Roller press

Abstract

A portable roller press can be configured with a suction base to stabilize the press during operation. The suction base can allow for the roller press to remain stationary when feeding cutting or embossing dies or templates through the rollers. Substantially the entire bottom surface of the roller press can correspond to the suction base. The suction base can be configured to be generally rectangular or generally oval or circular. The spacing between the roller can be maintained to a desired tolerance that is based on a working height of corresponding cutting or embossing dies or templates. A crankshaft distinct from a roller shaft can be used to transfer rotational forces to the rollers.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/570,165, filed May 11, 2004, entitled ROLLER PRESS; which is hereby incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

A roller press and, more particularly, a roller press with means to stabilize the roller press to a substantially flat surface.

BACKGROUND OF THE DISCLOSURE

Dies and sheet cutting presses are used to cut various patterns out of sheet materials. The presses are designed to apply uniform pressure to a die through a series of rollers to cut through a sheet or a plurality of sheets simultaneously. The resulting shapes are a result of the die that is inserted into the rollers in the roller press which applies pressure to the die and the material to be cut from.

BRIEF SUMMARY OF THE DISCLOSURE

A portable roller press can be configured with a suction base to stabilize the press during operation. The suction base can allow for the roller press to remain stationary when feeding cutting or embossing dies or templates through the rollers. Substantially the entire bottom surface of the roller press can correspond to the suction base. The suction base can be configured to be generally rectangular or generally oval or circular. The spacing between the roller can be maintained to a desired tolerance that is based on a working height of corresponding cutting or embossing dies or templates. A crankshaft distinct from an axis of any the rollers can be used to transfer rotational forces to the rollers. A pinion gear on an end of the crankshaft can be used to drive a drive gear positioned on one end of a roller shaft. The ratio of teeth on the drive gear relative to the pinion gear can be designed to reduce the rotational force needed to feed the cutting or embossing dies or templates through the rollers.

An embodiment of the disclosure includes a roller press including a frame, a crankshaft supported by the frame and configured to receive a first rotational force, a first roller supported by the frame and having a first roller shaft coupled to the crankshaft and configured to rotate based on a rotation of the crankshaft, a second roller supported by the frame and having a second roller shaft coupled to the first roller shaft and configured to rotate synchronized to the rotation of the first roller, and a suction base coupled to the frame and configured to stabilize the roller press by applying a partial vacuum on at least a portion of the suction base.

An embodiment of the disclosure includes a roller press including a frame, a crankshaft supported by the frame and configured to receive a first rotational force, a pinion gear positioned near a first end of the crankshaft, a first roller supported by the frame and having a first roller shaft, a drive gear positioned on the first roller shaft and coupled pinion gear to rotate the first roller shaft based on a rotation of the crankshaft, a first roller gear positioned on the first roller shaft, a second roller supported by the frame and having a second roller shaft, a second roller gear positioned on the second roller shaft and coupled to the first roller gear and configured to rotate synchronized to the rotation of the first roller, and a suction base coupled to the frame and configured to stabilize the roller press by applying a partial vacuum on at least a portion of the suction base.

An embodiment of the disclosure includes a method of rolling material in a roller press, including stabilizing a roller press to a surface using a partial vacuum, rotating a crankshaft of the roller press, and supplying a working material to a working area of the roller press.

An embodiment of the disclosure includes a method of manufacturing a roller press, including locating the crankshaft in the frame, locating the first roller in the frame so as to couple the first roller shaft to the crankshaft, locating the second roller in the so as to couple the second roller shaft to the first roller shaft, and coupling the frame to the suction base.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, objects, and advantages of embodiments of the disclosure will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like elements bear like reference numerals.

FIG. 1 illustrates an embodiment of a roller press.

FIG. 2 illustrates a front view of an embodiment of a roller press.

FIG. 3 illustrates a top view of an embodiment of a roller press.

FIG. 4 illustrates aside view of an embodiment of a roller press.

FIG. 5 illustrates a side view of an embodiment of a roller press.

FIG. 6 illustrates an embodiment of an inner gear mechanism of a roller press.

