Dual mini-blind cutter

Information

  • Patent Grant
  • 6314851
  • Patent Number
    6,314,851
  • Date Filed
    Monday, May 31, 1999
    25 years ago
  • Date Issued
    Tuesday, November 13, 2001
    23 years ago
Abstract
A mini-blind cutter for selective manual in-store sizing of a first mini-blind product and a second mini-blind product. Each of the mini-blind products include a head rail, a plurality of slats, and a bottom rail having a different geometry and or material composition. A die assembly is movable from a first position to a second position includes a first and second region to receive the first and second mini-blind products. A blade carrier assembly includes at least two blade carriers and permits permit independent translation of the blade carriers to accommodate the different sized mini-blind products.
Description




FIELD OF THE INVENTION




This invention relates generally to the art of sizing window coverings such as mini-blinds. more particularly the present invention relates to a cutter for selective cutting of two mini-blind products, wherein the blinds are made of different material (e.g. vinyl and aluminum) and different geometric characteristics.




BACKGROUND OF THE INVENTION




Numerous types of window coverings are now being sold in a variety of outlets. Window coverings of the type with which the present invention is concerned include mini-blinds, as opposed to draperies and curtains which may be sold in the same outlets, but which involve different sizing requirements. The type of outlets that sell custom mini-blinds typically include custom specialty shops and department stores which usually ask the customer for window dimensions and then submit orders to factories or distribution centers where the products are cut to a specific size. Not only must the customer make two visits to these outlets to obtain the product, but the custom mini-blinds are relatively expensive.




Mass merchandisers also distribute mini-blinds. In many such outlets only stock sizes are carried, because some windows, especially in newer homes and offices are of standard dimensions. These mini-blinds are usually much less expensive than those obtained from custom outlets because of the economy realized from carrying a limited stock of sizes and because there are no sizing operations which must be performed on the products.




In recent years, a third option has been made available to the customer. This option involves the in-store sizing of mini-blinds and various other window coverings to customer specifications. An example of how in-store sizing can be accomplished is disclosed in commonly owned U.S. Pat. No. 5,339,716 issued Aug. 23, 1994 to Sands et al. and entitled “MINI BLIND CUTTER” (the '716 patent). This patent discloses a mini-blind cutter for cutting mini-blind slats, as well as mini-blind bottom rails and headrails to a desired size. The mini-blind cutter may be used to cut the mini-blind slats and rails on either end as a readjustment of mounting mechanisms or ladders is not required.




The mini-blind cutter disclosed in the '716 patent includes a framework having a receiving area for receiving the end of the mini-blind to be cut. A cutter blade is attached to a bar which is slidably mounted to the framework. This bar includes a rack engaged with a pinion gear that is rotated by a ratchet handle. Movement of the ratchet handle thus slides the bar along the framework and forces the cutter blade through the end portion of the mini-blind. The mini-blind cutter is used to cut the mini-blind slats, headrail and bottom rail on either end, so readjustment of the mounting mechanism or ladders is not required when sizing the mini-blind.




Additionally, commonly owned U.S. Pat. No. 5,456,149 issued Oct. 10, 1995 to Elsenheimer et al. and entitled “SIZING SYSTEMS FOR WINDOW COVERINGS” (the '149 patent) discloses a system for sizing various window products such as roller shades, mini-blinds, pleated shades and vertical blinds. This system is used in department stores and mass merchandising outlets. The '149 patent discloses a system having four stations with a flip-top horizontal surface containing sizing equipment on opposed sides. The system includes fixed cutters, e.g. for roller shades and for cutting the headrail of vertical blinds.




Another system for trimming a venetian blind assembly is disclosed in U.S. Pat. No. 4,819,530 issued Apr. 11, 1989 to Huang entitled “APPARATUS METHOD FOR TRIMMING A VENETIAN BLIND ASSEMBLY”. The device disclosed in this patent employs a hydraulic or pneumatic cylinder or solenoid to drive the blade in order to cut the various components of the mini-blind.




