Abstract:
A method of cutting a cellular shade and a cutting machine thereof mainly applicable for cutting an assembled cellular shade to a certain size is provided. The cutting method includes providing an assembled cellular shade; providing a cutting machine having a sawing mechanism and a chopping mechanism; pulling out beams of the cellular shade, such that the beams and a cellular piece are staggered, and performing a beam cutting operation; and pulling out the cellular piece, such that the cellular piece and the beams are staggered, and performing a cellular piece chopping operation. The cutting machine mainly includes a table with at least one cutting work area disposed thereon. Using the assembly feature of the cellular shade, the beams and the cellular piece are staggered for a small distance temporarily. The beams are sawed with the sawing mechanism on the table, and the cellular piece is chopped with the chopping mechanism sequentially, such that the measuring and cutting operations of the cellular shade are performed quickly on a single table.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This non-provisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No(s). 200610090937.8 filed in China, P.R.C. on Jul. 4, 2006, the entire contents of which are hereby incorporated by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of Invention 
         [0003]    The present invention relates to a method of cutting a cellular shade and a cutting machine thereof. More particularly, the present invention relates to a method of cutting the metal beams and cloth cellular piece of an assembled cellular shade to a certain size on a single table and a cutting machine thereof. 
         [0004]    2. Related Art 
         [0005]    Presently, cellular shades are quite popular because of their simple style and unique cell design. The cellular shades store air in the hollow layer of the cellular piece to maintain the constant indoor temperature, and their functions of insulating ultraviolet light and heat can effectively protect the furniture and carpet. Moreover, the cellular shades can absorb 30% of the noise. Normal window shade manufacturers have to preset the shades to different lengths and widths when the shades are produced for the retail in market, and consumers have to buy these specs of shades available on market, or have to customize shades with required size. 
         [0006]    The structure of a common cellular shade comprises an upper beam, a lower beam, and a cellular piece inbetween (another structure comprising an upper beam, one or two middle beams, a lower beam, and cellular pieces with each of the pieces between two neighboring beams is also available), and the cell piece inbetween is connected with support lines between the beams. The beams described above are mainly made of a metal material such as aluminum or iron, and the cellular pieces are made of paper, cloth, or non-woven cloth. If the two kinds of components of different materials are cut with a single cutter at the same time, the cut sections will often have burrs and raw edges. As the cellular pieces are strictly required to be clean, and the non-woven cloth material is very easy to get contaminated during the mixed cutting, presently to cut the cellular shades purchased by the consumers, the beams and cellular pieces are cut by the manufacturers according to the required size using cutting machines with different cutters, and then are assembled. 
         [0007]    Though the method of cutting a cellular shade will not cause burrs, raw edges or contamination of the metal beams and cellular pieces, as the cutting has to be performed before the products are assembled, the consumers&#39; demand cannot be met on time. Further, as the specs are ordered uniquely or in a small batch, the cost is very high, and the competitiveness is low. 
       SUMMARY OF THE INVENTION 
       [0008]    Accordingly, the technical problem to be solved by the present invention is to provide a cutting method that may cut beams and cellular pieces respectively on a single table without disassembling assembled cellular shade products. 
         [0009]    Another technical problem to be solved by the present invention is to provide a cutting machine of a cellular shade that may perform measuring and cutting on a single table without disassembling the structure of beams and cellular pieces of the cellular shade. 
         [0010]    To achieve the aforementioned objects, the technical scheme given in the present invention is to provide a method of cutting a cellular shade comprising at least two beams and a cellular piece. The method comprises providing a cutting machine having a table, a sawing mechanism, and a chopping mechanism; performing the beam cutting, including keeping the cellular shade in the assembled state, pulling out the beams for a small length, such that the beams and the cellular piece are staggered, and placing the beams into the sawing mechanism to perform the measuring, holding and cutting operations; and performing the cellular piece cutting, including keeping the cellular shade in the assembled state, pulling out the cellular piece for a small length, such that the cellular piece protrudes, and the cellular piece and the beams are staggered, and placing the cellular piece into the chopping mechanism to perform the measuring, holding and cutting operations. 
