Abstract:
A system for punching at least one hole in at least one sheet-like material. In particular, a device and system that is uniquely configured and sized to be a table top unit for automatic punching of paper. The system has a sheet feeder, a sheet transport module and a punching die module that allows a punching die to be easily changed. The paper being punched by the punching die module is moved only a short distance from the sheet feeder and while the paper is still supported by the sheet feeder. The sheet feeder is located outside the system&#39;s housing to facilitate adjustment and troubleshooting. This advantageously allows for a smaller, compact unit that is effective and efficient.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to an automatic punching machine for paper. In particular, an improved punching machine that is sized to be a table top unit for entry level users in crowded environments. 
       BACKGROUND OF THE INVENTION 
       [0002]    Punch machines are commonly used in business and commercial uses for punching holes in paper for mechanical binding of books. Generally automatic punch machines are large standalone units that take up a lot of space. The paper is stacked outside of the machine and is fed fully into the punching device to a punch station in order for the paper to be punched with the use of various motors. 
         [0003]    Therefore, there is a need for a compact punch device for the entry level person that is both effective and efficient. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention is a punch device that is capable of punching holes into stacks of paper. 
         [0005]    The system for punching at least one hole on at least one sheet-like material comprises a sheet feeder, a sheet transport module that receives a sheet like material from the sheet feeder and a punching die module adapted that receives the sheet-like material from the sheet transport module. 
         [0006]    The punching die module comprises a punching die having means to punch holes in the sheet-like material; a punching die table for receiving the punching die, a handle having a thickness and a plurality of apertures that extend through the thickness, a position pin having a length greater than the thickness, wherein the punching die correspondingly mates with the apertures on the handle with the position pin extending through the apertures and connecting the punching die to the handle; a locking pin extending from the handle and protruding from the bottom surface of the handle and a stop block abutting the punching die table for engaging and aligning the punching die to the punching die table. 
         [0007]    The sheet feeder of the system of the present invention comprises a feeder tray adapted to receive the sheet-like material in a horizontally stacked fashion, having means to move the sheet-like material upward and downward, an adjustable arm is positioned above the sheet-like material and is movable in a first horizontal direction and a plurality of foot pusher solenoids attached to the adjustable arm for engaging and moving the sheet-like material from the sheet feeder to the sheet transport module and a rear paper stop attached to the adjustable arm for aligning a first edge of the horizontally stacked sheet-like material. 
         [0008]    The sheet feeder of the present invention may further comprise a side jogger adapted to position above the sheet-like material movable in a second horizontal direction, a front paper stop attached to the side jogger for aligning a second edge of the horizontally stacked sheet-like material and a detection cell adapted to position above the sheet-like material for signaling the movement of the feeder tray so that the horizontally stacked sheet-like material are at a pre-determined position. 
         [0009]    The sheet transport module of the present invention comprises a main beak movable in and out in a horizontal position for pulling multiple pages of sheet-like material from the stack of sheet-like material, a separator beak attached to the main beak movable in and out in said horizontal position for separating a predetermined number of pages of sheet-like material from the stack of sheet like material, a hammer movable up and down in a vertical position for pinching the predetermined number of pages of sheet-like material separated by the separator beak and pulled by said main beak; a first pair of rollers movable up and down in a vertical position rotating in a first direction, a second pair of rollers fixedly positioned below the first pair of rollers rotating in a second direction opposite of the first direction; and a solenoid that activates the first pair of rollers and said second pair of rollers wherein the first and second pairs of rollers cooperatively engage to pinch and move the predetermined number of pages of sheet-like material from the main beak to the punching die module. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Preferred embodiments of the present invention have been chosen for purposes of illustration and description and are shown in the accompanying drawings forming a part of the specification wherein: 
           [0011]      FIG. 1  is a perspective view of the present invention with the punching die module partially extending outside the housing and is shown with a prior art sheet feeder. 
           [0012]      FIG. 2  is an enlarged perspective view of a portion of the punching die module of  FIG. 1 . 
           [0013]      FIG. 3  is an enlarged side view of a portion of the punching die module of  FIG. 1 . 
           [0014]      FIG. 4  is a perspective view of the sheet transport module and sheet feeder of the present invention, to be used in conjunction with the punching die module of  FIG. 1 . 
