WO1996009148A1

WO1996009148A1 - Method and apparatus for cutting wallpaper

Info

Publication number: WO1996009148A1
Application number: PCT/US1994/010702
Authority: WO
Inventors: David Weinberg; Tom Owen; J. Vernon Johnson
Original assignee: D.W. Wallcoverings, Inc.
Priority date: 1994-09-21
Filing date: 1994-09-21
Publication date: 1996-03-28

Abstract

A method of cutting preselected border patterns in wallpaper stock (12). The method involves passing the wallpaper web (12) through a cutting station (20) which includes a plurality of cutting devices (26), typically lasers (58). A programmable controller (100) guides and directs the lasers (58) to cut the wallpaper border in a continuous preselected pattern, which is usually non-lineal in nature. The apparatus includes uncoiling (14) and recoiling devices (16) to uncoil the paper rolls, transport the flat wallpaper web (12) through the cutting station (20), and rewind the cut, flat web into rolls for eventual sale.

Description

METHOD AND APPARATUS FOR CUTTING WALLPAPER

Summary of the Invention

This invention relates to wallpaper processing, and will have particular application to a method and machine for cutting non-linear border edges of a wallpaper web.

Until now, wallpaper, and particularly, wallpaper border, was almost always possessed of straight terminal edges. The wallpaper processing industry heretofore lacked the technology to cut wallpaper border edges in a continuous non-linear pattern. As such, the decorative enhancement value of borders was of limited value, since intricate patterns always had some extraneous background due to the inability of the industry to economically cut consistent patterns. All previous efforts at cutting non-linear patterns failed. Inconsistent pattern cuts and perforations almost always resulted, and numerous yards of wallpaper border had to be scrapped or sold as irregular. Hand cutting is simply too slow to be commercially acceptable on a large mass-production scale.

The method and apparatus of this invention represents a breakthrough in wallpaper processing technology. The method involves the uncoiling of the rolled wallpaper and delivering the resulting paper web to a cutting station. The cutting station includes a plurality of laser generators which are shiftable under the direction of a programmable controller. As the web passes through the cutting station, the lasers, under specific programming instructions from the controller, cut precise patterns along one or both borders of the web. The patterns are preselected based upon the edge pattern of the particular web being cut and programmed into the controller. The cut wallpaper is delivered to a recoiler where it is wound up in rolls for sale.

Accordingly, it is an object of this invention to provide for a novel method and apparatus for cutting or perforating wallpaper. Another object is to provide for a method and apparatus which cuts consistent and precise patterns in continuous travel paper stock.

Another object is to provide a wallpaper cutting method which is economical, efficient, and simple to learn. Another object is to provide an efficient, durable and easy to operate machine for cutting wallpaper.

Other objects will become apparent upon a reading of the following description. Brief Description of the Drawings

A preferred embodiment of an apparatus is depicted for purposes of illustration on wherein:

Fig. 1 is a diagrammatical representation of the component parts of the wallpaper cutting apparatus. Fig. 2 is a top plan view of the wallpaper edge cutting station.

Fig. 3 is a side elevation view of the cutting station of Fig. 2.

Fig. 4 is an end elevation view of the cutting station.

Fig. 5 is a fragmented plan view of a wallpaper web cut by the method and apparatus of this invention. Description of the Preferred Embodiment

The preferred embodiment herein described in not intended to be exhaustive or to limit the invention to the precise form described. It is chosen and described to illustrate the principles of the invention, so that others skilled in the art may best follow the teachings thereof as they apply to both the method and the apparatus.

Referring first to Fig. 1, reference numeral 10 generally designates the wallpaper cutting apparatus of this invention which is shown in diagram form.

Apparatus 10 is generally used to cut rolls of wallpaper 12 which are guided from an incoiler 14 to a recoiler 16. Rolls of wallpaper 12 proceed through the various stations of apparatus 10 as a flat web 18, as shown in Fig. 1.

