Method for manufacturing punch capable of punching and embossing simultaneously

Abstract

Disclosed is a method for manufacturing a punch, which includes the steps of injection-molding a jig with melted materials so that a lower plate and an upper plate are integrally formed at least partially to connect cutting holes to be formed in the lower and upper plates and also so that a convex embossment is formed on the lower plate; cutting a connection portion of the lower and upper plates to form a gap in which a sheet member is to be supplied so that the cutting holes are separated between the lower and upper plates, the cutting work being conducted so that an upper surface of the lower plate is formed to have a height greater than an upper surface of the formed convex embossment; and assembling a punching member, which includes at least one first punch pin passing through the cutting holes to punch the sheet member and form a predetermined pattern therein and a second punch pin having a concave embossment at a front end thereof in correspondence to the convex embossment, to the jig.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/886,391, filed Jul. 6, 2004, which is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a punch, and more particularly to a method for manufacturing a punch capable of simultaneously punching and embossing a sheet member such as a card, a letter paper, a picture, a board, or a paper in a predetermined pattern.

BACKGROUND OF THE INVENTION

A punch generally includes a jig having a cutting hole of a predetermined pattern, a base for supporting the jig below it, and a punching member having a sharp cutting blade which slides through the cutting hole of the jig. This punch punches a sheet member according to the pattern of the cutting hole when the punching member passes through the jig by means of the stroke operation for descending the punching member toward the jig while the predetermined sheet member is put into a corresponding punching area of the jig.

In the punch configured as mentioned above, it is also possible to form an embossing design of a predetermined pattern in the sheet member if a convex embossment (or, a concave embossment) of a predetermined pattern is formed on the surface of the jig and a concave embossment (or, a convex embossment) in correspondence with the convex embossment (or, the concave embossment) is formed at the front end of the punching member.

However, since the conventional punch is configured just to perform either a punching function or an embossing function, a user should handle two kinds of punches to decorate a sheet member with a punching design and an embossing design together. In addition, when using each punch, the user may measure a punching point and an embossing point just with the eye whenever conducting the punching or embossing work, so the obtained punching and embossing patterns are irregular, and even a complex design is impossible to work.

SUMMARY OF THE INVENTION

The present invention is designed to solve the problems of the prior art, and therefore it is an object of the present invention to provide a method for manufacturing a punch capable of simultaneously punching and embossing a sheet member in a predetermined pattern by just one stroke.

Another object of the invention is to provide a method for manufacturing a punch capable of forming various punching and embossing designs, which is impossible in the prior art, by mixing a punching member with pins for embossing in various ways.

In order to accomplish the above object, the present invention provides a method for manufacturing a punch, comprising the following steps of: (a) injection-molding a jig with melted materials so that a lower plate and an upper plate are integrally formed at least partially to connect lower and upper cutting holes to be formed on the lower and upper plates respectively and also so that a convex embossment is formed on the lower plate; (b) cutting a connection portion of the lower and upper plates to form a gap through which a sheet member is to be supplied so that the lower and upper cutting holes are separated on the lower and upper plates respectively, and so that an upper surface of the lower plate is formed at the position higher than an upper surface of the convex embossment; and (c) assembling a punching member, which includes a first punch pin passing through the cutting holes to punch the sheet member and form a predetermined pattern therein and a second punch pin having a concave embossment at a front end thereof in correspondence to the convex embossment, to the jig.

Preferably, a trimming hole on the lower plate for cutting a marginal edge of the sheet member are integrally formed with a guide opening on the upper plate for guiding vertical movement of a punch pin corresponding to the trimming hole in the step (a), and the trimming hole and the guide opening are separated by cutting in the step (b).