FIG. 6A illustrates a schematic representation of roller direction and force applied by an embodiment of a roller press.

FIG. 7 illustrates views of an embodiment of a frame and rollers of a roller press.

FIG. 8 illustrates a perspective view of an embodiment of a suction base.

FIG. 9 illustrates a phantom view of the embodiment of the suction base.

FIG. 10 illustrates a phantom side view of the embodiment of the suction base.

FIG. 11 illustrates a phantom front view of the embodiment of the suction base.

FIG. 12 illustrates a cross sectional view of the embodiment of the suction base.

FIG. 13 illustrates a phantom top view of the suction base.

FIG. 14 illustrates views of an embodiment of a lever used with the suction base.

FIG. 15 illustrates views of an embodiment of a shaft arm used with the suction base.

FIG. 16 illustrates views of an embodiment of a base for use with the suction base.

FIG. 17 illustrates sectional view of the embodiment of the suction base.

FIG. 18 illustrates an embodiment of a roller.

FIG. 19 illustrates an embodiment of a roller.

FIG. 20 illustrates an embodiment of a crank handle.

FIG. 21 illustrates an embodiment of a crankshaft.

FIG. 22 illustrates an embodiment of a bottom frame portion.

FIG. 23 illustrates an embodiment of a top frame portion.

FIG. 24 illustrates an embodiment of a thrust spacer.

FIG. 25 illustrates an embodiment of a thrust spacer.

FIGS. 26A-B illustrate isometric and side views of a roller frame and roller portion of an embodiment of a roller press.

FIGS. 27A-C illustrate views of an embodiment of a cutting assembly.

DETAILED DESCRIPTION OF THE DISCLOSURE

FIG. 1 illustrates a roller press 10 according to the present disclosure, wherein the roller press 10 may be secured to a flat working surface by use of a suction base 12, as further described below. The roller press 10 as described herein may be utilized with any cutting or embossing dies or templates, and also may be utilized with what is known as thin dies or chemically etched dies which may have a width of approximately two and a half inches.

As also shown in FIG. 1, the press 10 includes a crank handle 14 which can be used to apply force to the rollers, as further described below. The press 10 further includes a cover 16 which covers the gears and other internal workings of the press. The press 10 also includes a feed surface 18 which is located on each side of a working area 20. The working area 20 is defined by the space between the rollers, as will be further described below. The feed surface 18 provides a resting surface for a die or embossing template, or the like that is fed into the working area 20. Positioning a feed surface 18 on each side of the working area 20 allows material to be supported on both the input side and output sides of the press 10. Additionally, positioning a feed surface 18 on each side of the working area 20 allows material, such as a die or embossing template, to be fed into the press 10 from either side.

FIG. 2 illustrates a front view of the press 10 as disclosed herein, and further illustrates a suction lever 22 which is operated by the user to activate and deactivate the suction base 12. The suction lever 22 can be rotated to substantially deform a portion of the suction base 12, thereby creating a low pressure area under the suction base 12 when the suction base is positioned on a relatively flat surface. The working area 20 is further illustrated in FIG. 2, to be the area where the die with shuttle or embossing template or the like is inserted into while the crank handle 14 is rotated by the user.

FIG. 3 illustrates a top view of the press of the present disclosure.

FIG. 4 illustrates a righthand side view of the press 10 of the present disclosure. Likewise, FIG. 5 illustrates a left side view of the press 10 of the present disclosure.

FIG. 6 illustrates the inner gear mechanism of the press 10, wherein the gears and rollers are supported by a frame illustrated by 24. The frame supports a top roller 25 and a bottom roller 27. The crank handle 14 includes a crank shaft 29 with a bushing at the frame on the crank handle end and a crank pinion gear 26 at the opposite end of the frame. The crank pinion gear 26 meshes with and rotates a top roller gear 28. The top roller gear 28 is coupled to and rotates with the top roller 25. Likewise, at the crank handle end of the frame, roller gear 32 rotates when the top roller 25 rotates. Likewise, a bottom roller gear 30 is meshed with and rotates in an opposite direction than the top roller gear 32. When bottom roller gear 30 rotates, since it is coupled to the bottom roller 27, the bottom roller 27 rotates in a direction opposite than the upper roller 25.

