Patent Publication Number: US-6216354-B1

Title: Device for making straight and curved score lines

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to the field of tools in the area of box making and scoring, and more particularly to a tool for making straight and curved score lines, such as for forming boxes, paper sculptures, toys, and artwork that include curved sides as part of their design. 
     2. Description of the Prior Art 
     The inventor herein has obtained U.S. Pat. Nos. 5,484,373 and 5,707,327 and has a pending U.S. patent application No. 08/880,759 all directed to kits and methods of forming straight scoring lines for different type of boxes. The inventor has also filed a U.S. Provisional Patent Application No. 60/058,072 on Aug. 5, 1997 for an invention entitled “Curved Line Scoring Device”. The device of this invention comprises a scoring plate with a plurality of grooves formed therein and a scoring tool for use in forcing the sheet material into a scoring groove to form a score line. 
     People are attracted to new and unique designs. In the area of box and container making, boxes with curved sides offer a refreshing break from the monotony of rectangular solid type boxes. Heretofore, other than the inventor&#39;s own invention “Curved Line Scoring Device” noted above, there has been no simple way for the do-it-yourselfer box maker, hobbyist, artist, and others who wished to create curved creases in card stock, cardboard, plastic, and other sheet material to do so. This can be very difficult to do consistently and repeatedly. Accordingly, there remains a need for a device for use in making curved score lines in sheet material. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide a device for making score lines, particularly curved score lines, in sheet material such as card stock and plastic sheet material that is easy to use and which helps guide a user in forming perfect curved scoring lines in sheet material. 
     Another object of the invention is to provide a device for making curved and other shaped score lines in sheet material such as to form pocket boxes. 
     These and other objects of the invention are set forth below. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top view of a first embodiment of the scoring plate of the invention. 
     FIG. 2 is an end view of the scoring plate of FIG. 1 along view lines  2 — 2 . 
     FIG. 3 is a top view of an optional scoring template overlay portion of the invention. 
     FIG. 4 is a top view of a scoring tool of the invention. 
     FIG. 5 is a plan view showing a sheet of cardstock scored to make a pillow box. 
     FIG. 6 is a plan view showing the scored cardstock of FIG. 5 cut as required. 
     FIG. 7 is a top view of a pillow box when folded. 
     FIG. 8 is an end view of the folded pillow box of FIG. 9 along lines  8 — 8 . 
     FIG. 9 is a cross-sectional view of a sheet of material to be scored placed between the scoring plate and the template overlay portion. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1 and 2 a first embodiment of the scoring plate  10  of the invention is shown. Scoring plate  10  can comprise a planar base  12  with a plurality of semi-circular grooves  14  a˜i formed therein in an upper surface  15  thereof. Grooves  14  a˜i are preferably about 0.3175˜0.476 mm (⅛″ to {fraction (3/16)}″) wide and about 0.3175˜0.476 mm (⅛″ to {fraction (3/16)}″) deep. Dimensioned as such, grooves 14 a˜i will function well for scoring paper cardstock having a thickness of about 0.025″. For other thickness of material, the depth and width can be adjusted as required. Scoring plate  10  can conveniently be formed of plastic material with grooves  14  a˜i formed in upper surface  15  therein. Alternately, wood or other materials can be used. The radii and circumferences of the semi-circular grooves  14   a˜i  can be between any size as desired such as between 1″ and 16″. In the drawings groove  14   a  has a 6″ radius, groove  14   b  has a 5½″ radius, groove  14   c  has a 5″ radius, groove  14   d  has a 4½″ radius,  14   e  has a 4″ radius, groove  14   f  has a 3½″ radius, groove  14   g  has a 3″ radius, groove  14   h  has a 2½″ radius, and groove  14   i  has a 2″ radius. The center of each semi-circle is on a common line  16 . A grid pattern of lines  18  and  20  are provided. Lines  20  are tangent to the curves at the common vertical centerline  16  of the curves, and thus are perpendicular to the common vertical centerline  16 . Lines  18  are tangent to the curves at points 90 degrees and 180 degrees rotated from the vertical centerline  16 , and are parallel to the vertical centerline  16 . The plurality of lines  18  and the plurality of lines  20  are at some fixed distance apart from each other, such as ¼″ to ½″. The lines of grid pattern  18  and  20  further extend on the scoring plate beyond the curves and are used to help orient the card stock being scored correctly on the scoring plate  12  so that the curved scoring line is correctly placed. X axis (vertical) indicator markings  22  and curve diameter indicator markings  24  are formed on scoring plate  12  (such as in inch measurements.) A pair of protrusions  26  are optionally located on scoring plate  12  and extend above upper surface  15  for use with an optional scoring template, as will be discussed below. Protrusions  26  can be cylindrical plugs. For purposes of forming straight score lines as may be required, an elongate straight groove  28  can be formed on scoring plate  12  and can preferably be about 0.3175˜0.476 mm (⅛″ to {fraction (3/16)}″) wide and about 0.3175˜0.476 mm (⅛″ to {fraction (3/16)}″) deep. 