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and aspects of the present invention will become apparent from the following description of embodiments with reference to the accompanying drawing in which:

FIG. 1 is an exploded perspective view showing a punch according to a preferred embodiment of the present invention;

FIG. 2 is a perspective view showing the punch of FIG. 1, which is assembled;

FIG. 3 is a partially sectioned perspective view showing an inner configuration of a jig of FIG. 1 in detail;

FIG. 4 is a side view schematically showing a type of punching member provided to the punch of the present invention;

FIG. 5 is a partially exploded perspective view showing a punching member in correspondence with FIG. 3;

FIG. 6 is a plane view showing an example of a punching and embossing pattern formed in a sheet member according to the present invention;

FIG. 7 is a side view schematically showing another type of punching member provided to the punch of the present invention;

FIG. 8 is a partially exploded perspective view showing a punching member according to the type of FIG. 7;

FIG. 9 is a plane view showing a front end surface of an integrated punch pin of FIG. 8;

FIG. 10 is a partially sectioned perspective view showing an example of the jig in correspondence with FIG. 8;

FIG. 11 is a plane view showing another example of a punching and embossing pattern formed in the sheet member according to the present invention;

FIG. 12 is a plane view showing that a sheet member is supplied to a punching area for usage of the punch according to the present invention;

FIG. 13 is a perspective view showing a jig of a punch according to another embodiment of the present invention;

FIG. 14 is a sectioned perspective view showing the jig in correspondence with FIG. 13;

FIG. 15 is a plan view showing the jig in correspondence with FIG. 13;

FIG. 16 is a sectional view showing the jig in correspondence with FIG. 14;

FIG. 17 is a perspective view showing a punching member in correspondence with the jig of FIG. 13;

FIG. 18 is a plane view showing an example of a punching and embossing pattern formed in the sheet member according to another embodiment of the present invention;

FIG. 19 is a flow chart showing a method for manufacturing a punch according to the present invention;

FIG. 20 is a sectional view showing a mold corresponding to the jig of FIG. 16 according to the method of the present invention; and

FIG. 21 is a sectional view showing a preform of the jig taken from the mold of FIG. 20 according to the method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the present invention will be described in more detail referring to the drawings.

FIG. 1 is an exploded perspective view showing a punch according to a preferred embodiment of the present invention, and FIG. 2 is a perspective view showing the punch of FIG. 1 in an assembled state.

Referring to FIGS. 1 and 2, the punch of the present invention includes a jig 100 having a punching area 101, a base 105 for supporting the jig 100, a punching member 115 for punching and embossing a sheet member supplied to the jig 100 with selectively descending against the jig 100, and a handle 130 used for pressing the punching member 115.

The jig 100 supports the supplied sheet member and gives the punching area 101 for punching and embossing the sheet member in a predetermined pattern. As exemplary shown in FIG. 3, the punching area 101 of the jig 100 has at least one cutting hole 101a of a predetermined pattern and at least one convex embossment 102 of a predetermined pattern at a position spaced apart from the cutting hole 101a. Here, the punch of the present invention is not limited to the above example, but may be modified so that a concave embossment of a predetermined pattern is formed in the jig 100, of course.

Preferably, the jig 100 may have an upper plate 100a and a lower plate 100b, which are faced in parallel with each other so that a gap G is interposed between them for insertion of a sheet member to be punched. In this case, the cutting hole 101a is formed in the upper plate 100a and the lower plate 100b respectively, and the convex embossment 102 is formed only in the lower plate 100b. Additionally, a guide hole 101b for guiding movement of a corresponding punch pin may be formed in the upper plate 100a in correspondence to the convex embossment 102.

The base 105 supports the jig 100 below it and gives a support surface for supplying a sheet member to the punching area 101.

The punching member 115 is installed to be vertically movable against the jig 100, and acts for punching and embossing a sheet member supplied to the jig 100 when it descends. For convenient handling of the punching member 115, an elastic body 110 for elastically biasing the punching member 115 upward is interposed between the punching member 115 and the jig 100. Preferably, the elastic body 110 is a spring, which is symmetrical to the punching area 101 and biases the punching member 115 upward with being held by a plurality of protrusions 103 formed on the upper plate 100a of the jig 100.

The punching member 115 has an assembly of punch pins, which are respectively corresponding to the cutting hole 101a and the convex embossment 102 of the jig 100 and protruded downward. The punching member 115 may be classified into two types respectively shown in FIGS. 4 and 7 according to the structure of the punch pin assembly.