Other mini-blind cutters are available to manually cut headrails manufactured from steel which include a drive mechanism consisting of either an elongated lever arm or a rotary input coupled with a cam driver device.




However, there are no mini-blind cutter mechanisms for use in in-store sizing which can accommodate two blind configurations having different shapes and wherein the blinds are made of different materials such as vinyl and steel.




Accordingly, it would be advantageous to be able to provide a mini-blind cutter which would be able to cut two different mini-blind products having different geometric or material characteristics, e.g. where the headrail and bottom rail components are formed from either steel or vinyl. It would also be advantageous if the system is compact and able to be used in conjunction with sizing systems such as the one described in the '149 patent referenced above.




SUMMARY OF THE PRESENT INVENTION




The present invention relates to a blind cutter for selective, in-store sizing of a first mini-blind product and a second mini-blind product having different geometric configurations. Each mini-blind product to be sized includes a headrail, a plurality of slats and a bottom rail. The blind cutter includes a framework and a die assembly coupled to the framework. The die assembly is moveable from a first position to a second position with respect to the framework. The die assembly preferably includes a first region for receiving a portion of the headrail, a plurality of slats and the bottom rail of the first mini-blind product, and a second region for receiving a portion of the headrail, a plurality of slats and the bottom rail of the second mini-blind product. The cutter further includes a blade carrier assembly attached to the framework. The blade carrier assembly includes a blade attached thereto. A drive system is connected to the framework and blade carrier assembly to provide translation of the blade. The blade is translated proximate the first region of the die assembly to size the first mini-blind product when the die assembly is in a first position. The blade is also translated proximate the second region of the die assembly to size the second mini-blind product when the die assembly is in a second position.




In another aspect of the invention, the frame includes a base plate having a bottom surface defining a base plane. The drive system includes a handle assembly disposed to rotate in a plane parallel to the base plane.




In yet another aspect of the invention the cutter also includes a drive system having a second blade carrier provided with a second blade. The two blade carriers are connected to the framework and blade carrier assembly to provide independent linear translation of a first blade carrier for a pre-determined first distance. The drive system further provides simultaneous linear translation of the first and second blade carriers for a pre-determined second distance.




In a further aspect of the invention a blind cutter for in-store sizing a mini-blind product including a head rail, a plurality of slats, and a bottom rail, the blind cutter includes a framework and a die assembly. The die assembly is coupled to the framework having a region for receiving a portion of each of the head rail, plurality of slats, and bottom rail. A blade carrier assembly is attached to the framework, and includes a first blade carrier having a first blade member attached thereto, and a second blade carrier having a second blade member attached thereto. A drive system is connected to the framework and blade carrier assembly to provide independent linear translation of the first blade carrier for a pre-determined first distance, and simultaneous linear translation of the first and second blade carriers for a pre-determined second distance.




In another aspect of the invention a blind cutter is capable of selectively in-store sizing a first mini-blind product and a different second mini-blind product. The blind cutter includes a framework and a die assembly coupled to the frame work. The die assembly includes a first region for receiving a portion of the head rail, plurality of slats and bottom rail of the first mini-blind product, and a second region for receiving a portion of the head rail, plurality of slats and bottom rail of the second mini-blind product. The die assembly is movable from a first position for cutting the first mini-blind product to a second position for cutting the second mini-blind product. A blade carrier assembly is attached to the framework and includes a first blade carrier having a first blade member attached thereto, and a second blade carrier having a second blade member attached thereto. A drive is connected to the framework and blade carrier assembly to provide linear translation of the first and second blade carriers to size the first mini-blind product when the die assembly is in the first position, and to size the second mini-blind product when the die assembly is in the second position.