Apparatus 10 operates to continuously feed web 18 from incoiler 14 to the recoiler 16. Apparatus 10 includes generally a cutting station 20 which is positioned between incoiler 14 and recoiler 16 and serves to cut the various edge patterns in web 18. A tensioner, shown as a single roller 22 is positioned between incoiler 14 and cutting station 20 to maintain a constant tension on web 18 to ensure accurate cutting. Tensioner 22 is a conventional machine well- known in this industry.

Cutting station 20 will be described in detail below, and includes generally /09148 PC17US94/10702

a cutting table 24, cutting elements 26 and rollers 28 and 30. After web 18 exits cutting station 20, it passes through nip rollers 32, 34 idler roller 36 and web positioning rollers 38 and 40 before being wound up in roll form at recoiler 16.

Figs. 2-4 illustrate the component parts of cutting station 20. Cutting table 24 includes side walls 42 and 43 and end walls 44 and 45, and defines a generally rectangular upper cutting surface 46. Rollers 28 and 30 are journalled in bearings (not shown) adjacent table end walls 44, 45, respectively with web 18 traveling across table surface 46 in the direction of arrow 48.

Cutting elements 26 include a main support frame 50 which is generally rectangular in configuration and located adjacently above cutting table 24.

Frame 50 includes interconnected side frame members 51, 52 and end frame members 53, 54. Corner parts 56 support frame 50 in its position above table 24.

A plurality of laser light generators 58 are carried and supported by frame

50. Four lasers are shown for purposes of illustration of this embodiment, but it is understood that any number of lasers may be employed as needed for a particular cutting operation. Since all lasers 58 are the same in this embodiment, only one will be described for purposes of clarity.

Each laser 58 is carried by a support beam 60. A plurality of rods 62, 63, 64, 65, 66, 67, 68, 69 extend between side frame members 51, 52 and serve to support each beam 60. Each rod 62-69 is adjustably connected to one of beams 60 and terminates in a turn handle referenced by numerals 72-79 respectively. Each rod is cormected mechanically to its counterpart so that synchronized sliding movement of its connected beam 60 is achieved.

The mechanical connection between rods 62, 66; 63, 67; 64, 68; and 65, 69 includes (as an example only) pulleys 80, 81 spanned by cables 82. For purposes of clarity, reference numerals have been assigned to only one set of pulleys and their connecting cable with the understanding that all of the sets of pulleys operate in the same manner.

Master control rods 84, 85 extend between side frame members 51, 52 adjacent the end frame members 53, 54 as shown. Master control drive rod 84 terminates in a handle 86 and may be operatively cormected to motor 88 of conventional construction. Pulleys 89, 90 and cable 92 operatively connect drive rod 84 to master control drive rod 85 for effecting synchronous rotation of rods 84, 85.

Drive rod 84 is operatively connected to each beam 60 to effect simultaneous synchronous movement of all beams in response to rotation of the drive rod. The operative connection in conventional in nature and may include a gear box 96 connected to each rod 62-65 or some other equivalent structure. As is known in the art, each laser generator 58 produces a ray of high intensity light. This beam is directed at the passing proper web 18 in order to cut the paper in the manner which will be described below. Preferably the laser is aimed through a conventional optics system which includes directional mirrors 98 operatively connected by galvanometer 94 to a programmable controller 100, and an encoder 104. Software program 102 carries the image of the pattern 13 to be cut in web 18 and with controller 100 and encoder 104 serves to direct the position of mirrors 98 to guide the laser beams to the appropriate points on the passing paper web 18. For proper effectiveness of apparatus 10, wallpaper roll 12 must have a repeating pattern (see Fig. 5). A typical computer aided design (CAD) software program is loaded into controller 100 and the pattern 13 is traced with a light pencil to record the pattern into the controller's memory. Each pattern 13 is stored for future use as needed. A starting point is then determined by uncoiling wallpaper roll 12 and advancing the web 18 through tensioner 22 until the leading edge of the web is overlying cutting table upper surface 46. One of the beams 60 is shifted by turning handle 72 to rotate rods 62, 66 until the laser ray is aligned with the precise start point of the pattern 13. The other beams 60 are similarly shifted until all lasers 58 to be used have been properly honed at various points of the pattern 13.