The punching member 115 schematically shown in FIG. 4 has a punch pin assembly, composed of at least one punch pin 116 having a cutting blade at its front end, and at least one second punch pin 117 having a concave embossment (or, a convex embossment) at its front end and having a body separated from the first punch pin 116. The punching member 115 conducts punching and embossing to a sheet member at the same time when it descends against the jig 100. Here, the first punch pin 116 is preferably longer than the second punch pin 117 for easier punching. More specifically, a length difference d between the first punch pin 116 and the second punch pin 117 is preferably larger than the gap G of the jig 100.

FIG. 5 shows an example of the punching member 115 corresponding to the jig 100 of FIG. 3. The punching member 115 of FIG. 5 is also substantially corresponding to the type of FIG. 4. Referring to FIG. 5, in the punching member 115, a first punch pin 116 corresponding to the cutting hole 101a of the jig 100 and having a cutting blade 116a at its front end and a second punch pin 117 having a concave embossment corresponding to the convex embossment 102 of the jig 100 at its front end 117a are arranged in a predetermined pattern. The first punch pin 116 is longer than the second punch pin 117 as much as at least the gap G of the jig 100. Additionally, the punching member 115 may be further provided with a rim cutting pin 118 for cutting a rim portion of the sheet member in a predetermined pattern.

When using the punching member 115 and the jig 100 configured as mentioned above, at a stroke of the punching member 115, the first punch pin 116 passes through the cutting hole 101a of the jig 100 to punch the sheet member, and then the second punch pin 117 is compressed with the convex embossment 102 of the jig 100 with the sheet member positioned between them to emboss the sheet member. Thus, as shown in FIG. 6, a punching pattern 2 and an embossing pattern 3 are formed in the sheet member 1 at the same time. In addition, the rim portion is also cut away in a predetermined pattern.

Meanwhile, FIG. 7 shows a punching member 215 having an integrated punch pin 216, in which an embossing unit and a punching unit are provided integrally. Referring to FIG. 7, at least one integrated punch pin 216 is arranged to the punching member 215 in a predetermined pattern, and other punch pins for either punching or embossing may also be further provided. The integrated punch pin 216 includes an embossing unit of which a diameter is relatively large, and a punching unit protruded from one side of the embossing unit and extended to a front end thereof with a diameter relatively smaller than the embossing unit. In addition, a concave embossment (or, a convex embossment) of a predetermined pattern is formed on the front end surface of the embossing unit of the integrated punch pin 216, and a cutting blade is formed at the front end surface of the punching unit, so the integrated punch pin 216 punches and embosses the sheet member at the same time when it descends against the corresponding jig. In the integrated punch pin 216, the length L from the front end surface of the embossing unit to the front end surface of the punching unit is preferably greater than the gap G of the jig for better punching work.

FIG. 8 shows an example of a punching member 215 corresponding to the type of FIG. 7 in detail, and FIG. 10 shows a jig 300 corresponding to the punching member 215 as an example.

Referring to FIG. 8 first, the punching member 215 is provided with at least one integrated punch pin 216 of a predetermined pattern, which conducts punching and embossing at the same time. Additionally, the punching member 215 may be further provided with other punch pins 217 for punching only without embossing, and a rim cutting pin 118 for cutting away a rim of the sheet member.

The integrated punch pin 216 includes, as shown in FIG. 9, an embossing unit 219 having a first front end surface 219a on which a concave embossment corresponding to the convex embossment 302 (see FIG. 10) of the jig 300 is formed, and a punching unit 218 having a second front end surface on which a cutting blade corresponding to the cutting hole 301c of the jig 300 is formed.