     Referring to FIG. 3, a top plan view of a first optional scoring template overlay portion  30  is shown. Scoring template overlay portion  30  is preferably formed of sheet plastic or metal  32  into which a series of slots  34   a˜i  are formed. In the case of scoring template overlay portion  30 , it is adapted for forming semicircular scoring lines, and thus has a series of semi-circular slots  34   a˜i . For ease of use, the inventor has found that tough, clear plastic, for example, about 0.238˜0.3175 mm ({fraction (3/32)}″ to ⅛″) in thickness, with slots  34   a˜i  being about 0.3175˜0.476 mm (⅛″ to {fraction (3/16)}″) wide to accept a scoring tool will function well. Diameter size indicator markings  36  are preferably placed on sheet  32  adjacent to slots  34   a˜i . Likewise, X axis indicator markings  38  can be placed on sheet  32  as well. If desired, a grid pattern of lines  40  and  42  to form squares can be placed on template  32 , such as by printed lines and the like. The grid pattern of lines  40  and  42  further extend on the template overlay portion  30  beyond the slots  34   a˜i  and are used to help orient the template overlay portion  30  on the card stock being scored. For purposes of forming straight score lines, straight slot portion  44  is preferably formed in template. A pair of apertures  46  are preferably formed in optional scoring template overlay portion  30  and are sized slightly larger than protrusion  26  positioned on scoring plate  26 . The purpose of apertures  46  is to allow optional scoring template overlay portion  30  to be aligned such that its semi-circular slots  34   a˜i  align with semi-circular grooves 14 ˜i  in plate portion  10 . Used in combination, scoring plate  10  and scoring template overlay portion  30  make forming curved score lines much easier. Although as shown in the figures as semi-circular grooves and slots in scoring plate and overlay template, respectively, the grooves and slots can assume other shapes, such as oval, elliptical, parabolic, or irregular shapes. 
     Turning to FIG. 4, a view of a scoring tool  50  is shown. Scoring tool  50  has a handle  52  with a scoring tip  54  which is rounded and free from sharp edges to avoid cutting the sheet material to be scored. Scoring tip  54  is sized to be smaller than slots  34   a˜i  formed in overlay template  30  and grooves  14   a˜i  in scoring plate  10 . 
     A user wishing to form curved score lines in sheet material  60 , for example, such as cardstock or plastic material with a thickness of about 0.635 mm (0.025″), will decide what the shape and relative position of the score lines should be. For complex curves, the curve can be transferred with pencil and the like to the surface of the material to be scored, if desired. The sheet material  60  to be scored will then be laid on scoring plate  10  such that the grooves are properly oriented relative to the sheet material  60 . As shown in FIG. , the optional scoring template overlay portion  30  may be laid on top of sheet material  60 , and with its apertures  46  over protrusions  26 , thereby lining up slots  34   a˜i  of overlay template  30  with grooves 14 a˜i  of scoring plate  10 . The user will then take scoring tool  50  and place it in the selected slot (or directly on sheet material if no overlay portion  30  is used), and bear down to score sheet material  60 . A scoring line will thus be formed in the desired position on the card stock  60 . Depending on the sheet material being used, the scoring pressure necessary will vary. However, by adjusting the pressure applied to the scoring tool, a user can quickly get the feel to make proper score lines. Use of the optional scoring template overlay portion  30  will prevent scoring tool  50  from causing scoring anywhere else other than the desired position, and accurate scoring lines can thus be formed. 
