Abstract:
A press and a method for assembling the same are provided. The press includes a first plate, a second plate, and a coupling portion. The first plate includes a first side, a second side, and a substantially convex surface extending therebetween. The convex surface includes a plurality of openings extending therethrough that provide a vacuum force. The second plate includes a first side, a second side, and a substantially flat surface extending therebetween. The coupling portion couples the first plate to the second plate such that the first side of the first plate and the first side of the second plate are substantially aligned.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Provisional Application No. 61/267,674, filed Dec. 8, 2009, which is hereby incorporated by referenced in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The field of the invention relates generally to presses and, more particularly, to a sign press including a vacuum system and method for assembling the same. 
       BACKGROUND OF THE INVENTION 
       [0003]    Known sign presses include a first plate and a second plate, wherein the first plate is pressed against the second plate to couple a first layer to a second layer. At least one known sign press includes a vacuum system that facilitates retaining the first layer against the first plate and the second layer against the second plate. Improper alignment of the first and second layers and/or adjustment of the first and second plates may result in an inadequate press. 
       BRIEF SUMMARY OF THE INVENTION 
       [0004]    In one aspect, a press is provided. The press includes a first plate, a second plate, and a coupling portion. The first plate includes a first side, a second side, and a substantially convex surface extending therebetween. The convex surface includes a plurality of openings extending therethrough that provide a vacuum force. The second plate includes a first side, a second side, and a substantially flat surface extending therebetween. The coupling portion couples the first plate to the second plate such that the first side of the first plate and the first side of the second plate are substantially aligned. 
         [0005]    In another aspect, a method is provided for assembling a press. The method includes providing a first plate and providing a second plate. The first plate includes a first side, a second side, and a substantially convex surface extending therebetween. The convex surface includes a plurality of openings extending therethrough that are configured to provide a vacuum force. The second plate has a first side, a second side, and a substantially flat surface extending therebetween. The first plate is coupled to the second plate using a coupling portion such that the first side of the first plate and the first side of the second plate are substantially aligned. 
         [0006]    The features, functions, and advantages that have been discussed can be achieved independently in various embodiments of the present invention or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a front side perspective view of a press according to an exemplary embodiment of the present invention; 
           [0008]      FIG. 2  is a right side perspective view of the press shown in  FIG. 1 ; 
           [0009]      FIG. 3  is a top perspective view of a first plate of the press shown in  FIG. 1 ; 
           [0010]      FIG. 4  is a front side perspective view of the first plate shown in  FIG. 3 ; 
           [0011]      FIG. 5  is a right side perspective view of the first plate shown in  FIG. 3 ; and 
           [0012]      FIG. 6  is a top perspective view of a second plate of the press shown in  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0013]      FIGS. 1 and 2  show a sign press  100  positioned on a supporting surface  102 . Sign press  100  includes a first plate  104  and a second plate  106 . Second plate  106  includes at least one coupling portion  108  that is configured to couple second plate  106  to first plate  104 . Sign press  100  is configured to press a vinyl layer (not shown) onto a substrate (not shown). More specifically, the vinyl layer is positioned on first plate  104 , the substrate is positioned on second plate  106 , and sign press  100  is configured to press the vinyl layer onto the substrate. 
         [0014]      FIGS. 3-5  show first plate  104  having a first side  110 , an opposing second side  112 , and a bottom surface  114  that extends from first side  110  to second side  112 . In the exemplary embodiment, first plate  104  is oriented such that bottom surface  114  faces second plate  106 . In the exemplary embodiment, bottom surface  114  is fabricated from a tolerant material, such as rubber, that facilitates applying a uniform pressure across an uneven surface to reduce a probability of forming air bubbles between the vinyl layer and the substrate. 
         [0015]    Bottom surface  114  includes a substantially convex profile having a substantially consistent arc that extends from first side  110  to second side  112 . The substantially consistent arc of bottom surface  114  enables moving first plate  104  across second plate  106  in a rolling motion to facilitate reducing a probability of forming air bubbles between the vinyl layer and the substrate. 