Still a further aspect of the invention is a blind cutter for in-store sizing a mini-blind product including a head rail, a plurality of slats, and a bottom rail. The blind cutter includes a framework and a die assembly coupled to the framework. The die assembly has a region for receiving a portion of each of the head rail, plurality of slats, and bottom rail. A blade carrier assembly is attached to the framework and includes at least one blade carrier movable from a first extended position in which the mini-blind product is loaded into the blind cutter for sizing and a second retracted position in which the mini-blind product has been sized. A drive system includes a driving pawl and track and is connected to the framework and blade carrier assembly to provide linear translation of the at least one blade carrier to size the mini-blind product. The drive system further includes a switch for releasing the driving pawl from the track to permit manual movement of the first blade carrier from the retracted to the extended position.











BRIEF DESCRIPTION OF THE DRAWINGS




The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:





FIG. 1

is a perspective view of the right or exit side of the mini-blind cutter of the present invention;





FIG. 2

is a perspective view of the left or loading side of the mini-blind cutter of

FIG. 1

;





FIG. 3

is a top plan view of the cutter shown in

FIG. 1

;





FIG. 4

is a rear elevation view of the mini-blind cutter of

FIG. 1

;





FIG. 5

is a front elevation view of the mini-blind cutter of

FIG. 1

;





FIG. 6

is an elevation view of the right side of the mini-blind cutter of

FIG. 1

;





FIG. 7

is an elevation view of the mini-blind cutter of

FIG. 1

in a first engaged position;





FIG. 8

is an elevation view of the mini-blind cutter of

FIG. 1

in the fully extended position;





FIG. 9

is an elevation view of the mini-blind cutter of

FIG. 1

in the loading position where the die assembly is in the first or lower position;





FIG. 10

is an isometric view of the die assembly of the mini-blind cutter of

FIG. 1

;





FIG. 11

is a right elevation view of the die assembly of

FIG. 10

;





FIG. 12

is a cross-sectional view taken generally along line


12





12


of

FIG. 11

;





FIG. 13

is a cross-sectional view taken generally along line


13





13


of

FIG. 6

;





FIG. 14

is a cross-sectional view taken generally along line


14





14


of FIG.


6


.





FIG. 15

is an exploded view of the rear end plate, slide mechanism and a partial fragmentary view of the die assembly of the mini-blind system of

FIG. 1

;





FIG. 16

is a cross-sectional view taken generally along line


16





16


of

FIG. 6

in the starting position;





FIG. 17

is a cross-sectional view taken generally along line


16





16


of

FIG. 6

in the fully extended position;





FIG. 18

is a cross-sectional view taken generally along lines


18





18


of

FIG. 6

;





FIG. 19

is a cross-sectional view taken generally along lines


18





18


of

FIG. 6

with the headrail, bottom rail and slats in loaded in the cutter;





FIG. 20

is a cross-sectional view taken generally along lines


18





18


of

FIG. 6

with the slat blade having extended through the bottom rail;





FIG. 21

is a cross-sectional view taken generally along lines


18





18


of

FIG. 6

with the slat carrier engaged with the slats and the headrail blade engaged with the head rail;





FIG. 22

is a cross-sectional taken generally along lines


18





18


of

FIG. 6

with the slat carrier, head rail carrier in the fully extended position;





FIG. 23

is a perspective view of the right or exit side of a second embodiment of the mini-blind cutter;





FIG. 24

is a plan view of the right side of the mini-blind cutter of

FIG. 23

;





FIG. 25

is a plan view of the left side of the mini-blind cutter of

FIG. 23

;





FIG. 26

is a plan view of the right side of the mini-blind cutter of

FIG. 23

with the pawls disengaged from the rack;





FIG. 27

is a partial plan view of the right side of the mini-blind cutter of

FIG. 23

with the die assembly in the first position;





FIG. 28

is cross-sectional view taken generally along line


28





28


of

FIG. 27

;





FIG. 29

is cross-sectional view taken generally along line


29





29


of

FIG. 27

;





FIG. 30

is a partial plan view of the left side of the mini-blind cutter of

FIG. 23

with the die assembly in the first position;





