Abstract:
An insert assembly is received in a recess on the outer surface of a rotary cutting cylinder. The insert has a hole for a slug ejector pin which is slidingly engagable with the insert. The hole is arranged on the insert to communicate with a through hole in the recess that extends into the interior of the cylinder. When the slug ejector pin is inserted in the pin hole, the pin proximal end is received in the recess hole adjacent to the compressible core and the pin distal end projects from an outer surface of the insert. When the pin is assembled with the insert and the insert is assembled with the cylinder, the pin proximal end operatively engages the compressible core when the pin retracts into the pin hole of the insert and the pin proximal end operatively engages the insert when the pin projects from the pin hole.

Description:
BACKGROUND AND SUMMARY 
       [0001]    The disclosure relates to a pin eject system in a rotary cutting die arrangement comprising a rotary die cutting cylinder and an anvil roll with a media passing therebetween. The rotary cutting die arrangement is used in the converting industry to cut parts from a media passing between the two cylinders. The pin eject system facilitates the separation of the cut part from the media. 
         [0002]    In one aspect, the disclosure relates to a rotary die cutting cylinder of the rotary die cutting arrangement with an insert removably attached to the outer surface of the rotary die cutting cylinder. The insert receives a pin to provide the pin ejection feature. The insert may be received in a recess formed on the outer surface of the rotary die cutting cylinder and held in position with a mechanical fastener with the pin projecting from the surface of the insert. The insert may also have a die cavity and the ejector pin may project through a hole in the die cavity of the insert. The pin is located within the insert and is biased outward from the outer surface of the rotary die cutting cylinder by a compressible, springing core disposed in the bore of the rotary cutting cylinder. During cutting, the media is compressed, for instance, in a die cavity formed on the face of the insert, and the anvil roll, and cut. The portion of the media in the cavity pushes against the ejector pin and the pin retracts through its hole in the insert against the compressible core. As the insert and die cavity rotate away from the anvil roll, the pin moves outward by the biasing force of the compressible core and ejects the part (or die cut slug) from the cavity. The pin eject system prevents the build-up of small die cut slugs in die cavities of the die. 
         [0003]    In another aspect, the disclosure relates to an anvil roll of the rotary die cutting arrangement with an insert and a pin ejection feature that cooperates with a die cavity of a rotary cutting cylinder to maintain the cut media within the die cavity or to separate the media from the cut media within the die cavity. The insert may be received in a recess formed on the outer surface of the anvil roll and held in position with a mechanical fastener with the pin projecting from the surface of the insert. In one example, when the anvil rotates, the insert and pin eject feature of the anvil roll comes into register with die cavity of the rotary cutting cylinder. The pin housed in the insert projects into a cutting die area of the cutting cylinder and is biased outward by a compressible, springing core disposed in the bore of the anvil roll. The ejector pin projects through its hole in the insert in the anvil roll outer surface and comes into register with the die cavity at selected points during cutting. As the media is compressed in the cavity between the rotary cutting cylinder and the anvil roll, and cut, the pins push the material into the die cavity. As another example, inserts with the pins may be provided on other areas of the anvil roll. The pins may project outward from the anvil roll in areas outside of the die cavity during cutting. As the media is compressed in the cavity between the rotary cutting cylinder and the anvil roll, and cut, the pins push the material outside of the die cavity away from the material within the die cavity, thereby facilitating the removal of the die cut portion from the remaining portion of the media outside of the cavity. 
         [0004]    More in particular, the disclosure is directed to the insert assembly comprising the insert and pin which facilitates the set-up of a cylinder, and changeover from job to job. The insert assembly, which is removably attachable at the outer surface of the rotatory die cutting cylinder, eliminates the need to install pins through the bore of the cylinder and reduces set-up of the cylinder and increases operational flexibility. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is an exploded view of a rotary die cutting cylinder showing a compressible core, axial opposite journal bearers, and recesses on an outer diameter surface of the cutting cylinder for receiving one or more insert assemblies which define a plurality of die cavities with ejector pins in the die cavities. 
           [0006]      FIG. 2  is a partial cross-sectional view of one ejector pin engaging an insert assembly and another ejector pin pushing against the compressible core. 
           [0007]      FIG. 3  is a perspective view of an ejector pin. 
           [0008]      FIG. 4  is a side view of an exemplary rotary die cutting cylinder showing one insert without a die cutting cavity received in a recess of the outer face of the rotary cutting die cylinder and additional detail of an empty recess. 