         [0011]    To realize the aforementioned cutting method, the present invention makes full use of the structural features of the assembly of the beams and the cellular piece of the cellular shade, and designs a cutting method that forms the cutting space by moving the beams or cellular piece for a small length. The technical scheme provided by the present invention provides a cutting machine of a cellular shade, which comprises a table; a sawing mechanism disposed on the table and having a first measuring device, a first pressing device, and a sawing device, for measuring the cutting size of the beams, pressing the beams and sawing the beams; and a chopping mechanism disposed on the table and having a second measuring device, a second pressing devices, and a chopping device, for measuring the cutting size of the cellular piece, pressing the cellular piece and chopping the cellular piece. 
         [0012]    The advantages of the present invention lie in that the overall efficiency of cutting the cellular shade is improved significantly. The steps of “disassembling the beams and the cellular piece, cutting the beams and the cellular piece on different tables respectively, and assembling the beams and the cellular piece” are simplified to direct measuring and cutting in the assembled state in the present invention, which meets the consumers&#39; requirements on instant cutting and variable sizes. 
         [0013]    Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The present invention will become more fully understood from the detailed description given herein below for illustration only, and which thus is not limitative of the present invention, and wherein: 
           [0015]      FIG. 1  is a flow chart of the steps of the cutting method according to a preferred embodiment of the present invention. 
           [0016]      FIG. 2  is a flow chart of the steps of the beam cutting operation according to a preferred embodiment of the present invention. 
           [0017]      FIG. 3  is a flow chart of the steps of the cellular piece cutting operation according to a preferred embodiment of the present invention. 
           [0018]      FIG. 4  is a schematic view of an assembled cellular shade in the closed state according to a preferred embodiment of the present invention. 
           [0019]      FIG. 5  is a combined stereogram of a cutting machine according to a preferred embodiment of the present invention. 
           [0020]      FIG. 6  is a schematic stereogram of the sawing mechanism according to a preferred embodiment of the present invention. 
           [0021]      FIG. 7  is a schematic stereogram of the chopping mechanism according to a preferred embodiment of the present invention. 
           [0022]      FIG. 8  is a top view of the sawing mechanism according to a preferred embodiment of the present invention. 
           [0023]      FIG. 9  is a top view of the chopping mechanism according to a preferred embodiment of the present invention. 
           [0024]      FIGS. 10A and 10B  are schematic views of the actions of the first measuring device according to a preferred embodiment of the present invention. 
           [0025]      FIGS. 11A and 11B  are schematic views of the actions of the second measuring device according to a preferred embodiment of the present invention. 
           [0026]      FIG. 12  is a top sectional view of the guiding portion and the flange potion of the guiding and positioning cover according to a preferred embodiment of the present invention. 
           [0027]      FIG. 13  is a schematic stereogram from another angle of the sawing mechanism of according to preferred embodiment of the present invention. 
           [0028]      FIG. 14  is a schematic stereogram from another angle of the chopping mechanism according to a preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    A preferred embodiment is illustrated in detail with reference to the drawings. 
         [0030]    Referring to the flow charts of  FIGS. 1 ,  2 , and  3 , and the structural views of  FIGS. 4 ,  5 ,  6 , and  7 , the cutting method of the present invention comprises the following steps. 
         [0031]    An assembled cellular shade  10  having two beams  11 , a cellular piece  12 , and a support line  13  connected inbetween is provided first (Step S 100 ), and then a cutting machine  20  (Step S 110 ) comprising a table  30 , a sawing mechanism  40  and a chopping mechanism  50  is provided. 