         [0016]    Bottom surface  114  defines a plurality of openings  116  that are configured to provide an adjustable vacuum force on bottom surface  114  to facilitate retaining various sizes of vinyl layers. More particularly, in the exemplary embodiment, first plate  104  is configured to be coupled to a vacuum device (not shown) that is configured to pull air from openings  116  to create the vacuum force on bottom surface  114 . In the exemplary embodiment, openings  116  are evenly distributed across bottom surface  114  such that bottom surface  114  is configured to retain the vinyl layer with a substantially uniform vacuum force. 
         [0017]    In one embodiment, the vacuum force may be increased to retain a relatively large vinyl layer and/or decreased to retain a relative small vinyl layer. Additionally or alternatively, each opening  116  may be selectively openable and/or closeable, such that a portion of bottom surface  114  has a vacuum force. For example, in such an embodiment, first plate  104  includes a control mechanism (not shown) such as, without limitation, a knob, a slide, and/or a lever that is configured to selectively open and/or close at least one opening  116 . In such an embodiment, selectively opening and/or closing openings  116  may adjust the vacuum force at desired portions of bottom surface  114  independent of adjusting the vacuum force at the vacuum device. 
         [0018]    First plate  104  includes at least one first flange  118  that extends from first side  110  and at least one second flange  120  that extends from second side  112 . In the exemplary embodiment, a first handle  122  is coupled to first flange  118 , and a second handle  124  is coupled to second flange  120 . In an alternate embodiment, handles  122  and  124  are coupled to any suitable location of first plate  104 . Handles  122  and  124  facilitate handling first plate  104 . Notably, in the exemplary embodiment, handles  122  and  124  perform substantially similar functions and may be used interchangeably within the detailed description of the invention. In the exemplary embodiment, each handle  122 ,  124  includes at least one spacer  126  that enables maintaining a distance between the respective handle  122 ,  124  and supporting surface  102 . 
         [0019]      FIG. 6  shows second plate  106  having a first side  128 , an opposing second side  130 , and a top surface  132  that extends from first side  128  to second side  130 . In the exemplary embodiment, second plate  106  is oriented such that top surface  132  faces first plate  104  and, more specifically, bottom surface  114 . 
         [0020]    Top surface  132  has a substantially flat profile. In the exemplary embodiment, top surface  132  includes a plurality of fillers  134 . Fillers  134  are configured to provide a suitable thickness for top surface  132  to employ various substrate thicknesses ranging from 10 mil (0.01 in.) to three-fourths of an inch (0.75 in.). 
         [0021]    In one embodiment, at least one filler  134  and/or substrate may be moveable between a first position and a second position, such that the at least one filler  134  and/or substrate is easily accessible to a user for installation and/or withdrawal in the first position, and the at least one filler  134  and/or substrate is suitably retained for use on second plate  106  in the second position. For example, second plate  106  may include a centering device (not shown) coupled to an actuator (not shown) such as, without limitation, a pedal that is configured to selectively move the at least one filler  134  and/or substrate between the first position and the second position. 
         [0022]    Second plate  106  includes a retaining mechanism  136  configured to secure the substrate on top surface  132 . More specifically, retaining mechanism  136  is a spring-loaded arm that is suitably securable in various positions to facilitate retaining various sizes of substrates. In the exemplary embodiment, retaining mechanism  136  is coupled along second side  130 . In an alternate embodiment, retaining mechanism  136  is coupled to any suitable location of second plate  106 . 
         [0023]    Coupling portion  108  enables sign press  100  to be convertible between a first configuration and a second configuration. Coupling portion  108  includes at least one flange  138  that is configured to be coupled to one of first handle  122  and second handle  124 . More specifically, in the first configuration, coupling portion  108  is configured to couple to first side  110  of first plate  104  via first handle  122 . In the second configuration, coupling portion  108  is configured to couple second side  112  of first plate  104  via second handle  124 . 