FIG. 31

is cross-sectional view taken generally along line


31





31


of

FIG. 30

;





FIG. 32

is a partial plan view of the right side of the mini-blind cutter of

FIG. 23

with the die assembly in the second position;





FIG. 33

is cross-sectional view taken generally along line


33





33


of

FIG. 32

;





FIG. 34

is cross-sectional view taken generally along line


34





34


of

FIG. 32

;





FIG. 35

is a partial plan view of the left side of the mini-blind cutter of

FIG. 23

with the die assembly in the second position; and





FIG. 36

is cross-sectional view taken generally along line


35





35


of

FIG. 35

;











DETAILED DESCRIPTION




Referring generally to

FIG. 1

a mini-blind cutter


10


will be described. Cutter


10


is used to cut one or both ends of a mini-blind product


12


having a headrail


14


, a plurality of slats


16


and a bottom rail


18


. In the preferred embodiment both ends of the mini-blind product


12


is cut. All of these components may be downsized with cutter


10


to properly size the mini-blind for a given window opening. Cutter


10


may be used to cut two different mini-blind configurations. One exemplary first configuration includes a vinyl headrail, vinyl bottom rail and either aluminum or vinyl slats. A second exemplary configuration includes a steel headrail and bottom rail and aluminum slats. Cutter


10


could also be configured to cut steel slats.




In the preferred embodiment the geometric shape of the cross-section of the mini-blind components of the first and second configurations to be sized are also different. Cutter


10


could also be adapted to cut a wide variety of other combinations of mini-blind components or other components of pleated, cellular, venetian or vertical blinds.




Referring generally to

FIG. 1

, mini-blind cutter


10


, according to the present invention, includes a framework or frame


20


supporting a movable die assembly


22


that works in cooperation with a carrier assembly


24


. Die assembly


22


is movable from a first or lowered position to cut a mini-blind having the first configuration to a second or raised position to cut a mini-blind having the second configuration. Die assembly is shown in the first lowered position in FIG.


9


and in the second raised position in

FIGS. 1 and 6

.




A drive system


28


is supported on frame


20


to drive a portion of carrier assembly


24


relative to die assembly


22


to effectuate the cutting of the mini-blind components in either the first or second positions.




Referring generally to

FIGS. 1-5

, frame


20


includes a bottom plate


30


having a front side


30




a


, a rear side


30




b


, a loading side


30




c


, an exit side


30




d


, a top surface


30




e


and a bottom surface


30




f


. Bottom plate


30


further includes a front channel


32


proximate front side


30




a


and a center channel


34


located a set distance from front channel


32


in a direction toward rear side


30




b


. Front and center channels


32


,


34


are parallel to one another and to front side


30




a


. Channels


32


,


34


extend from loading side


30




c


to exit side


30




d


of bottom plate


30


.




Frame


20


further includes a front plate


36


located in front channel


32


, and a rear plate


38


located in center channel


34


. Front plate and rear plate


36


,


38


include an upper aperture


40


,


42


and a lower aperture


44


,


46


configured to receive an upper and lower shaft


48


,


50


respectively. Upper and lower shafts


48


,


50


are used in conjunction with carrier assembly


24


. Each of front plate and rear plate


36


,


38


includes a pair of threaded apertures


52


extending through an exit side edge


36




e


,


38




e


to upper apertures


40


,


42


and lower apertures


44


,


46


to receive a set screw


58


for setting the position of upper and lower shafts


48


,


50


.




Each of front plate


36


and rear plate


38


, includes an internal side


36




a


,


38




a


and an external side


36




b


,


38




b


. Internal sides


36




a


and


38




a


face one another while external sides


36




b


,


38




b


face away from one another. Each internal side


36




a


,


38




a


includes a channel


64


,


66


formed therein. (See FIGS.