         [0032]    Then the sawing operation on the beams  11  is performed (Step S 120 ), wherein the two beams  11  of the cellular shade  10  are pulled out, such that the beams  11  protrudes from the end of the side edge of the cellular shade  10 , such that the beams  11  and the cellular piece  12  are staggered, as the dashed lines in  FIG. 4  show. And instead of being disassembled, the assembled state that the support line  13  is threaded between the beams  11  and the cellular piece  12  is still maintained. After that, the cellular shade  10  is placed into the sawing mechanism  40  to perform the measuring, pressing, cutting and releasing operations on the beams  11 . The sawing mechanism  40  described in the operation (Step  120 ) further comprises a first measuring device  41 , a first pressing device  42 , and a sawing device  43 . The operation includes measuring, pressing, cutting, and releasing, which represent the following four steps respectively: marking the size to cut with the first measuring device  41  and fixing so as to position the placed beams  11  (Step S 120   a ), pressing the beams  11  with the first pressing device  42  (Step S 120   b ), then withdrawing the first measuring device  41  from the beams  11  (Step S 120   c ) to prevent collision with the sawing device  43  in the subsequent cutting stroke, and cutting the beams  11  with the sawing device  43  (Step S 120   d ). When the sawing device  43  is started, the first measuring device  41  has been withdrawn from the beams  11  earlier, so as to prevent the damage caused by the collision with the first measuring device  41  when the sawing device  43  moves downwardly. After the sawing device  43  is reset, the pressing state of the first pressing device  42  can be released to release the cellular shade  10  (Step S 120   e ). 
         [0033]    Then, the chopping of the cellular shade  120  is performed (Step S 130 ). Firstly, the cellular shade is turned by 90 degrees, such that the beams are in vertical positions in a Z direction (as the directions of the beams  11  and the cellular piece  12  of  FIG. 14  show). The cellular piece  12  of the cellular shade  10  is pushed out, such that the cellular piece  12  and the beams  11  are staggered, while the assembled state in which the supported line  13  is threaded is still maintained. The cellular shade  10  is placed into, the chopping mechanism  50  to perform measuring, pressing, cutting and releasing operations on the cellular piece  12 . The chopping mechanism  50  described in the operation (Step  130 ) further comprises a second measuring device  51 , second pressing devices  52 , and a chopping device  53 . The operation includes measuring, pressing, cutting, and releasing, which represent the following four steps respectively: marking the size to cut with the second measuring device  51  and fixing so as to position the placed cellular piece  12  (Step S 130   a ), withdrawing the second measuring device  51  from the cellular piece  12  after the cellular piece  12  is positioned, such that it is not in contact with the cellular piece  12  (Step S 130   b ), pressing the cellular piece  12  with the second pressing devices  52  (Step S 130   c ), and cutting the cellular piece  12  with the chopping device  53  (Step S 130   d ). Before the chopping device  53  is started and contacts the cellular piece  12 , the second measuring device  51  has been withdrawn from the cellular piece  12  earlier, so as to prevent the damage caused by the collision with the second measuring device  51  when the chopping device  53  or the second pressing devices  52  move downwardly. After the chopping device  50  is reset, the pressing state of the second pressing devices  52  can be released to release the cellular shade  10  (Step S 130   e ). 
         [0034]    Certainly, in the method described above, whether the beams  11  or the cellular piece  12  of the cell  10  are cut causes no difference, i.e., Step S 100  and Step S 110  can be performed in a reversed order, and S 120  and S 130  can also be performed in a reversed order, and the implementation of the present invention is not influenced. 
         [0035]    Moreover, in Step S 100  of the aforementioned cutting method of the present invention, the beams  11  and the cellular piece  12  of the cellular shade  10  are not limited to have the structure of two beams  11  and a cellular piece  12  inbetween as described above, and can have a structure of over two beams  11  (e.g., three beams or even four beams) having a cellular piece  12  disposed between two neighboring beams  11 . 
         [0036]    Referring to  FIGS. 4 ,  5 ,  6 ,  7 ,  8 , and  9 , the cutting machine  20  used to realize the above steps in the present invention comprise the following components. 
         [0037]    A table  30 , which has a first work area  31  and a second work area  32  respectively for disposing the length directions of the beams  11  of the cellular shade  10  to cut along the direction of the X coordinate axis. Certainly, the aforementioned first work area  31  and second work area  32  can be arranged in a same plane, or be arranged in different planes. 