As shown in FIG. 6A, as shown in a schematic representation, the lower or bottom roller 27 rotates in a first direction with the top roller 25 rotating in an opposite direction, therefore producing a force in a direction A, as shown in FIG. 6A as being right to left. Therefore, the die, for example, would be fed through the rollers in a right to left orientation as shown in FIG. 6A. It will be appreciated by those skilled in the art that the rollers may rotate in both directions so that dies may be fed through the roller press from and to both sides.

FIG. 7 illustrates additional front, side and top views of the frame, the rollers, and the gears as illustrated in FIG. 6.

FIG. 8 illustrates a perspective view of a separate embodiment of the suction base 12, shown as item 34. Although the suction base 12 is shown as substantially the entire lower surface, such is not a requirement, and a suction base may include a plurality of smaller suction surfaces, each operated by one or a plurality of levers. FIG. 9 illustrates a phantom top view of the suction base 34. FIG. 10 illustrates a side view of the suction base 34, and FIG. 11 provides a front view of the suction base 34. The suction base 34, just as the suction base 12 operate in substantially the same manner, however the suction base 12 shown in FIG. 1 has a rectangular configuration, while the suction base 34 as shown in FIG. 8 has a circular configuration. In any event, the suction bases of the present disclosure operate by a lever 22 being operated or rotated to create a suction of the bottom surface of the suction base relative to a flat surface that the press 10, with the suction base is resting on.

As shown in FIG. 12, a cross-sectional view of the suction base 34 includes the handle 22, a resilient or rubber base material 34, and a housing 36. Internal of the housing 36 is a cam 38 that is connected to the rubber base 34 via a U-shaped bracket 40 that is secured to the internal surface of the rubber base 34. The cam 38 rotates when the handle 22 is rotated at one end and rotates through a coupling 42 opposite of the handle end. Therefore, when the lever is rotated, and the cam 38 is rotated, pressure is applied to the rubber base 34 via the U-shaped bracket 40, creating a partial vacuum or low pressure area between the rubber base 34 and the flat surface adjacent to the rubber base 34 that the press 10 is resting upon. When it is desired to remove the press from the flat surface that the press is resting upon, the user rotates the handle 22 so as to eliminate the partial vacuum created between the deformable rubber base 34 and the flat surface that the press is resting upon.

FIG. 14 illustrates manufacturing drawings for the lever, handle, or knob utilized with the suction base.

FIG. 15 illustrates manufacturing drawings for the cam, or shaft arm 38 according to the present disclosure. The shaft arm 38 couples the suction lever 22 to the resilient material of the suction base such that the rotation of the suction lever is coupled through the shaft arm 38 to at least a portion of the resilient material to deform the material thereby creating a low pressure area when the suction base is placed on a substantially flat surface.

FIG. 16 illustrates manufacturing drawings for the suction base 36 according to the present disclosure. FIG. 17 illustrates the rubber surface 34, otherwise known as a suction cup housing as disclosed herein.

FIG. 18 illustrates detailed drawings for the top roller 25.

FIG. 19 illustrates the bottom roller 27.

FIG. 20 illustrates the handle utilized with the crank handle 14.

FIG. 21 illustrates the crank shaft 29 according to the present disclosure. FIGS. 22, 23, 24, and 25 illustrate the components that comprise the frame 24 shown in FIG. 6. Providing further detail, FIG. 22 illustrates the bottom portion of the frame, FIG. 23 illustrates the top portion of the frame, in which the bottom frame and the top frame interlock with each other so that the holes are aligned for the crank shaft and for the rollers. At one end of the frame, as shown in FIG. 6, is a thrust spacer with closed holes, as shown in FIG. 25 illustrated as item 44 in FIG. 25 and item 44 in FIG. 6. At the opposite side internally of the frame and partially shown in FIG. 6 is the thrust spacer with open holes illustrated as 46 both in FIG. 24 and in FIG. 6. The thrust spacer with the open holes allows the spacer to be removed from the assembled roller assembly to disassemble same.