14


and


15


). Each channel


64


,


66


has an orientation of eighty five (


85


) degrees relative to a bottom edge


36




c


,


38




c


of each front and rear plate


36


,


38


respectively. Each channel


64


,


66


further includes a pair of slots


68


,


70


centrally located in the channel and having an axis which is also orientated at eighty five (


85


) degrees relative to bottom edge


36




c


,


38




c.






Frame


20


further includes a pair of slide blocks


72


,


74


. Each slide block has a width narrower than the width of each channel


64


,


66


to permit each slide block,


72


,


74


to slidably move within each respective channel


64


,


66


. Each slide block


72


,


74


includes a groove


76


,


78


which has an orientation of five (5) degrees relative to an outer edge


72




a


,


74




a


of slide block


72


,


74


respectively. Each slide block


72


,


74


is slidably located in channel


64


,


66


of front and rear plates


36


,


38


respectively. In this orientation each groove


76


,


78


is perpendicular to bottom plate


30


regardless of the location of slide block


72


,


74


within channels


64


,


66


.




Each slide block


72


,


74


further includes a pair of threaded apertures


81


. Each slide block


72


,


74


is removably secured to front and rear plate


36


,


38


respectively by a pair of screws


83


which are located through slots


68


,


70


and threaded into apertures


81


of slide blocks


72


,


74


. By loosening screws


83


it is possible to move each slide block along channel


64


,


66


to effectively move groove


76


,


78


closer to or further from the exit side of cutter


10


. This adjustment of slide blocks


72


,


74


allows for optimal operation of cutter


10


as will be described below.




Frame


20


also includes a top plate


86


attached to front plate


36


and rear plate


38


. Top plate


86


includes a plurality of through holes which are aligned with a plurality of threaded holes in a top portion


36




d


,


38




d


of front and rear plates


36


,


38


. Top plate


86


is attached to front and rear plates


36


,


38


with a plurality of screws


88


. Each screw


88


extends through a respective through hole and is threaded into a respective threaded hole.




Additionally, frame


20


includes a first support plate


90


located between front plate


36


and rear plate


38


proximate loading side


30




c


of bottom plate


30


. A second support plate


92


is located parallel to first support plate


90


a set distance from the left or loading side


30




c


of bottom plate


30


. A shelf plate


94


is located parallel to bottom plate


30


and is supported atop first and second support plates


90


,


92


. (See FIGS.


2


and


13


). Shelf plate


94


is attached to first and second support plates


90


,


92


with a plurality of screws


96


. Additionally shelf plate


94


is attached to front plate


36


and rear plate


38


with a pair of screws


98


.




Shelf plate


94


supports a slat shear plate


100


that is used in conjunction with die assembly


22


and carrier assembly


24


which will be described in greater detail below. Slat shear plate


100


is attached to shelf plate


94


with a pair of screws


102


. (See FIG.


2


).




Frame


20


also includes a spring tower


104


attached to bottom plate


30


in a slot


106


proximate the rear side


30




b


of bottom plate


30


. Bottom plate


30


further includes a through slot


108


extending from rear side


30




b


of bottom plate


30


a set distance toward front side


30




a


. (See FIGS.


1


and


4


).




Referring generally to

FIGS. 10-12

, die assembly


22


will now be described in greater detail. As noted above die assembly


22


cooperates with frame


20


to permit die assembly


22


to be moved from a first lowered position for cutting a first mini-blind product having a first configuration to a second raised position for cutting a second mini-blind product having a second configuration. Die assembly


22


includes a first region


110


for receiving a portion of each of the headrail, plurality of slats, and bottom rail of the first mini-blind product, and a second region


112


for receiving a portion of each of the headrail, plurality of slats, and bottom rail of the second mini-blind product.




Die assembly


22


includes a bottom die plate


114


and an opposing top die plate


116


. Die assembly


22


further includes a support side plate


118


located intermediate top die plate


116


and bottom die plate


114


. Support side plate


118


is attached to top die plate


116


and bottom die plate


114


with screws


120


. Support side plate


118


has a front side


118




a


, a rear side


118




b


, a top side


118




c


, a bottom side


118




d


, a loading side surface


118




e


and a cutting side surface


118




f.