         [0038]    A sawing mechanism  40  is disposed at one end of the first work area  31 , and has a first measuring device  41 , a first pressing device  42 , and a sawing device  43 . The first measuring device  41  is disposed on the table  30 , and can move along the direction of the X coordinate axis, so as to adjust the distance to a saw blade  434  on the sawing device  43 , and the distance is the length to be cut from the beams  11 . The first pressing device  42  is disposed at another position on the table  30  on the plane of the first work area, and presses the beams  11  along the direction of the Y coordinate axis. The first measuring device  41  is withdrawn from the beams  11  (e.g., by means of sliding driven by pneumatic cylinders) after the beams are pressed, so as to prevent the collision with the sawing device  43 . The sawing mechanism  43  is disposed between the first measuring device  41  and the first pressing device  42 , and can move along the direction of the Z coordinate axis to cut the beams  11 . 
         [0039]    A chopping mechanism  50  is disposed on the second work area  32 , and has a second measuring device  51 , a pair of second pressing devices  52  disposed separately, and a chopping device  53  disposed between the two second pressing devices. The second measuring device  51  is disposed on the table  30 , and can move along the direction of the X coordinate axis to adjust the distance from the chopping device  53 , and the distance is the size of the cellular piece  12  to cut. The second pressing devices  52  are disposed at another position on the same X coordinate axis of the table  30 , and press the cellular piece  12  along the direction of the Z coordinate axis. Before the chopping device  53  is started and contacts the cellular piece  12 , the second measuring device  51  has been withdrawn from the cellular piece  12  earlier (e.g., by means of sliding driven by pneumatic cylinders) so as not to obstruct the chopping stroke of the chopping device  53 . The chopping device  53  is disposed between the two second pressing devices  52 , and has a chopping cutter  533  moving along the direction of the Z coordinate axis to cut the cellular piece  12 . 
         [0040]    Referring to further descriptions on  FIGS. 8 ,  10 A, and  10 B, the first measuring device  41  of the embodiment of the present invention comprises: a slide base component  411  fixed on the table  30 , wherein the slide base component  411  includes a brake sliding block  414  movable between a first position  412  and a second position  413 , and the brake sliding block  414  has a screw fixing member  4141 ; a freely movable vernier  415  disposed on the brake sliding block  414 ; and a positioning block  416  disposed at the end of the vernier  415 . 
         [0041]    When the first measuring device  41  operates, the brake sliding block  414  is at the first position  412 , the position of the vernier  415  is adjusted to the length to cut by holding the handle of the vernier  415  manually, the vernier  415  is fixed with the screw fixing member  4141 , such that the positioning block  416  precisely position the place where the beams  11  will be cut, and after the first pressing device  42  presses, the brake sliding block  414  is drawn back to the second position  413 , such that the positioning block  416  leaves the cutting area where the beams  11  are. 
         [0042]    As shown in  FIGS. 6 ,  8 , and  13 , the first pressing device  42  of the embodiment of the present invention comprises: a slide base component  421  fixed on the table  30 , which has a pressure sliding block  422  that can actively move along the direction of the Y coordinate axis; a baffle  423  fixed on the table  30 ; and a cushion block  424  that can move linearly, individually, and freely between the pressure sliding block  422  and the baffle  423 . 
         [0043]    The sawing device  43  of the embodiment of the present invention comprises: a slide base component  431  fixed on the table  30 , which has a sliding mechanism  432  movable along the direction of the Z coordinate axis; a cutter rotating mechanism  433  disposed in the sliding mechanism  432 ; and a saw cutter  434  assembled in the cutter rotating mechanism  433 . Certainly, the saw cutter  434  is replaceable, and can be replaced after the cutter reaches its life span or when other specs of cutters are required. 
         [0044]    Furthermore, as shown in  FIGS. 5 ,  6 , and  13 , the sawing device  43  further comprises an outer cover  435  to cover the saw cutter  434 , and a microswitch  436  disposed at the opening position of the outer cover and connected to the power source of the rotating mechanism  433 . When the outer cover  435  is opened, the power source of the rotating mechanism  433  is shut down to guarantee the safety of the operator. 
         [0045]    The cutting of the cellular piece  20  with the chopping mechanism  50  of the present invention is implemented in a manner that the beams  11  are at upper and lower positions, and the cellular piece  12  is in the middle (as the beams  11  and the cellular piece  12  in  FIG. 14  show), and detailed description on this is given below. 