         [0024]    Sign press  100  is positionable between an open configuration and a closed configuration. More specifically, in the open configuration, first plate  104  is positioned at an obtuse angle with respect to second plate  106 , wherein handle  122  is the vertex. Additionally, in the closed configuration, first plate  104  is positioned at a negative angle with respect to second plate  106 , wherein handle  122  is the vertex. 
         [0025]    During operation, the vacuum device pulls air from openings  116  defined by bottom surface  114  to create the vacuum force on bottom surface  114 . With sign press  100  in the open configuration, the vinyl layer is positioned on bottom surface  114  and is retained by the vacuum force. More specifically, the vinyl layer has a finished side and an adhesive side, and the finished side of the vinyl layer is positioned directly against bottom surface  114  such that the adhesive side of the vinyl layer faces away from bottom surface  114 . 
         [0026]    The substrate is positioned on top surface  132  and is retained by retaining mechanism  136 . More specifically, in the exemplary embodiment, at least one filler  134  provides a suitable thickness for top surface  132 , and the substrate is placed on top surface  132 . Moreover, in the exemplary embodiment, retaining mechanism  136  retains the substrate against top surface  132  such that the substrate is restricted from lateral movement. 
         [0027]    With the vinyl layer and the substrate secured by first plate  104  and second plate  106 , respectively, sign press  100  presses bottom surface  114  towards top surface  132 . More specifically, in the exemplary embodiment, the convex profile of first plate  104  facilitates pressing the vinyl layer against the substrate along a line of pressure that is parallel to handle  122 . 
         [0028]    First plate  104  moves in a rolling motion such that the line of pressure moves from first sides  110 ,  128  to second sides  112 ,  130  to reduce a probability of forming air bubbles between the vinyl layer and the substrate. As the line of pressure presses the adhesive side of the vinyl layer against the substrate, the vinyl layer detaches from bottom surface  114  and couples to the substrate because the adhesive force between the vinyl layer and the substrate is greater than the vacuum force retaining the vinyl layer against bottom surface  114 . 
         [0029]    Sign press  100  is moved from the open configuration to the closed configuration such that first plate  104  is rotated about handle  122 . As sign press  100  moves from the open configuration to the closed configuration, coupling portion  108  is configured to move handle  122  in an upward direction such that a distance from first side  110  of first plate  104  moves away from first side  128  of second plate  106 . Moreover, as sign press  100  moves from the closed configuration to the open configuration, coupling mechanism is configured to move handle  122  in a downward direction such that first side  110  of first plate  104  moves toward first side  128  of second plate  106 . 
         [0030]    To facilitate pressing the adhesive side of the vinyl layer against the substrate, sign press  100  may be converted between the first and second configurations. For example, in the exemplary embodiment, to convert sign press  100  from the first configuration to the second configuration, coupling portion  108  is decoupled from first side  110  and positioned along second side  112 . More specifically, coupling portion  108  is coupled to second side  112  of first plate  104  via second handle  124 . Moreover, in the exemplary embodiment, to convert sign press  100  from the second configuration to the first configuration, coupling portion  108  is decoupled from second side  112  and positioned along first side  110 . More specifically, coupling portion  108  is coupled to first side  110  of first plate  104  via first handle  122 . 
         [0031]    After sign press  100  has fully pressed the vinyl layer onto the substrate, sign press  100  is returned to the open configuration and the coupled vinyl layer and substrate are removed from sign press  100 . 
         [0032]    Exemplary embodiments of the press and methods for assembling the same are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of the systems and steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods and systems described herein may have other industrial and/or consumer applications and are not limited to practice with presses as described herein. Rather, one or more embodiments described herein may be implemented and utilized in connection with many other industries. 
         [0033]    As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly stated. Further, references to “one embodiment” are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising,” “including,” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. 
         [0034]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.