46  are then released so the registration roller  48 ′ can draw the strip into the cutter. 
     Since the distance between the edge of the strip and the fiducial mark  61  is known, the registration roller  48 ′ can be operated to position the strip at the appropriate cutting position. Clamps in the cutter  30  similar to clamps  38  are pivoted to a closed position to clamp the strip at the cutting position. A first cut that includes a portion of the over printing then is made and the leading edge waste is drawn into a waste collector  64  adjacent the transport table outlet end  18 . 
     The registration roller in cutter  30  is again activated to advance the strip farther into the cutter mechanism  30  by a distance sufficient to locate the trailing edge of the image at a cutting location. Since the width of the print is known, the registration roller within the cutter  30  under the control of a stepper motor (not shown) can advance the strip so as to position the trailing edge of the print for a second cut. Making the second cut separates a first print  52  in the row and the print, now cut to size, is delivered to a print stacker (not shown) at the outlet end  18  of the transport table  12  (FIG.  6 ). 
     Additional lateral advances and cuts are made until all of the photographic images in the first row  53 A are separated and trimmed to size. The next cycle then begins with the longitudinal advance of the next row  53 B of prints into the cutter  28 . 
     Accordingly, it should be appreciated that the present invention accomplishes its intended objects in providing a method and apparatus for cutting prints of various sizes from a larger sheet. The apparatus provides for the movement of a sheet of prints along orthogonal paths of travel so that the proper cuts can be made to sever prints of various widths from a larger sheet. The transport table  12  includes roller arrangements that are selectively engaged for moving a sheet in two directions across the transport table. Cutter mechanisms adjacent the inlet and out let end of the transport table include means that cooperate with fiducial marks on the sheet of prints. The cooperation provides for locating the sheet at the proper cutting locations first for severing a strip of photos from the sheet and then severing individual photos from the strip. 
     Having described the invention in detail, what is claimed as new is: