Patent Abstract:
Making a plurality of notching marks on flanges of a rule to enable bending of the rule, including: punching the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and tapering the flanges positioned around sharp notching angles made on the channel letter.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority under 35 U.S.C. §119(e) of co-pending U.S. Provisional Patent Application No. 62/345,692, filed Jun. 3, 2016, entitled “Flat Notching.” The disclosure of the above-referenced application is incorporated herein by reference. 
     
    
     BACKGROUND 
     Technological Field 
       [0002]    The present disclosure relates to notching marks made on flanges of a rule. 
       Background 
       [0003]    Notching marks are made on flanges of a rule to enable bending of the rule into a channel letter. However, additional preparations may be desirable to generate certain shapes or designs of the channel letter. 
       SUMMARY 
       [0004]    In general, this disclosure describes apparatus and methods related to making notching marks on the flanges of a rule to enable bending of the rule into a channel letter. As used herein, a “rule” may generally refer to a flat metallic strip. Additionally, a “profile” as used herein may generally refer to the rule having a rib as described below. In general, the rule or profile may be interchangeably used. In one embodiment, the flat notching marks are made on flanges of the rule to enable bending of the rule. Embodiments shown below also describe the flat notching marks made on flanges of the rule to enable bending of the rule into sharp angles. 
         [0005]    In one embodiment, a method of making a plurality of notching marks on flanges of a rule to enable bending of the rule is disclosed. The method includes: punching the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and tapering the flanges positioned around sharp notching angles made on the channel letter. 
         [0006]    In another embodiment, an apparatus for making a plurality of notching marks on flanges of a rule to enable bending of the rule is disclosed. The apparatus includes: means for punching the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and means for tapering the flanges positioned around sharp notching angles made on the channel letter. 
         [0007]    In another embodiment, a device configured to make a plurality of notching marks on flanges of a rule to enable bending of the rule is disclosed. The device includes: a punching device configured to punch the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and a tapering device configured to taper the flanges positioned around sharp notching angles made on the channel letter. 
         [0008]    Other features and advantages of the present disclosure should be apparent from the following description which illustrates, by way of example, aspects of the disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The details of the present disclosure, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings. 
           [0010]      FIG. 1A  shows the rule bent into a channel letter shape. 
           [0011]      FIG. 1B  shows the completed channel letter (e.g., letter “K”). 
           [0012]      FIG. 2A  shows a strip of rule. 
           [0013]      FIG. 2B  shows a flange formed on the rule. 
           [0014]      FIG. 2C  shows one side surface of a strip of profile. 
           [0015]      FIG. 2D  shows the other side surface of the strip of profile. 
           [0016]      FIGS. 3A and 3B  show the two ends of a rule connected at a point once the channel letter is formed. 
           [0017]      FIG. 4  shows one example of a sharp notching angle. 
           [0018]      FIG. 5A  shows a notching device in accordance with one embodiment. 
           [0019]      FIG. 5B  a top perspective view of a sketch of the notching device in accordance with one embodiment. 
           [0020]      FIG. 6A  shows the notching marks made on the flange of the rule using the notching punches of the notching device illustrated in  FIGS. 5A and 5B , for example. 
           [0021]      FIG. 6B  is a side perspective view of the rule with the notching marks and also showing the bending locations. 
           [0022]      FIG. 6C  shows the rule partially bent at a bending location. 
           [0023]      FIG. 6D  shows the rule completely bent into the sharp angle. 
           [0024]      FIG. 7A  shows the rule with the notching marks such that the flange pieces are tapered with tapered portions removed. 
           [0025]      FIG. 7B  shows the rule completely bent into the sharp angle. 
           [0026]      FIG. 8  illustrates the difficulties of the rivet side with the bulged head not attaching flat to the surface, which can cause the channel letter to wobble when attached to a surface. 
           [0027]      FIG. 9A  shows a first step of a process for using the flat notching punch to remove the flange piece from the first end of the rule. 
           [0028]      FIG. 9B  shows the two ends of the rule with flange pieces. 
           [0029]      FIG. 9C  shows the two ends coupled together by sliding the two ends toward each other and the overlapping portion over the second end until the flange pieces meet without overlapping. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. In some instances, well-known structures and components are shown in simplified form for brevity of description. As used herein, like reference numerals refer to like features throughout the written description. 
         [0031]    Rules (or profiles) may be used to form channel letters. For example,  FIGS. 1A and 1B  show a channel letter box  100  made with a profile in accordance with one embodiment of the present disclosure.  FIG. 1A  shows the rule bent into a channel letter shape.  FIG. 1B  shows the completed channel letter (e.g., letter “K”). As can be seen in  FIG. 1B , for example, the channel letter box  100  includes a top rib  110  for retaining the top plate and a bottom rib  112  for fitting into a bottom plate. In one embodiment, the channel letter can be shaped into any shape, not just a letter of the alphabet or writing (e.g., Chinese letters). For example, the channel letter can be in a shape such as a heart shape. 
         [0032]    In one embodiment, the rules can be made into strips or rolls.  FIG. 2A  shows a strip of rule  200 .  FIG. 2B  shows a flange  202  formed on the rule  200 .  FIG. 2C  shows one side surface  220  of a strip of profile  210 .  FIG. 2D  shows the other side surface  230  of the strip of profile  210 . The other side surface  230  may include ribs  232 ,  234  to support the top and bottom covers of a channel letter. Thus, in one embodiment, a profile can be formed using a rule with at least one strip of rib attached to one surface of the rule. 
         [0033]    In some embodiments, the profile  210  can have a first surface  230  shown in  FIG. 2D . The first surface  230  may also be referred to herein as the “inside surface,” indicating that the first surface  230  may generally become the inside of a resulting channel letter once the profile  210  has been cut and folded. The profile  210  (or the rule  200 ) can generally have a profile height  236  on the order of a few centimeters (cm), for example, one or two cm to in excess of  20  cm. The profile height  236  can also describe the height of the first surface  230 . The profile  210  may also be many meters long (in the direction of the profile axis  238 ). In some embodiments, the profile  210  (and the rule  200 ) can be stored in large rolls from which certain portions or lengths can be cut, for example, to produce the portion of the profile  210  shown. Lengths or sections of the profile  210 , can be cut from the roll and then fed into a profile cutting and bending machine (not shown) to make a variety of channel letters or shapes from the profile  210 . 
         [0034]    In some embodiments, the rule  210  can be formed of a suitable metallic material, such as aluminum, steel, stainless steel, or various other alloys that provide a malleable, yet sturdy construction. The rule  210  may further have a protective coating to prevent corrosion or oxidation and to provide a suitable mounting surface for the ribs  232 ,  234 . Such a protective coating can be applied at least to the first surface  230 , but can also be applied to an outside surface  220 . The outside surface  220  is opposite the first surface  230  and may generally become the outside of the resulting channel letter once the profile  210  is cut and folded. 
         [0035]    In certain embodiments, such a protective coating may be an enamel coating. In some other embodiments, the profile  210  can be coated with certain types of powder coating, lacquer, or paint applied to the entire rule  200 . In some embodiments, coating the rule  200  in enamel can have certain chemical advantages for adhering or bonding of the ribs  232 ,  234 . The coating can further have desirable artistic or design characteristics provided by different colored coatings having various reflective or textured properties. For example, a white first surface  230  may have desirable reflective properties for light emitted from within a completed channel letter. The colors and coatings of the first surface  230  can be different from the colors and coatings of the outside surface. 
         [0036]    As described above, the profile  210  can further have the ribs  232 ,  234 . In some embodiments, the ribs  232 ,  234  can be attached, bonded, or otherwise adhered to the first surface  230  of the profile  210 . In some embodiments, the ribs  232 ,  234  can be formed of a polymer, elastomer, plastic, fiber-reinforced plastic (FRP), or other suitable synthetic materials. In some other embodiments, the rib  232 ,  234  can be attached using a machine that applies or adheres the ribs  232 ,  234  in place on a blank surface  230  of the profile  210 . 
         [0037]    As noted above, the notching marks are made on the flanges of a rule to enable bending of the rule into a channel letter. However, additional preparations may be desirable to generate certain shapes or designs of the channel letter. 
         [0038]      FIGS. 3A and 3B  show notching marks  320  on the flanges  310  of the rule  300 . Notching marks  320  are of different angles, which can range from 0 degree to 180 degrees. A notching angle of 0 degree would be no notching mark, while a notching angle near 180 degrees (e.g., between 140 and 180 degrees) would be a flat notching mark. 
         [0039]      FIG. 4  shows one example of a sharp notching angle  400 . As shown in  FIG. 4 , in areas near the sharp notching angle  400 , the flanges interfere with each other, and the flanges must be filed and grounded to bend them into the sharp angle. 
         [0040]      FIG. 5A  shows a notching device  500  in accordance with one embodiment. Typically the notching device  500  is one of the units of a bending apparatus. 
         [0041]      FIG. 5B  is a top perspective view of the notching device  500  in accordance with one embodiment. The illustrated embodiment of  FIG. 5B  includes four notching punches  510 ,  512 ,  514 ,  516  of different angles (e.g., 30, 60, 120, and flat or 180 degrees). In one embodiment, the notching punch  510  makes a 30° notching mark. In another embodiment, the notching punch  512  makes a 60° notching mark. In another embodiment, the notching punch  514  makes a 120° notching mark. In yet another embodiment, the notching punch  516  makes a 180° or flat notching mark. In other embodiments, notching marks of different angles can be made. 
         [0042]      FIG. 6A  shows the notching marks  600 ,  610 ,  612 ,  614 ,  616 ,  618  made on the flange of the rule  680  using, for example, the notching punches of the notching device  500  illustrated in  FIGS. 5A and 5B . 
         [0043]    In one example, the notching marks  610 ,  612 ,  614  are made with the 30° notching punch  510 , while the notching marks  616 ,  618  are made with the 60° notching punch  512 . Further, the notching mark  600  is made with the flat notching punch  516  to enable the rule  680  to be bent into a sharp angle. 
         [0044]      FIG. 6B  is a side perspective view of the rule  680  with the notching marks  600 ,  610 ,  612 ,  614 ,  616 ,  618  and also showing the bending locations  620 . 
         [0045]      FIG. 6C  shows the rule  680  partially bent at bending location  632 . The flange  630  is completely removed by the flat notching punch to make the sharp angle bend (as shown in  FIG. 6D ). 
         [0046]      FIG. 6D  shows the rule  680  bent into the sharp angle  640 . It can be seen in the illustrated embodiment of  FIG. 6D  that when the rule  680  is bent at location  632  into the sharp angle  640 , the adjacent flange pieces  652 ,  654  may contact or overlap at location  650 . In one embodiment, the sharp notching angle  640  is an angle between 140 and 180 degrees. 
         [0047]    To avoid the contact or interference, the flange pieces (e.g., the adjacent flange pieces  652 ,  654  in  FIG. 6C  or  FIG. 6D ) can be tapered. 
         [0048]      FIG. 7A  shows the rule  700  with the notching marks  600 ,  610 ,  612 ,  614 ,  616 ,  618  such that the flange pieces  712 ,  722  are tapered with tapered portions  710 ,  720  removed. In one embodiment, the notching punches (e.g., punches  510 ,  512 ,  514 ,  516 ) of the notching device (e.g., notching device  500 ) are used to taper the flange pieces. In another embodiment, a cutting device is used to taper the flange pieces. 
         [0049]      FIG. 7B  shows the rule  700  bent into the sharp angle  640 . It can be seen in the illustrated embodiment of  FIG. 7B  that when the rule  700  is bent into the sharp angle  640 , the adjacent flange pieces  712 ,  722  do not contact, overlap, or interfere with each other. 
         [0050]    In a further embodiment, the flat notching punch of the notching device is used for other purpose as well. For example, the flat notching punch can be used to punch out the flange of one end of the channel letter formed with the rule. 
         [0051]    As shown in  FIGS. 3A and 3B , once the channel letter is formed using the rule  300 , the two ends need to be connected at point  380  (in  FIG. 3A ) or  390  (in  FIG. 3B ). Thus, to connect the two ends, the ends are overlapped and riveted. However, since the flange side is made to attach the channel letter to a surface, the bulged head of the rivet causes the channel letter to not attach properly (e.g., attach flat) to the surface. 
         [0052]      FIG. 8  illustrates the difficulties of the rivet side with the bulged head not attaching flat to the surface  830 , which can cause the channel letter to wobble when attached to a surface  830 . As shown in  FIG. 8 , the two ends  800 ,  810  of the rule (i.e., the flange of the rule) are overlapped and riveted with a rivet  820 . However, the rivet  820  causes the channel letter to not attach properly to the surface  830  because the rivet  820  has a rounded and bulged head. Thus, in some embodiments, it is desirable to put the rivet which attaches the two ends on the rule side (e.g., side  200  of  FIG. 2B ) rather than on the flange side (e.g., side  202  of  FIG. 2B ). 
         [0053]      FIGS. 9A to 9C  show the process for using the flat notching punch to remove the flange piece  904  from the first end  900  of the rule (see  FIG. 9A ). The remaining flange piece coupled to the first end  900  of the rule is labelled as  902 . 
         [0054]      FIG. 9B  shows the two ends  900 ,  910  of the rule with flange pieces  902 ,  912 . The flange piece  902  is coupled to the first end  900 , while the flange piece  912  is coupled to the second end  910 . The first end  900  also includes an overlapping portion  906  that will receive the rivets. 
         [0055]    As shown in  FIG. 9C , the two ends  900 ,  910  are coupled together by sliding the two ends  900 ,  910  toward each other and the overlapping portion  906  over the second end  910  until the flange pieces  902 ,  912  meet without overlapping. Finally, the two ends  900 ,  910  are attached together using the rivets  920 . In other embodiments, the two ends  900 ,  910  can be attached using adhesives or other attachment means such as by soldering. 
         [0056]    The above descriptions of the disclosed embodiments are provided to enable any person skilled in the art to make or use the disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the disclosure. For example, although the examples shown in the illustrated figures include only one sharp angle made for a channel letter, multiple sharp angles can be made for the channel letter. Thus, it will be understood that the description and drawings presented herein represent embodiments of the disclosure and are therefore representative of the subject matter which is broadly contemplated by the present disclosure. It will be further understood that the scope of the present disclosure fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present disclosure is accordingly limited by nothing other than the appended claims. 
         [0057]    Accordingly, the foregoing embodiments are merely presented as examples and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatus and/or devices. The description of the present disclosure is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.

Technology Classification (CPC): 1