Die assembly


22


further includes a headrail die block


122


attached intermediate top die plate


116


and bottom die plate


114


distal support side plate


118


. Headrail die block


122


includes a front side


122




a


, a rear side


122




b


, a top side


122




c


, a bottom side


122




d


, a loading side surface


122




e


and a cutting side surface


122




f.






Headrail die block


122


and support side plate


118


each include a guide flange


124


,


126


extending from front side


122




a


and rear side


118




b


respectively. Guide flanges


124


,


126


are employed to guide die assembly


22


within grooves


76


,


78


as it is moved from the first position to the second position. Each flange


124


,


126


extends from top side


122




c


,


118




c


to bottom side


122




d


,


118




d


respectively.




In the preferred embodiment each flange


124


,


126


is rectangular and extends outward from headrail die block


122


and support side plate


118


. (See FIG.


10


). Of course other geometric configurations that cooperate with grooves


76


,


78


may also be used.




Headrail die block


122


includes a first slot


128


having the shape of the cross-section of the first headrail and a second slot


130


having the shape of the a cross-section of the second headrail. The first slot


128


is located proximate top die plate


116


and second slot


130


is located proximate bottom die plate


114


.




Die assembly


22


further includes a bottom rail die


132


having a bottom surface


132




a


and a rear surface


132




b


. Bottom rail die


132


includes a slot


133


having the configuration of the cross-section of the bottom rail of the second configuration. Bottom surface


132




a


of bottom rail die


132


is located adjacent bottom die plate


30


. Rear surface


132




b


of bottom rail die


132


is located adjacent support side plate


118


. In this manner die assembly


22


includes a first opening or receiving area


134


defined by the open space intermediate headrail die block


122


and support side plate


118


, and a second opening


136


defined by the space intermediate headrail die block


122


to bottom rail die


132


.




Bottom rail die


132


also includes a cutting side surface


132




c


having a curved form configured to match the curved form of a cutting blade


138


of the carrier assembly


24


. Similarly, slat shear plate


100


includes a cutting side surface


100




a


having a curved form configured to match the curved form of cutting blade


138


.




Die assembly


22


further includes a catch lever


140


manufactured or formed from a nylon material. Catch lever


140


includes a beveled catch portion


142


configured to secure die assembly in the second position. Catch lever


140


also includes a lift lever


144


to aid in the raising and lowering of die assembly


22


from the first lowered position to the second or raised position. Catch lever


140


must have sufficient resiliency to permit beveled catch portion


142


to engage and disengage top plate


116


by an operator without excessive force. Additionally, catch lever


140


must have sufficient strength to maintain die assembly in the raised second position. Although nylon is the preferred material, other materials having similar characteristics could be used.




Referring again to

FIG. 1

, carrier assembly


24


will now be described in greater detail. Carrier assembly


24


includes a slat/bottom rail blade carrier


146


(hereinafter slat carrier) and a headrail blade carrier


148


(hereinafter headrail carrier). Each of the slat carrier


146


and headrail carrier


148


is independently and slidably attached to upper shaft


48


and lower shaft


50


. As described above, upper shaft


48


and lower shaft


50


are located within an upper aperture


40


,


42


and a lower aperture


44


,


46


of front plate


36


and rear plate


38


respectively. Upper shaft


48


and lower shaft


50


are fixed relative to front plate


36


and rear plate


38


by set screws


58


.




Slat carrier


146


includes an upper section


150


having a bearing aperture


152


extending therethrough and a lower section


154


having a bearing aperture


156


extending therethrough. A pair of bearings


158


are press fit within bearing apertures


152


,


156


. Slat carrier


146


slidably moves on upper and lower shafts


48


,


50


by means of pair of press fit bearings


158


. A center region


162


is integrally formed with and connects upper section


150


and lower section


154


together.