The beams 60 are then locked in position by a conventional loading mechanism (not shown). Controller 100 and encoder 104 are then switched into an automatic run mode and the apparatus 10 activated to pull web 18 across cutting table 24, through rollers 32-40 and to recoiler 16.

Encoder 104 reads the speed of passage of paper web 18 through cutting station 20 and relays this information to controller 100. Galvanometer 94, which is in electrical communication with controller 100 responds to electrical impulses to effect shifting of mirrors 98 to direct the laser rays to appropriate points on web 18 in response to the pattern 13 carried in software 102. Vacuum box 106 serves to draw web 18 tight against table 24 and also collects crumbs which fall as the result of the laser cuts. Apparatus 10 is designed to cut non-lineal patterns in wallpaper web 18.

These patterns can include any pattern such as a sawtooth straight-line cut, trapezoidal cuts, as well as curved line cuts, dependent upon the type of edge pattern carried by a particular roll of wallpaper. One or more additional cutting stations 20 or additional lasers 58 may be added to perform more complex pattern cuts as necessary.

It is understood that the technology utilized in the laser generators 58, as well as the associated directional aiming mirrors 98 and the guiding software is known to those skilled in the art and details regarding their exact configuration have been omitted in the interests of clarity. It is further understood that the invention is not limited to the precise details and steps above given, but may be modified within the scope of the following claims.

Claims

What Is Claimed Is:

1. A method of cutting wallpaper borders comprising the steps of: a) Providing a quantity of rolled wallpaper; b) Uncoiling said rolled wallpaper to form a wallpaper web; c) Providing a cutting stations including a plurality of cutting means for cutting a continuous preselected non-linear pattern along a border of said wallpaper web; d) Continuously delivering said wallpaper web to said cutting station at a preselected velocity wherein said cutting means arts a continuing preselected non-linear pattern along said wallpaper border; and e) Recoiling said wallpaper web.

2. The method of Claim 1 wherein step c) includes spacing said cutting means away from said wallpaper web during cutting.

3. The method of Claim 1 wherein said wallpaper web is kept tensioned during step d).

4. The method of Claim 2 wherein said cutting means includes a plurality of laser generators, and step c) includes providing means for controlling movement of said laser generators to ensure precise cutting of said preselected patterns.

5. Apparatus for cutting wallpaper borders comprising uncoiler means for uncoiling wallpaper rolls into a web, means for cutting said web along its border in continuous preselected patterns, means for recoiling said web after cutting, and delivery means for transporting said web from said uncoiler means and through said means for cutting to said means for recoiling.

6. Apparatus of Claim 5 wherein said means for cutting includes a plurality of cutters, control means operatively connected to said cutters for selectively positioning said cutters to cut said web in continuing non-lineal patterns.

7. Apparatus of Claim 6 wherein said plurality of cutters includes a plurality laser generators spaced from said web as the web passes said means for cutting.

8. Apparatus of Claim 7 wherein said control means includes a programmable controller.

9. Apparatus of Claim 5 and further including guide means for positioning said web after cutting but prior to recoding.

10. Apparatus for cutting wallpaper border edges comprising: a) an uncoiler means for uncoiling wallpaper rolls into a generally flat web; b) a cutting table defining a generally flat top surface; c) means for cutting said wallpaper positioned adjacently above said cutting table; d) control means for adjustably shifting said means for cutting during passage of said wallpaper wherein said wallpaper border edges are cut in continuing preselected non-linear patterns; and e) recoiler means for recoiling said wallpaper web into rolls.

11. Apparatus of Claim 10 and tension means positioned between said uncoiler means and recoiler means for maintaining tension on said wallpaper web as the wallpaper passes over said cutting table top surface.

12. Apparatus of Claim 10 wherein said means for cutting includes a plurality of laser light generators and shiftable support means for carrying said laser light generators.

13. Apparatus of Claim 12 wherein said control means includes a programmable controller, linkage means operably connecting said controller to said support means wherein the support means is shifted in response to instructions from said controller to position said laser light generators and effect cutting said continuous non-linear patterns.