     Having described the various parts of the device, its use in forming a pillow box  58  is now summarized with respect to FIGS. 5-8. By way of example for use in forming a pocket box with a length of 10″ and width of approximately 6″ and a depth (or thickness) of 2″, with two side cylindrical sections with a 5″ radius when viewed along a long axis of the box, the device of the invention can be used as follows. 
     1. A piece of cardstock  60  is provided in the size of 10″ (the length) by 13″ (twice the width plus one inch for an overlap seam). 
     2. The cardstock is scored with score lines parallel to the 10″ edge at 6″ and 12″,  62  and  64 , respectively. This essentially defines three panels; those three being the two sides of the box  66   a  and  66   b— each 10″ by 6″, and the 1″ wide overlapping seam panel  68 . This can be accomplished by overlaying the cardstock  60  on scoring plate  10  positioned over elongate slot  28 . If desired, the optional template overlay portion  30  can be positioned over scoring plate  10  such that elongate slot  44  is directly over elongate groove  28  and elongate straight score  62  and  64  can be formed as desired. 
     3. Each of the side panels are scored at each end using the 5″ radius semicircular scoring groove  14   c  by laying the cardstock  60  on scoring plate  10 , and optionally laying scoring template aligned with scoring slot  34   c  so that the short (6″) edge of each panel is tangent to the 5″ radius scoring slot  34   c  and directed inwardly into the cardstock  60  in a convex manner, and the long edge is parallel to the scoring lines which are parallel to the centerline of the scoring slots, and the score line  70  is convex toward the end of the panel. Such a score line  70  is formed at the end of each side  66  of the box to be formed. 
     4. Each side panel  66   a  and  66   b  is now scored at each end using the same scoring slot  34   c , but lining up the cardstock  60  so the score line  72  is convex toward the center of panels  66   a  and  66   b . This will yield football-shaped sections  74  at each end of both side panels  66   a  and  66   b . These areas will become the ends  74  of the pillow box  60 . 
     5. The cardstock areas  76  outside of the football-shaped sections  74  at the end of each side panel  66   a  and  66   b  are cut off with scissors or a craft knife and discarded. 
     6. The football-shaped sections are folded inwards back and forth along the score lines  72  to soften the material for final folding along these lines later. 
     7. The 1″ by 10″ seam panel  68  is flexed back and forth along score line  64  to make score line  64  adjacent to it pliable. It is then folded back toward the inside of the box so it lies flat against the inside of the opposite side panel  66   a . It is then attached to the inside of the panel  66   a  with glue, adhesive or double-sided tape. 
     8. The pillow box  58  is essentially complete at this point. All that is required is to fold the four football-shaped sections  74  inwardly where they will lock in place, being held there by tension in the folds  72  and friction between the football-shaped sections  74  and the side panels  66   a  and  66   b , forming the pillow box  58  as shown in FIGS. 7 and 8. 
     The combination of the length, width, and thickness of the pillow boxes made as described above are fixed by the length and width of the cardstock being used. The radius of the scoring slot chosen determines the thickness of the box. Larger radii will result in thinner boxes. It is anticipated that the manufacturer of the kit will provide a chart showing the final finished pillow box dimensions using various cardstock sizes and scoring slot radii. 
     In addition to being used to form pillow boxes, the scoring templates of the invention can be used to make other scored items having curved scoring lines as part of their design, such as toys, models, and artwork of various kinds, just to name a few. The device can also be used to form embossed curved designs on boxes, models and artwork. 
     The drawings and the foregoing description are not intended to represent the only form of the invention in regard to the details of this construction and manner of operation. In fact, it will be evident to one skilled in the art that modifications and variations may be made without departing from the spirit and scope of the invention. Although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purpose of limitation, the invention being delineated with respect to the following claims.