Similarly, headrail carrier


148


is slidably located on upper shaft


48


and lower shaft


50


by a pair of bearings


164


. While in the preferred embodiment the pair of bearings


164


is not press fit, it is possible to employ press fit bearings in the headrail carrier as well as the slat carrier. The use of press fit bearings allows for greater stability of the carriers during the cutting operation.




Slat carrier


146


is movably connected to headrail carrier


148


by means of at least one connecting rod


166


. However, in the preferred embodiment three connecting rods


166


are utilized. Each connecting rod


166


includes a first bolt


167


extending through a respective aperture


170


in headrail carrier


148


and threadably secured to a spacer


172


. In this manner spacer


172


is fixed relative to headrail carrier


148


. A cap screw


174


having a head


176


extends through a non-threaded aperture


178


in the slat carrier


146


and is threadably secured to spacer


172


. Each aperture


170


includes a counter bore


180


having a depth equal to the length of head


176


. This permits the top of head


176


to be flush with an external or rear surface


146




a


of slat carrier


146


.




Connecting rods


166


establish a maximum and minimum distance between slat carrier


146


and headrail carrier


148


. The maximum distance is achieved when head


176


is seated within the base of counter bore


180


. (See FIGS.


1


and


16


). The minimum distance is achieved when an internal or front surface


146




b


, of slat carrier


146


is adjacent spacer


172


. (See FIG.


17


). In the minimum distance position, head


176


of cap screw


174


is a set distance from slat carrier


146


.




Slat carrier


146


further includes blade


138


secured to the center region


162


by means of two screws extending therethrough. (See FIG.


1


). The geometry of blade


138


is described in the '716 patent referred to above and is incorporated herein by reference. Slat carrier


146


also includes a chute region


184


located proximate blade


138


and is defined by the open region intermediate upper section


150


and lower section


154


. Lower section


154


includes a top beveled surface


155


having a sloped region extending downward toward the cutting side


30




d


of base


30


. Chute region


184


permits the cut portions of the bottom rail and slats to easily exit cutter


10


to a waste receptacle for example. (See FIG.


1


).




An indicator


188


is attached to cutting side surface


146




c


of upper section


150


of slat carrier


146


. Indicator


188


includes a pointer


190


that extends over top plate


86


to indicate the position of slat carrier


146


during the cutting process. Top plate


86


may additionally include indicia indicating the position of slat carrier


146


during the cutting process.




Slat carrier


146


further includes a pair of spring attachment bosses


192


attached to rear surface


146




a


of slat carrier


146


. Each boss


192


includes an aperture for receiving an end of a return coil extension spring


194


. In the preferred embodiment two springs


194


are employed. (See FIG.


6


).




Also attached to slat carrier


146


is an arm


196


which communicates with drive system


28


. Arm


196


is attached to rear surface


146




a


of slat carrier


146


with screws. As illustrated in

FIG. 1

, the screws attaching arm


196


extend through center region


162


. In the preferred embodiment center region


162


includes through holes and arm


196


includes a pair of threaded holes to securably receive the screws.




Turning to headrail carrier


148


, a piercing blade


198


is attached to a center portion


199


of headrail carrier


148


. Piercing blade


198


has a “W” shaped configuration, including a center piercing section


198




a


and two side sections


198




b


, extending from center piercing section


198




a


. Piercing blade


198


has a substantially uniform thickness. However, piercing blade


198


may also have a beveled region proximate the cutting portions of the center and side sections


198




a


,


198




b


. The uniform thickness provides for a more uniform cut and longer blade life.




Referring to

FIGS. 1

,


2


and


8


drive system


28


will now be described. Drive system


28


includes a handle assembly


200


having a handle


202


pivotally attached to a handle arm


204


. A clutch bearing


205


is attached to arm


204


distal handle


202


to limit movement of handle arm


204


in a single rotary direction. In the preferred embodiment the handle assembly is supplied by Reid Tool Supply located in Muskegon Michigan and identified by part number KHQ-20.