           [0015]      FIG. 5  is a perspective view of the side stop and paper stop of the present invention. 
           [0016]      FIG. 6  is a perspective view of the adjustable arm of the present invention and the rear stop where the paper stop is located. 
           [0017]      FIG. 7  is a perspective view of the handle and punching die of the punching die module of the present invention outside the housing. 
           [0018]      FIG. 8  is a perspective view of the punching die table and stop block of the punching die module of the present invention in the housing, with the punching die module removed from the housing. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0019]    With reference to the drawings,  FIGS. 1-4  show the mini punch system, device or machine  100  of the present invention comprises a housing  5 , a sheet feeder  10 , a sheet transport module  30 , a punching die module  40  and a paper output  20 . 
         [0020]    As shown in  FIGS. 1, 2 and 3  the punching die module  40  comprises a punching die  50  that is connected to a handle  42  that is capable of self-positioning and locking the punching die module  40  in the housing  5 . Punching die module  40  is slidably insertable to be positioned within housing  5 .  FIG. 1  shows the punching die module  40  partially extending outside the housing  5 .  FIGS. 2 and 3  are enlarged views of the portion of the punching die module  40  that is outside the housing  5  as shown in  FIG. 1 . As a lift of paper P on the sheet feeder  10  that is fed is registered against one side of the punching die module  40 , the lateral position of the punching die  50  will depend on the punching pattern, the pitch that is desired by the user, and/or the width of the sheets that are being punched so that the punched holes are correctly centered and aligned across the sheet. To achieve this, the handle  42  of the punching die module  40  has a plurality of apertures  47 , or holes, that are positioned to correspond to the standard sheet format widths for the specific punching pattern or pitch of the relevant punching die  50 . A punching die is shown in  FIG. 7 . Different punching dies  50  can be interchanged and connected to the handle  42  and used with machine  100  depending on the punching configuration the user desires. A label or indicator is provided next to the holes  47  to indicate the various formats and numbers of punching holes that correspond to the holes. For example, one format is for  32  holes positioned along a 11″ long paper with 3:1 pitch punching die  50  in the machine. The handle  42  further comprises a position pin  46  that fits within the holes  47 . The positioning pin  46  may be capped by a knob  45  to be easily manipulated by the user. It is contemplated that the knob  45  be made of plastic. The punching die handle  42  has a thickness. The length of the positioning pin  46  is greater than the thickness of the punching die handle  42  as shown in  FIG. 3 . The punching die module  40  further comprises a punching die table  52  which is located within the housing  5 . The punching die table  52  acts as a track and slidably receives the punching die  50  thereon. See  FIG. 8 . A stop block  53  is fixed within the housing  5  and below the punching die table  52  at the first end of the punching die table  52 . The punching die module  40  has a locking pin  56  fixed on the bottom surface of the handle  42 . The punching die module  40  further comprises a spring loaded rotating lever  60  fixedly positioned at the housing  5  (See  FIG. 1 ). The rotating lever  60  is located under the punching die module  40  and is connected to a cam  58  located inside the machine housing  5 . The method of setting the punching die  50  to the correct position comprises the steps of: pull/slide with the handle  42  of the punching die module  40  out of the machine housing  5  on the punching die table  52 ; insert the position pin  46  in the hole  47  corresponding to the sheet width and the number of holes to be punched; push/slide with handle  42  connected to the punching die  50  back in place in the housing  5  on the punching die table  52  and rotate the spring loaded rotating lever  60  to lock the punching die module  40  in position. When the punching die module  40  is slid back into place on the punching die table  52  within the housing  5 , the bottom of the position pin  46  will abut the stop block  53  which will position the punching die module  40  into the correct lateral position for the chosen format and hole number. The punching die table  52  and stop block  53  of the punching die module  40  is shown in  FIG. 8  with the punching die  50  removed from the machine  100 . In  FIG. 8 , the punching die table  52  can be seen within the housing  5  where the punching die  50  can be slid into the machine  100 . The stop block  53  can also be seen in  FIG. 8 . 