FIG. 26A shows an isometric view of an embodiment of the upper roller 25 and the lower roller 27 positioned within a frame 24. The frame can be formed of a substantially rigid material, such as zinc, aluminum, or magnesium. Of course, the frame 24 may be manufactured of some other substantially rigid material that maintains the relationship of the top roller 25 to the bottom roller 27 and does not substantially deform under operation. Thus, the frame material may also include plastic, steel, and the like. The frame can be, for example, die cast, machined, or otherwise formed.

FIG. 26B shows a front view of the roller assembly and shows the working height maintained between the upper roller 25 and the lower roller 27. The distance between the roller 25 and 27 can be determined, in part, based on the working height of the material that is to be passed through the rollers 25 and 27. The distance between the rollers 25 and 27 can be configured to allow a chemical etched cutting die to penetrate the material into a corresponding cutting pad by an amount that is greater than 0.015 inch and advantageously approximately 0.050 inch. A smaller amount of penetration may not allow complete cutting of the material, while a larger penetration may require an undue amount of force to pass the material through the rollers.

For example, the distance between the rollers 25 and 27 can be maintained to within a tolerance of less than approximately 0.010 inch when using a cutting die that uses a chemical etched die. The total distance between the outside diameters of the top roller 25 and bottom roller 27 can be maintained to approximately 0.317±0.005 inch when an associated cutting assembly has a working height of approximately 0.325 inch, not including the material being worked. This can correspond to a distance of approximately 0.907 inches between the rotating axis of the top roller 25 and the rotating axis of the bottom roller 27.

FIG. 26B shows a front view of the roller assembly and illustrates the relationship between the pinion gear 26 and drive gear 28 positioned substantially on one end of the rollers 25 and 27 or the roller shafts on which the rollers can be mounted. The top roller gear 32 and bottom roller gear 30 can be positioned on substantially the opposite side of the rollers 25 and 27. The pinion gear 26 can have gear teeth that engage with complementary gear teeth on the drive gear 28. The relationship between the ratio of the teeth on the drive gear 28 relative to the number of teeth on the pinion gear 26 can be adjusted based in part on the desired torque multiplication. For example, for a hand driven roller press, the ratio of the teeth on the drive gear 28 to the pinion gear 26 can be approximately 5:1 and is typically greater than about 4:1. The ratio can be reduced if the length of the crank handle is increased, and may be further increased if the length of the drive handle is decreased. However, the dimensions of the frame generally limit the range of gear ratios.

FIG. 27A-C illustrates an embodiment of a shuttle that can be used with the roller press. The shuttle can include an upper sheet 112 and a lower sheet 114. The sheets 112 and 114 may be made of a polycarbonate, nylon, or other polymer material that may include a conformable cutting pad which allows the transfer of force from the rollers through to the die 110 and the sheet material to be cut from, shown in the side view of FIG. 27B as a piece of paper 120. The shuttle, which comprises the die 110 and the two polymer sheets 112 and 114 are fed into the working area between the rollers by feeding the shuttle into the rollers via the feed surface areas. The crank handle can be rotated and the rollers work in cooperation with each other to feed the shuttle from one side of the press to the other side of the press, while applying pressure to the shuttle.

Although the disclosure has been described by way of example and with reference to particular embodiments thereof it is to be appreciated that improvements or modifications may be made thereto without departing from the scope and spirit of the disclosure as set out in the claims.

Claims

1. A roller press comprising:

a frame;

a crankshaft supported by the frame and configured to receive a first rotational force;

a first roller supported by the frame and having a first roller shaft coupled to the crankshaft and configured to rotate based on a rotation of the crankshaft;

a second roller supported by the frame and having a second roller shaft coupled to the first roller shaft and configured to rotate synchronized to the rotation of the first roller; and

a suction base coupled to the frame and configured to stabilize the roller press by applying a partial vacuum on at least a portion of the suction base.