The first front end surface 219a of the embossing unit 219 is at least corresponding to a partial sectional area of the integrated punch pin 216, and the concave embossment corresponding to the convex embossment 302 of the jig 300 is formed thereon. In addition, the second front end surface 218a of the punching unit 218 is corresponding to a remained sectional area of the integrated punch pin 216, and the cutting blade corresponding to the cutting hole 301c of the jig 300 is formed thereon. The second front end surface 218a is further protruded rather than the first front end 219a. Preferably, the second front end surface 218a of the punching unit 218 may be perpendicularly protruded from the center portion of the first front end surface 219a of the embossing unit 219 so that a punching pattern is formed at the center of an embossing pattern.

The jig 300 of FIG. 10, which corresponds to the punching unit 215, includes a convex embossment 302 of a predetermined pattern formed on the lower plate 300b of the jig 300, and a cutting hole 301c of a predetermined pattern formed in the lower plate 300b at a position adjacent to the convex embossment 302. Preferably, a guide hole 301b for guiding movement of the punch pin corresponding to the convex embossment 302 is formed in the upper plate 300a.

A position of the convex embossment 302 adjacent to the cutting hole 301c may be located out of the convex embossment 302, or at the center of the convex embossment 302. Here, if the cutting hole 301c is formed to pass through the center of the convex embossment 302, it is possible to obtain a design in which a punching pattern is formed at the center of an embossing pattern.

Additionally, it is also possible that cutting holes 301a of a predetermined pattern corresponding to other punch pins 217 of the punching member 215, not adjacent to the convex embossment 302, are formed in the upper and lower plates 300a and 300b.

When using the punching member 215 and the jig 300 configured as above, at the stroke of the punching member 215, the punching unit 218 of the integrated punch pin 216 passes through the cutting hole 301c of the jig 300 to punch the sheet member, and then the concave embossment of the embossing unit 219 of the integrated punch pin 216 is compressed with the convex embossment 302 of the jig 300 with the sheet member interposed therebetween to emboss the sheet member. Thus, as shown in FIG. 11, it is possible to obtain a design in which a punching pattern 2 passing through an embossing pattern 3 is formed together with other punching patterns 2, and a rim portion is additionally cut away in a predetermined pattern.

In addition to that, a button member 120 may be combined upon the punching member 115 or 215. The button member 120 is covered by a cap 125, which is combined with the base 105 with an open top, so an upper portion of the button member 120 is partially exposed. A rim portion of the button member 120 around the exposed upper portion is supported by the cap 125 so as to prevent the button member 120 from being deviated out due to an elastic force applied to the punching member 115 or 215. The cap 125 is combined to the lower base 105 with covering not only the button member 120 but also the punching member 115 or 215 and the elastic body 110 in a bundle. According to this configuration, a user may conveniently move the punching member 115 or 215 downward toward the punching area 101 of the jig 100 or 300 by downwardly pressing the button member 120 exposed outward.

Preferably, the button member 120 is pressed by using the handle 130 pivotably connected to one side of the base 105 by means of a hinge 106, which ensures the user to descending the button member 120 more easily.

Now, operation of the punch configured as mentioned above according to a preferred embodiment of the present invention will be described.

First, as shown in FIG. 12, a sheet member is put in the punching area 101 of the jig 100 or 300. Then, a user pushes the handle 130 downward by hand, so the handle 130 is pivoted against the base 105 to press the button member 120 downward. Then, the punching member 115 or 215 also descends toward the punching area 101 of the jig 100 or 300 together with the button member 120, thereby punching and embossing the sheet member in a predetermined pattern.

More specifically, in case the punching member 115 is provided with the first punch pin 116 having the cutting blade 116a and the second punch pin 117 having the concave embossment 117a, and the cutting hole 110a corresponding to the first punch pin 116 and the convex embossment 102 corresponding to the concave embossment 117a are formed in the upper and lower plates 100a and 100b of the jig 100, the first punch pin 116 passes through the cutting hole 101a of the upper plate 100a of the jig 100, the sheet member 1, and the cutting hole 101a of the lower plate 100b subsequently, thereby punching the sheet member, when the punching member 115 descends. After that, the second punch pin 117 descends through the guide hole 101b of the upper plate 100a so as to compress the sheet member 1 between the second punch pin 117 and the convex embossment 102, thereby embossing the sheet member 1.