           [0009]      FIG. 5  is another side view of the rotary die cutting cylinder of  FIG. 4  rotating about a center axis of the cylinder showing one insert with a die cutting cavity and another insert without a die cutting cavity. 
           [0010]      FIG. 6  is an exploded cross-sectional view of an exemplary insert assembly showing an insert with a die cavity, a bushing and a pin. 
           [0011]      FIG. 7  is a exploded view of an alternate view of the insert assembly of  FIG. 6 . 
           [0012]      FIG. 8  illustrates a kit comprising insert assemblies with inserts of the type shown in  FIGS. 1-7  in addition to instructions for assembly of the pins with the insert and a rotary cylinder. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]      FIG. 1  is an exploded view of an exemplary arrangement of a rotary die cutting cylinder assembly  20 , showing recesses  22  on an outer diameter surface of a cylinder body  24 , and plurality of inserts  26  that may be formed therein. Each of the inserts may have one or more ejector pins  28  and may have one or more die cavities  30 , depending upon the application. The rotary die cutting cylinder has a compressible core  32  and axial opposite journal bearers  34 . The compressible core  32  may be a sleeve of polyurethane or rubber-like material. The journal bearers  34  may allow the rotary cutting cylinder assembly  20  to rotate relative to the equipment in which the rotary cutting cylinder assembly is installed. The recesses  22  may be formed on the outer diameter surface of the cylinder body  24  and sized to fit the outer peripheral shape of the insert  26 . The depth of the recess  22  may be such that when the insert  26  is received in the recess, the insert may be generally flush with outer surface of the rotary die cutting cylinder body  24  with a die cutting edge  30  of the insert, if provided, extending outward therefrom. One or more inserts  26  may have die cavities  30  and each insert may have one or more ejector pin locator holes  36 . The ejector pin locator holes  36  may be in positions in the die cavity to maximize the ability of the ejector pin  28  to eject a slug from the die cavity  30  once the media is cut. The insert  26  may also have ejector pin locator holes  36  outside of any provided die cavity, as the application requires. The insert  26  may also be provided with a fastener hole  37  having a counter bore through which a mechanical fastener  38 , for instance, a socket head cap screw, may be directed in removably attaching the insert in the recess of the rotary cutting die cylinder. 
         [0014]    In the example of the anvil roll with an insert and pin eject feature, the anvil may have the same general construction as the rotary die cutting cylinder shown in  FIG. 1 , but without a die cavity or cutting surfaces. Depending upon the application, the pins may project from the insert received in the anvil roll outer diameter surface in areas that come in register with the die cavities of the rotary die cutting cylinder at selected points of rotation of the anvil roll and rotary die cutting cylinder or areas outside of the die cavities of the rotary die cutting cylinder at selected points of rotation of the anvil roll and rotary die cutting cylinder. 
         [0015]    The ejector pin  28  comprises an elongate member with proximal and distal ends  40 , 42 . The pin proximal end  40  is configured to be received in the ejector pin locator hole  36  of the insert  26  from an inside surface  44  of the insert such that the pin distal end  42  projects from an outer surface of the insert  46  when the pin  28  is installed with the rotary die cutting cylinder body. The pin proximal end  40  may have an enlarged diameter portion. For instance, as shown in the drawings, the pin proximal end  40  may comprise an annular boss extending circumferentially around the pin proximal end. The pin ejector hole  36  may extend from the inside surface  44  of the insert to the outer surface  46  of the insert. The pin ejector hole  36  may have a large diameter portion  48  extending from the inside surface  44  of the insert to an intermediate position in the insert to form a shoulder  49  in the insert which is spaced from the outer surface  46 . The cylinder body recess  22  may have a through hole  50  extending from the bottom surface of the recess to the interior of the rotary cutting die cylinder adjacent to the compressible core  32 . A bushing  52  may be received in the recess through hole  50  and the large diameter portion  48  of the pin ejector hole. The bushing  52  may have a loose fit with the large diameter portion  48  of the pin ejector hole  36  and the through hole  50  of the recess  26 , thereby allowing the bushing to be inserted and removed from the pin ejector hole from the inside surface  44  of the insert  26 , and to allow the bushing to be removed from the through hole of the recess. The bushing  52  may have a bore  54  that may have a dimension that provides a loose fit with the pin  28 , thereby allowing the pin to slide freely in the bushing bore with some side to side play. The bushing  52  may be disposed between the shoulder  49  and the compressible core  32  when the insert  26  is received in the recess  22 . The enlarged diameter portion of the pin proximal end  40  may abut the bushing  52  on one side and the compressible core  32  on the other side thereby maintaining the pin  28  in sliding engagement with the insert  26 . The pin distal end  42  may be rounded to reduce the tendency of adhesive to adhere to the ejector pin and to limit the ejector pin from penetrating the slug and retaining the slug in the cavity. 