2. The roller press of claim 1, wherein the frame comprises:

an upper frame portion having a plurality of holes positioned to align the locations of the crankshaft, first roller and second roller; and

a lower frame portion configured to interlock with the top frame portion, and having a plurality of holes configured to align with the plurality of holes in the upper frame portion when the upper frame portion is interlocked with the lower frame portion.

3. The roller press of claim 1, wherein the frame is configured to position the first roller substantially a predetermined distance from the second roller, the predetermined distance based on a working height of an associated template.

4. The roller press of claim 1, wherein the frame is configured to locate the axis of the first and second rollers within a tolerance varying less than approximately 0.010 inch.

5. The roller press of claim 1, further comprising:

a pinion gear with gear teeth positioned on the crankshaft; and

a drive gear with gear teeth positioned on the first roller shaft and coupled to the pinion gear, the drive gear having at least four times the number of gear teeth of the pinion gear.

6. The roller press of claim 1, further comprising:

a drive gear positioned on the first roller shaft and configured to rotate based on the rotation of the crankshaft;

a first roller gear positioned on the first roller shaft; and

a second roller gear positioned on the second roller shaft coupled to the first roller gear, and configured to rotate in a substantially opposite direction of the first roller gear.

7. The roller press of claim 1, further comprising a feed surface configured to align a work piece with a space between the first and second rollers.

8. The roller press of claim 1, further comprising a cover configured to substantially cover the crankshaft and first and second rollers, the cover having at least one opening substantially aligned with a working area between the first and second rollers.

9. The roller press of claim 1, wherein the suction base comprises:

at least one resilient material covering at least a portion of a bottom of the suction base; and

a lever coupled to the resilient material and configured to displace a portion of the resilient material so as to produce a partial vacuum beneath the suction base.

10. The roller press of claim 9, wherein the resilient material substantially covers all of a substantially rectangular bottom of the suction base.

11. The roller press of claim 9, wherein the resilient material substantially covers all of a substantially oval bottom of the suction base.

12. A roller press comprising:

a frame;

a crankshaft supported by the frame and configured to receive a first rotational force;

a pinion gear positioned near a first end of the crankshaft;

a first roller supported by the frame and having a first roller shaft;

a drive gear positioned on the first roller shaft and coupled pinion gear to rotate the first roller shaft based on a rotation of the crankshaft;

a first roller gear positioned on the first roller shaft;

a second roller supported by the frame and having a second roller shaft;

a second roller gear positioned on the second roller shaft and coupled to the first roller gear and configured to rotate synchronized to the rotation of the first roller; and

a suction base coupled to the frame and configured to stabilize the roller press by applying a partial vacuum on at least a portion of the suction base.

13. The roller press of claim 12, wherein the first roller gear is positioned on the first roller shaft substantially opposite the drive gear.

14. The roller press of claim 12, wherein the drive gear is configured to rotate completely at least four times for each complete rotation of the drive gear.

15. The roller press of claim 12, wherein the suction base comprises a substantially rectangular suction base.

16. The roller press of claim 12, wherein the suction base comprises a substantially oval suction base.

17. The roller press of claim 12, wherein the suction base comprises:

a resilient material; and

a lever coupled to the resilient material and configured to displace a portion of the resilient material so as to produce a partial vacuum beneath a portion of the suction base.

18. The roller press of claim 17 wherein the suction base further comprises a shaft arm coupled to the lever and the resilient material, the shaft arm configured to deflect the portion of the resilient material when the shaft arm is rotated.

19. A method of rolling material in a roller press, the method comprising:

stabilizing a roller press to a surface using a partial vacuum;

rotating a crankshaft of the roller press; and

supplying a working material to a working area of the roller press.

20. A method of manufacturing the roller press of claim 1, the method comprising:

locating the crankshaft in the frame;

locating the first roller in the frame so as to couple the first roller shaft to the crankshaft;

locating the second roller in the so as to couple the second roller shaft to the first roller shaft; and

coupling the frame to the suction base.