         [0021]    By turning the spring loaded rotating lever  60  when the punching die module  40  is in position, the cam  58  pushes against the locking pin  56  and the punching die module  40  is locked in between those two fixed positions and is ready to operate. 
         [0022]    It is unique and novel the way the punching die  50  is set to the size of paper by moving the positioning pin  46  to various positions on the handle  42 . Most prior art machines move the paper to the die. In the present invention the punching die  50  is positioned by putting the positioning pin  46  in the correct hole  47  for the size of the paper sheet being punched. The punching die  50  is pushed/slid forward and into the housing  5  until the bottom of the positioning pin  46  abuts the stop block  53 . This sets the punching die  50  to the correct location on the punching die table  52  for operation. The user then turns the lever  60  to lock the punching die  50  in place on the punching die table  52 . The lever  60  turns a cam  58  until it engages locking pin  56 . This makes it very easy for the operator to set up and change the punching die  50  needed and holes to be punched. The sheet transport module  30  and sheet feeder  10  of the present invention are not shown in  FIG. 1 .  FIG. 1  shows a prior art sheet feeder. The sheet transport module  30  and sheet feeder  10  of the present invention are shown in  FIG. 4 . 
         [0023]    The sheet feeder  10 , as shown in  FIG. 4 , comprises a high pile feeder tray  51 , an adjustable arm  14  that has a plurality of foot pusher solenoids  12  attached thereto, an adjustable side jogger  22 , a detection cell  54  and its reflector  44 . The transport module  30  includes a sub-assembly incorporating the main beak  38 , the separator beak  39 , the hammer  36 , and a pressure spring  37 . Each foot pusher solenoid  12  aids in pushing/moving the paper from the sheet feeder  10  to the transport module  30 . They push the lift of paper, to be punched, to the head stops of the punching die  50 . The head stops are part of the punching die  50  where the paper are aligned against to allow the punching die  50  to properly punch holes on the paper. The side jogger  22  aids in the alignment of paper along one edge as it pushes and aligns the paper against the side stop  24  and the front paper stop  15 . This puts the paper in the correct alignment for receipt by the transport module  30  and then subsequently for the punching die  50  to punch. The detection cell  54  controls the rise of the stack of paper on the feeder tray  51 . The stack of paper is prevented from rising above the correct position for the main beak  38  and separator beak  39  to operate. The main beak  38 , separator beak  39  move in and out in a straight line. The hammer  36  moves up and down to pinch the lift of paper the main beak  38  and separator beak  39  have separated from the stack of paper on the feeder tray  51 . That lift of paper is brought to the opening of the machine  100  to be received by the transport module  30 . The hammer  36  releases the lift and the first set of rollers  28 ,  26  move down to pull the lift of paper into the punching die module  40 . Signaled by the detection cell  54  and its reflector  44 , the feeder tray  51  moves up to present the next lift of paper in front of the beaks  38  and  39 . The process then starts all over again. The foot pusher solenoids  12  are mechanically linked to a rear paper stop  16  which aids in the alignment of paper along another edge. Two foot pusher solenoids  12  are used for standard paper and three foot pusher solenoids  12  are used for tabbed sheets. Foot pusher solenoids  12  are made of plastic. They are attached to three solenoids that fire at the correct time to push the lift of paper being punched against the head stops of the die  50 . The feeder tray  51  is located outside of the machine housing  5 . To use the sheet feeder  10  a stack of collated sheets is loaded on the feeder tray  51  and registered against the rear side of the machine and the front plate of the machine in front of the feeder tray  51  and remain in such position with the aid of front paper stop  15  and rear paper stop  16 . The feeder tray  51  moves up and down. In one embodiment of the present invention, the maximum amount of paper to be loaded is two reams of paper. The user then can slide the adjustable arm  14  so that the rear paper stop  16  is positioned against the rear of the paper stack. Then the foot pusher solenoids  12  are also adjusted to abut the top surface of the stack of paper generally centrally. It is contemplated that a fine tuning adjustment is possible for the foot pusher solenoids  12  through an adjusting screw and compression spring to accommodate tabbed sheets for European sheet formats or different stocks of paper. The same adjustment is possible for side jogger  22 . 