         [0016]    In accordance with one aspect of the disclosure, the pin  28  may be assembled with the cutting cylinder body  24  by inserting the pin  28  in the bushing bore  54 , inserting the bushing  52  (with the pin inserted in the bushing bore) in the through hole  50  of the recess  22  with one side of the enlarged diameter portion of the pin proximal end  40  resting against the bushing and the other side against the compressible core  32 . The insert  26  may then be received in the recess  22  with the projecting portion of the bushing  52  in register with large diameter portion  48  of the pin ejector pin hole  36  and the pin projecting therefrom. The insert  26  may then be secured in place by directing the mechanical fastener  38  into the mounting hole  37  of the insert and a threaded hole  58  formed in the recess  22 . The insert  26 , the pin  28 , and the bushing  52  may be mounted in an anvil roll in a like manner. 
         [0017]    In accordance with another aspect of the disclosure, the ejector pins  28 , inserts, bushings, and mechanical fasteners may be supplied in a kit  60  together with a flexible die and/or rotary die cutting cylinder assembly  20  and/or anvil roll and/or its component parts. Operators using the rotary die cutting cylinder assembly  20  may access the kit  60  and be directed through instructions  62  for arranging the inserts  26 , ejector pins  28 , bushings  52 , and/or mechanical fasteners  38  in one or more holes of the die cavity depending upon the type of die utilized. For an anvil roll, the operator may be directed through instructions to arrange the inserts  26 , ejector pins  28 , bushings  52 , and/or mechanical fasteners  38  in one or more holes that match with the die cavity, or are outside of the die cavity, depending upon the type of anvil roll and rotary die cutting cylinder utilized. The instructions may include text or other indicia directing use of the inserts  26 , ejector pins  28 , bushings  52 , mechanical fasteners  38 , and/or rotary die cutting cylinder assembly  20  and/or anvil roll and/or its component parts. The inserts  26 , ejector pins  28 , bushings  52 , and/or mechanical fasteners  38  may be sold separately, in the kit  60 , or distributed together with the rotary die cutting cylinder assembly  20 , and/or anvil roll. The inserts  26 , ejector pins  28 , bushings  52 , and/or mechanical fasteners  38  may be sold separately and provided with sufficient instructions  62  directing the user to insert the ejector pins and bushings in the inserts, and into the recesses of the rotary die cutting cylinder or anvil roll as described previously. In connection with the sale or distribution of the inserts  26 , ejector pins  28 , bushings  52 , and/or mechanical fasteners  38 , cylinder  20  or compressible core  32 , the user (e.g., a purchaser of the ejector pins) is instructed that the purpose of the ejector pins, flexible die, or compressible core, is to remove, and install the components in a rotary die cutting cylinder and/or anvil roll as described previously. Several different length pins may be provided in the kit to provide operational flexibility given the media thickness, media composition, and depth of cut. Thus, the user is induced to replace, remove, and install the components in a rotary die cutting cylinder and/or anvil roll as described previously. 
         [0018]    As is seen in the foregoing description, the insert, pin, bushing and mechanical fastener, and their method of installation allows for maintaining the concentricity of the die which contributes to the quality of the products being produced by the process. The insert assembly and its method of installation are versatile and allow for use in a variety of different die and rotary cutter configurations, for instance, cutting blade size and dimensions, ejector pin hole locations and sizes, cylinder diameters, and differently shaped die cavities and ejector pin sizes. For instance, the ease of assembly of the insert and the pin with the cylinder allows an operator more flexibility in fine tuning operations, for instance, selecting a length of the pin needed for a given process based upon factors such as media thickness, media composition, depth of cut, die blade size, etc. The insert assembly is relatively inexpensive to manufacture and may be easily assembled with the die cutting cylinder. 
         [0019]    The embodiments were chosen and described in order to best explain the principles of the disclosure and their practical application to thereby enable others skilled in the art to best utilize the disclosed embodiments and with various modifications as are suited to the particular use contemplated. As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.