Cutting – Processes
Reexamination Certificate
2000-10-04
2004-08-10
Ashley, Boyer D. (Department: 3724)
Cutting
Processes
C083S034000, C083S039000, C083S075000, C083S076800, C083S365000, C083S368000, C083S371000, C700S134000, C700S150000, C700S167000, C700S259000, C347S157000
Reexamination Certificate
active
06772661
ABSTRACT:
FIELD OF THE INVENTION
This invention is related generally to the field of cutting of graphics areas or the like from sheets for various purposes, and other narrow-path-processing about graphics areas on sheets.
BACKGROUND OF THE INVENTION
The technical field involving the cutting of graphic areas from sheets, or otherwise doing narrow-path-processing about graphics images on sheets, includes, for example, the face-cutting of laminate sheets to form decals. More specifically, a graphic-image area on the face layer of a laminate needs to be cut away from the remainder of the face layer so that the graphic area (decal) can subsequently be pulled away from the backing layer of the laminate and be applied elsewhere as intended. Highly accurate face-layer cutting about the graphics is obviously highly desirable.
This is but one example in which highly accurate sheet cutting is desirable. In many other situations, highly accurate sheet cutting which is desired may not involve face-cutting, but through-cutting, in which the full thickness of the sheet is cut about a graphics area on the sheet. And in many situations, rather than highly accurate cutting, highly accurate scoring, creasing, line embossing or the like, in each case, of course, along a line the varying direction of which is determined by the shape of the graphics area. Together these types of operations on sheets with respect to graphics areas thereon are referred to herein for convenience as “narrow-path-processing.” For convenience, the prior art problems and the invention herein which solves such problems will be discussed primarily with reference to sheet-cutting apparatus.
Achieving extreme precision in locational accuracy in the cutting of sheets about graphics areas has been problematic. A variety of sheet-cutting methods, primarily involving various forms of die-cutting operations, have been used. However, the problem of achieving precision cutting has not been fully solved.
In some cases, various flatbed plotters are used. These are devices having a positionally-controlled cutting implement above a flat work surface on which the sheet to be cut rests. The cutting implements are controlled based on controller-supplied instructions based on the X-Y coordinates necessary to achieve cutting along the intended path, such as about the graphics area. However, these and other prior art devices have not been sufficient to achieve the high degree of precision that is desired, and that is achieved by the instant invention.
Among the particular problems in the art are problems related to distortion of the sheets between the time that graphics images are printed or otherwise applied thereon. More specifically, distortions in the sheet material caused by shrinkage or expansion of the sheet material after printing are common. This distortion, which is two-dimensional in nature, is particularly common and difficult when the sheets are of certain materials such as vinyl.
The problem of accurate cutting (or other narrow-path-processing) is exacerbated when, as is often the case, the graphics area or graphics areas to be cut from a sheet are very irregular in shape—i.e., with the perimeters of the graphic areas involving lines other than simple straight lines. When non-uniform shrinkage and/or expansion occurs, often by different amounts along different directions, and even by different amounts in different portions of a sheet along the same direction, achieving a precision cut is highly problematic. A sheet having such non-uniform distortions, e.g., a sheet which includes distorted portions and non-distorted portions or which includes multiple portions distorted by differing amounts and/or in differing directions, is significantly more difficult to accurately cut (or otherwise narrow-path-process) than a sheet which exhibits a non-varying distortion, e.g., a sheet which has uniformly expanded by a certain degree.
Therefore, a method and/or apparatus which overcomes non-uniform distortion to precisely cut graphic areas from sheets would be a significant advance. The invention is a marked improvement over sheet-cutting methods which assumed and accommodated non-varying distortion but were incapable of overcoming non-uniform, or varying, distortions.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an improved method and apparatus for precision cutting of graphics areas from sheets, thereby overcoming some of the problems and shortcomings of the prior art.
Another object of this invention is to provide a method and apparatus for improved accuracy in cutting around graphics areas in order to fully adjust for two-dimensional distortion in the sheets from which the graphics areas will be cut.
Another object of the invention is to provide an improved method and apparatus for cutting about graphics areas which automatically adjust for a wide variety of sheet distortion, including non-uniform two-dimensional distortion and distortions of differing degrees in one dimension or along one direction.
Still another object of the invention is to provide a method and apparatus for accurate cutting about graphics areas on sheets on which graphics areas are placed by printing, which readily accommodate post-printing distortions in the sheet material.
Another object of this invention is to allow for more efficient use of sheet material.
Yet another object of this invention is to allow for rapid cutting of graphics areas from the sheet material.
Another object of this invention is to provided a method and apparatus for improved accuracy in cutting around graphics areas which is applicable to a wide variety of cutting implements.
Another object of this invention is to provide a method for cutting graphics images from sheets which dynamically adjusts for varying distortions at different positions across each sheet, including distortions occurring during cutting operations, if any.
Still other objects of this invention is to provide an improved method and apparatus for narrow-path-processing about graphics images on sheet materials of various kinds.
These and other objects of the invention will be apparent from the following descriptions and from the drawings.
SUMMARY OF THE INVENTION
The instant invention overcomes the above-noted problems and satisfies the objects of the invention. The invention is an improved method and apparatus for cutting graphics areas from sheets. Stated more broadly, the invention is an improved method and apparatus for narrow-path-processing about graphics images on sheets, including by cutting, creasing, scoring or the like. Of particular note is that the instant invention provides a high-precision accuracy in the cutting of graphics images from sheets bearing such images which overcomes a wide variety of variable distortion in the sheets, including two-dimensional distortions. Broadly speaking, the improved narrow-path-processing for sheets is highly accommodating to a wide variety of distortion, including unpredictable distortions, in sheets having graphics areas.
The method of this invention, stated with respect to cutting graphics areas from sheets including such graphics areas, includes as a first step applying a plurality of registration marks on the sheet at and about the graphics area in predetermined positions with respect to the graphics area, or more particularly, with respect to the perimeter thereof which will be cut. This is done at the time the graphics which define such graphics area (or graphics areas) are applied. The method involves sensing the locations of the registration marks on the sheet of material at the time of cutting—i.e., at the time that the precise cutting path is being determined, and cutting the graphics area from the ready-to-cut sheet in response to the positions of the registration marks with respect to the graphics area (i.e., its perimeter which is to be cut) at that time. This method allows cutting to occur very precisely despite non-uniform distortions of the sheet, including two-dimensional distortion of the sheet, prior to cutting.
In highly preferred embodiments
Andersen Geo
Mikkelsen Steen
Ashley Boyer D.
Jansson Shupe & Munger Ltd
Mikkelsen Graphic Engineering
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