         [0024]    The sheet transport module  30  also includes a sub-assembly with two sets of linked rollers—the second set of rollers  48 ,  49  on the bottom which are fixedly positioned and the first set of (counter) rollers  28 ,  26  on the top mounted on a carriage  34  that are capable of being activated (moved up and down) by solenoid  32 . The second set of rollers  48 ,  49  and the first set of rollers  28 ,  26  are covered by a resilient material ensuring constant grip and allowing for paper weight, material and lift thickness variations. The sheet transport module  30  further comprises a second detection cell  55  and a stepper motor  66  (both within the housing  5 ) that is capable of driving the first set of rollers  26 ,  28  and the second set of rollers  48 ,  49  through a belt and pulley arrangement on the front of the machine  100 . 
         [0025]    The machine  100  is operated by pressing the start button on the machine keyboard  64  or interactive panel (not shown). The feeder tray  51  will begin to move up until the top of the stack of paper P blinds the detector cell  54  ray interaction with its reflector  44  which will trigger the start of the punching cycle. The speed of the upward movement of the tray  51  is fixed. It controls the bite thickness and the number of sheets to be punched at each cycle. It is pre-set to take 0.3 mm of paper, or 2-4 sheets of 80 gsm paper. The actual number of sheets will also depend on the thickness of the paper. When the punching cycle starts the separator beak  39  that is attached to the main beak  38  support will move out and penetrate the stack of paper and lift the byte that will be punched. The main beak  38  will move out simultaneously from its starting position into the space created in the stack by the separator beak  39 , the hammer  36  is activated by a solenoid immediately after the main beak  38  is fully moved out and the hammer  36  will move down by a solenoid and will pinch the lift of sheets to be punched before the main beak  38  moves back in. The main beak  38  will move back in its starting position and pull the lift of sheets to be punched into one of the bottom roller  48  and one of the top counter-roller  28  that are positioned closer to the stack of paper in the sheet feeder  10 . The pressure spring  37  function is to guide the lift so it correctly slides inside one of the bottom rollers  48  and one of the counter-roller  28 . The hammer  36  and main beak  38  hold the stack of paper until it makes it between the first and second sets of rollers  28 ,  26 ,  48 ,  49 . At that point the pressure of the rollers  28 ,  26  pull the paper into the punching die module  40 . It is useful in cases of wavy material which happens with paper that has come out of a copy machine. The first set of rollers  28  and  26  on top drop down to put pressure on the lift of paper against the second set of rollers  48  and  49  on the bottom. At this same time the hammer  36  releases the lift of paper. During this process, the foot of the foot pusher solenoids  12  is timed to periodically extend to push the paper towards the punching die module  40 . 
         [0026]    The main beak  38  can activated by a cam which is mechanically linked to the cam  58  fixedly positioning the punching die module  40  so both actions are fully synchronized such that there is enough time for the two sets of rollers ( 48 ,  49 / 28 ,  26 ) to transport the sheets to be punched into the punching die  50 . 
         [0027]    Once the lift, or stack of paper, is pulled into one of the bottom rollers  48  and one of the top rollers  28  and released by the hammer  36 , the two sets of rollers  48 ,  49 ,  28 ,  26  are activated by the stepper motor  66 . The activation signal is provided by an encoder linked to the cam system that activates the punching die  50  and the main beak  38  through programmable logic controller  62  located in the housing  5 . The programmable logic controller  62  controls the stepper motor  66 , the main beak  38 , the solenoids  12 , the feeder tray  51 , etc. The top counter rollers or first set of rollers  28 ,  26  turn clockwise and the bottom rollers, or second set of rollers  48 ,  49  turn counterclockwise, drawing the lift of paper into the housing  5 . 