In addition, in case the punching member 215 is provided with the integrated punch pin 216, which includes the embossing unit 219 having the first front end surface 219a on which the concave embossment is formed and the punching unit 218 having the second front end surface 218a on which the cutting blade is formed, and the convex embossment 302 corresponding to the concave embossment is formed on the jig 300, the second front end surface 218a of the punching unit 218 passes through the guide hole 301b of the upper plate of the jig 300, the sheet member 1 and the cutting hole 301c of the lower plate subsequently, thereby punching the sheet member 1, while the punching member 215 descends. After that, the first front end surface 219a of the embossing unit 219 compresses the sheet member 1 between the first front end surface 219a and the convex embossment 302 of the jig 300, thereby embossing the sheet member 1.

FIGS. 13 to 15 show a jig 400 of a punch according to another embodiment of the present invention. FIG. 17 shows a punching member 450 corresponding to the jig 400.

The jig 400 includes a lower plate 410 on which lower cutting holes 411 of a predetermined pattern, a convex embossment 412 and a trimming hole 413 for cutting a marginal edge of a sheet member to be punched are formed.

In addition, the jig 400 includes an upper plate 420 facing the lower plate 410 with a gap G between them, where upper cutting holes 421 having the same pattern as the lower cutting holes 411 and a guide opening 422 for guiding vertical movement of punch pins corresponding to the convex embossment 412 and the trimming hole 413 are formed.

The punching member 450 shown in FIG. 17 has a cutting blade formed at its front end, and the punching member 450 includes at least one first punch pin 451 passing through the upper and lower cutting holes 421 and 411, a second punch pin 452 having a concave embossment 453 corresponding to the convex embossment 412 at its front end and guided by the guide opening 422, and a third punch pin 454 having a cutting blade at its front end and passing through the trimming hole 413. Here, the first and third punch pins 451 and 454 are preferably formed to have a longer length than the second punch pin 452.

When a sheet member 1 is supplied between the lower plate 410 and the upper plate 420 and then the punch member 450 is pressed, the first and third punch pins 451 and 454 pass through the upper and lower cutting holes 421 and 411 and the trimming hole 413 to punch the sheet member, which may make a punching design in a predetermined pattern 12 as shown in FIG. 18. At the same time, as the second punch pin 452 descends and presses the sheet member against the convex embossment 412, an embossing pattern 13 as shown in FIG. 18 may be obtained.

According to this embodiment, as well understood from FIG. 16, the convex embossment 412 formed on the lower plate 410 has a height lower than an upper surface 410a, that is a surface on which the sheet member is placed, of the lower plate 410 by a predetermined distance D. This configuration may be realized by a specific punch manufacturing method of the present invention.

A reference numeral 403 denotes protrusions, which are substantially identical to the protrusions 103 of FIG. 3 and not described in detail here.

In the method for manufacturing the punch according to this embodiment, a manufacture process of the jig 400 is shown in FIG. 19. Referring to FIG. 19, a mold corresponding to the shape of the jig 400 is prepared (S100). FIG. 20 is a sectional view showing a preferable example of the mold 500 corresponding to a section of the jig of FIG. 16.

Inner spaces S1, S2 and S3 of the mold 500 are filled with materials, for example melted zinc that will be made into a jig. According to the present invention, the lower plate 410 and the upper plate 420 of the jig 400 are not individually molded in separate molds but integrally molded in the spaces S1 and S3.

In particular, the upper and lower cutting holes 421 and 411 of a punching pattern to be formed in the lower plate 410 and the upper plate 420 are integrally formed using a single molding element 501. In addition, the trimming hole 413 of the lower plate 410 is integrally formed with the guide opening 422 by means of a molding element 502.

Here, the convex embossment 412 to be formed on the lower plate 410 is formed by the mold 500.

When the mold 500 configured as mentioned above is prepared, a melted metal such as zinc is then put into the mold to injection-mold a jig (S200).