         [0046]    Referring to  FIGS. 11A and 11B , and the stereogram of the embodiment of the cellular shade  10  of  FIG. 14 , the second measuring device  51  of the embodiment of the present invention comprises a slide base component  511  fixed on the table, which has a brake sliding block  514  movable between a first position  512  and a second position  513 , and has a screw fixing member  5141 ; a freely movable vernier  515  disposed on the brake sliding block  514 ; and a positioning block  516  disposed at the end of the vernier  515 . 
         [0047]    Before the second measuring device  51  is actuated, the brake sliding block  514  is at the first position  512 . The operator can adjust the positions of the vernier  515  and the positioning block  516  so as to obtain a correct cutting distance between the positioning  516  and the chopping device  53 , and can use the screw fixing member  5141  to secure the relative position of the vernier  515  and the brake sliding block  514 . Before the second pressing devices  52  presses, the brake sliding block  514  is drawn back to the second position  513 , such that the positioning block  514  leaves the cellular shade  10  to prevent the collision with the second pressing devices  52 . 
         [0048]    Referring to  FIGS. 7 and 14 , the second pressing devices  52  of the embodiment of the present invention comprise: a pair of slide base components  521  fixed on the table, each having a pressure sliding block  522  that can actively move along the direction of the Z coordinate axis respectively; a base plate  523  fixed on the table  30  with a groove  524  disposed thereon; and a pair of cushion blocks  525  that can move linearly, individually, and passively between the pressure sliding blocks  522  and the base plate  523 . Thus, before the pair of the pressure sliding blocks  522  are pushed and actuated, the cellular piece  12  of the cellular shade  10  can be placed on the base plate  523 , and after the pressure sliding blocks  522  are pushed and actuated, the cushion blocks  525  and the cellular piece  12  are pushed to the base plate  523  to press the cellular piece  12 . Moreover, each of the surfaces in contact with the cellular piece  12  of the pressure sliding blocks  522 , the base plate  523 , and the cushion blocks  525  can have an additional contamination-proof pad  526 , which can be made of acrylics or plastic. 
         [0049]    As shown in  FIGS. 7 and 14 , the chopping device  53  of the embodiment of the present invention comprises: a slide base component  531  fixed on the table, which has a sliding mechanism  532  movable along the direction of the Z coordinate direction; and a chopping cutter  533  assembled in the sliding mechanism. Certainly, the chopping cutter  533  is installed replaceably to facilitate the replacement thereof. 
         [0050]    Referring to  FIGS. 5 and 14 , the chopping device  53  further comprises a guiding and positioning cover  534  to guide the positioning of the cellular shade  10 . The guiding and positioning cover  534  can be of a transparent material to facilitate the observation of the positioning of the beams  11  and the chopping device  53 . 
         [0051]    Referring to  FIGS. 7 ,  12 , and  14 , the chopping device  53  further has a flange portion  535 , which is disposed above the base plate  523  and the contamination-proof pads  526  of the table and is in front of the chopping cutter  533  relatively, and extends its thickness along the direction of the Z coordinate axis. The flange portion  535  is used to stop the beams  11  to enable the cellular piece to protrude, so as to facilitate the cutting. Furthermore, the chopping device  53  can further comprise a guiding portion  536 , which is disposed on the table  30  and abuts on the flange portion  535 , and extends in a direction parallel to the X coordinate axis. In addition to guiding and positioning, the guiding and positioning cover  536  can prevent direct contacts with the chopping cutter. 
         [0052]    Referring to  FIGS. 5 ,  13 , and  14 , a first waste channel  60  can be added at a position below the sawing device  43  corresponding to the sawing mechanism  40  on the table  30  of the present invention to guide the waste of the cut beams, and a first waste barrel  61  can be added at the end of the channel to collect the waste. Similarly, a second waste channel  62  can be added at a position below the chopping device  53  corresponding to the chopping mechanism  50  to guide the chopped waste, and a second waste barrel  63  can be added at the end of the channel to collect the waste. 
         [0053]    The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.