         [0028]    The positioning of the second set of rollers,  48 ,  49  and the first set of counter-rollers  28 ,  26  is set to allow for the minimum and maximum sheet lengths of paper allowed by the machine  100 . The position of one of the bottom roller  48  and one of the top counter-roller  28  to the beak&#39;s  38  starting position and to the punching die  50  axis is important so that the front of the lift to be punched would be inserted into an accurate positioning of the sheets into the punching die module  40 . The first set of rollers and second set of rollers  28 ,  26 ,  48  and  49  are positioned in the front of the punching die  50 . The two sets of rollers  48 ,  49 ,  28 ,  26  transport the lift to be punched towards the punching die  50  until the front of the lift hits the head stops that are incorporated into the punching die  50 . The front edge of the lift is detected by the position detector cell  55  which then sends a signal to the programmable logic controller  62  commanding the stepper motor  66 . This signal triggers the programmable logic controller  62  to send a given number of pulses to the stepper motor  66  for rotating the second set of rollers  48 ,  49  so the lift is precisely positioned inside the punching die  50  with its front edge aligned with the head stops of the punching die  50 . The head stops can comprise a plurality of pins that are longer and move down first. The paper hits the pins and the transport module  30  moves the paper into position. The paper is held on all four sides then the pins of the punching die  50  punch through the lift of paper. The number of pulses is pre-set so that the front edge of the lift will always align with the head stops of the punching die  50 . 
         [0029]    The position of the positioning pin holes  47  in the punching die  50  will depend on the desired punching pattern. The distance between the pin row holes and head stops will be equivalent to the sheet to hole edge margin. It is on a slide and the cam that moves the main beak  38  also moves this. The rotation of the second set of rollers  48 ,  49  will be stopped after this number of pulses has been delivered. The encoder will send a signal to the programmable logic controller  62  that will lift the carriage  34  supporting the top counter rollers  28 ,  26  and activate the side jogger  22  and foot pusher solenoids  12  to ensure square and perfectly aligned punching position of the lift. The carriage  34  will go down and the rotation of the  2  sets of rollers  48 ,  49  will be reactivated immediately after the punch pin punched the holes in the paper and disengaged, to push the punched lift, or punched paper, outside the punching die  50  and transported to the transport belts on the reception side, transport the next lift, or paper, to be punched into the punching die  50 . 
         [0030]    Most of the lift of paper is still visible from outside the housing  5  when it is being punched, with the first set of rollers  28 ,  26  lift up to release the pressure on the lift, or paper. The side jogger  22  and the foot pusher solenoids  12  activate with different solenoids to push the paper to the correct position to be punched. The side jogger  22  and foot pusher solenoids  12  move out of the way and the first set of rollers  28 ,  36  come down to eject the punched lift of paper to the reception tray of the paper output  20 . The cycle can then repeat. 
         [0031]    The lift of paper driven by the first set of rollers  28  and  26  and the second set of rollers  48  and  49  which are driven by a stepper motor  66  is unique and novel over the prior art. The use of a stepper motor  66  allows the paper to be transported only a short distance and stay very close to the feeder tray  51 . The foot pusher solenoids  12  and side jogger  22  complete the alignment. Also, the lift is still supported by the stack of paper to be fed into the machine  100  when being punched by the punching die module  40 . Prior art machines use a regular motor which requires the paper to be punched at a different location of the machine which would require the lift to be moved completely into and through the machine. This invention allows the machine to be more compact as the lift is being moved a short difference and therefore allows for a table top unit. The sheets are registered against the rear paper stop  16  of the feeder tray  51 . 
         [0032]    Once punched, the paper is transported and re-delivered upside down in the collated order onto a fixed reception tray with an optional pull tray at the paper output  20 . Punched sheets can be jogged by magnetic corner plates. 
         [0033]    Another unique and novel aspect of the machine  100  is that the side jogger  22  and foot pusher solenoids  12  are located outside of the housing  5  of the machine  100 . There are two paper stops  15 ,  16 : one paper stop  15  on the side stop  24  and one paper stop  16  on the rear stop  18  that are also located outside of the housing  5  of the machine  100 . The rear stop  18  and side stop  24  are moved until the paper stops  15 ,  16  are positioned against the side or back of the stack of paper loaded on the feeder tray  51 . This in turn sets the position of the side jogger  22  and foot pusher solenoid  12 . This allows for a quick and easy set up for the user as the components are easily seen and manipulated as they are located outside of the housing  5  of the machine. This also allows the paper to remain partially in the feeder tray  51  during the punching process as it is not required to fully enter the machine  100  to be punched. This allows the machine  100  to be more compact, requires less travel for the paper to be punched and therefore leaves less room for error. 
         [0034]    While the present invention has been described for use with paper, any sheet like material can be used with the mini punch device of the present invention.