FIG. 21 schematically shows a preform 600 of the injection-molded jig. As shown in FIG. 21, the lower plate 410 and the upper plate 420 are formed to be integrally connected with each other, and the lower and upper cutting holes 411 and 412 are interconnected and integrally formed. In addition, the trimming hole 413 is integrally formed with the guide opening 422.

Subsequently, a side portion of the preform 600 of the jig is cut away as much as the gap G to divide the lower plate 410 and the upper plate 420, and at the same time a space for supplying a sheet member to be punched is formed therebetween (S300). In FIG. 21, a portion that will be removed by cutting is shown as a dotted line DL. Accordingly, the lower and upper cutting holes 411 and 421 are also separated on the lower plate 410 and the upper plate 420 respectively, and the trimming hole 413 is also separated from the guide opening 422.

According to the method wherein the lower plate 410 and the upper plate 420 are integrally formed and then the gap G is formed between the lower plate 410 and the upper plate 420 by cutting as mentioned above, the lower and upper cutting holes 411 and 421 and the trimming hole 413 may be aligned very precisely. Otherwise, in the conventional technology in which the lower and upper cutting holes 411 and 421 and the trimming hole 413 are shaped in an injection molding process using a mold, a molded jig may be deformed due to distribution of melted materials or difference of cooling rates, and accordingly the alignment of the cutting holes 411 and 421 and the trimming hole 413 may be deviated.

In this embodiment, in the cutting process, a portion of the perform 600 higher than the upper surface of the convex embossment 412 is cut away so that the convex embossment 412 which has been formed in advance in the previous molding process may not damaged by a cutting blade. Accordingly, the upper surface 410a of the lower plate 410 is higher than the upper surface of the convex embossment 412. This process may prevent the convex embossment 412 having a relatively elaborate pattern from being damaged in the cutting process.

When the cutting process is completed, a jig as shown in FIG. 16 is produced, and then a punching member 450 separately fabricated and various parts mentioned above are assembled (S400).

According to the punch manufacturing method of this embodiment, the lower and upper plates are integrally formed so that the lower and upper cutting holes of a pattern in the lower and upper plates are connected with each other, and then the lower and upper plates are separated by cutting so that the lower and upper cutting holes of a pattern may be aligned without any error. In addition, the jig is cut so as not to interfere the convex embossment to thereby prevent the convex embossment from being damaged or deformed by a cutter.

The present invention has been described in detail. 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.

The punch according to the present invention may simultaneously punch and emboss a sheet member by only one stroke, thereby conveniently giving various designs in which a punching pattern and an embossing pattern is mixed.

In addition, since the pins for punching or embossing may be associated in various ways in the punch, it is possible to obtain various punching and embossing designs, which cannot be expected in the prior art.

This punch may be used for punching a sheet member such as a card, a letter paper, a picture, a board, or a paper, which requires decoration, as well as for punching work in offices or industries, thereby improving the beauty thereof.

Claims

1. A method for manufacturing a punch, comprising the following steps of:

(a) injection-molding a jig with melted materials so that a lower plate and an upper plate are integrally formed at least partially to connect lower and upper cutting holes to be formed on the lower and upper plates respectively and also so that a convex embossment is formed on the lower plate;

(b) cutting a connection portion of the lower and upper plates to form a gap through which a sheet member is to be supplied so that the lower and upper cutting holes are separated on the lower and upper plates respectively, and so that an upper surface of the lower plate is formed at the position higher than an upper surface of the convex embossment; and

(c) assembling a punching member, which includes a first punch pin passing through the cutting holes to punch the sheet member and form a predetermined pattern therein and a second punch pin having a concave embossment at a front end thereof in correspondence to the convex embossment, to the jig.

2. The method for manufacturing a punch according to claim 1, wherein a trimming hole on the lower plate for cutting a marginal edge of the sheet member are integrally formed with a guide opening on the upper plate for guiding vertical movement of a punch pin corresponding to the trimming hole in the step (a), and

the trimming hole and the guide opening are separated by cutting in the step (b).