Handle assembly


200


is operated in a plane parallel to the plane defined by top plate


86


. Further, handle arm


204


is operable in a plane parallel to the plane in which the mini-blind to be sized is located during the sizing operation. Handle


202


includes a longitudinal axis which is transverse to the plane of operation of the handle assembly


200


. Handle


202


may be pivoted for storage such that the longitudinal axis of handle


204


is substantially parallel to handle arm


204


. This feature allows cutter


10


to be more compact for shipping, as well as during use with the device described in the '149 patent.




Handle arm


204


is further attached to a shaft


206


having a worm


208


attached thereto. (See

FIG. 8

in dashed lines). A worm gear


210


is driven by worm


208


. A second output shaft


212


is coupled to worm gear


210


. (See FIGS.


16


-


18


). In the preferred embodiment, the worm and worm gear are selected to provide a thirty to one ratio. That is thirty rotations of handle assembly


200


results in one rotation of output shaft


212


. However other ratios may be employed as well. Preferably a ratio of between ten to one and forty to one may be employed. Depending on the material of the blinds to be cut the ratio may vary to provide the requisite mechanical advantage required for operation by an operator for in-store sizing.




Shaft


206


is secured to a drive system housing


216


by means of a sleeve bearing


214


that is attached thereto. Drive system housing


216


includes a load side plate


218


and an exit side plate


220


. Load side plate


218


and exit side plate


220


are positively located in channels


222


,


224


respectively in bottom plate


30


(See

FIGS. 1

,


2


and


14


). Drive system housing


216


further includes a housing cover


217


which is attached to exit side plate


220


.




Sleeve bearing


214


is attached to load side plate


218


. Shaft


206


is positively located relative to the sleeve bearing by a pair of collars attached to shaft


206


proximate the top and bottom of the sleeve bearing.




Output shaft


212


is rotatably attached to load side plate


218


and exit side plate


220


by a pair of bearings


226


. Output shaft


212


includes a first end


228


located proximate load side plate


218


and an opposing second end


230


. Additionally, output shaft


212


includes an elongated tab or key extending a set distance along the longitudinal axis of the output shaft proximate second end


230


. A cam


232


having a keyway


234


is located on output shaft


212


having a key such that keyway


234


is positively located by key


236


. (See FIG.


6


). A cam attachment plate


238


is attached to cam


232


with two screws


240


. Cam attachment plate


238


is further secured to output shaft


212


with a single screw


242


.




Referring to

FIGS. 1 and 6

cam


232


includes an operating edge


244


. A follower


246


is pivotally attached to arm


196


. Follower


246


is maintained in contact with operating edge


244


of cam


232


by means of extension springs


194


. In the preferred embodiment each extension spring


194


is formed from a 0.072 diameter wire, five inches long and rated at 8.4 pounds per inch. Of course other springs may be utilized that are able to retract headrail carrier and slat carrier, by biasing follower


246


against cam operating edge


244


. Each extension spring


194


is attached at a first end


248


to a boss


250


on spring tower


104


and at a second end


252


to boss


192


on slat carrier


146


. Extension springs


194


are always in tension thereby biasing follower


246


against cam operating edge


244


.




As noted above it is important for optimal cutting performance that blades


138


,


198


of headrail and slat carriers


146


,


148


respectively be in close proximity to bottom rail die


132


, slat shear plate


100


and headrail die


122


. In order to maximize dimensional integrity of slat carrier


146


relative to die assembly


22


, press fit bearings are utilized to minimize potential deflection of the slat carrier blade


138


during the cutting.




By design, the cutting surface of blades


138


,


198


are proximate the bottom rail die


132


, shear plate


100


and head rail die


122


respectively. However, as a result of component variability and resulting tolerance stack up, as well as wear of the blades, it is desirable to be able to adjust the position die assembly


22


relative to the cutting surface of blades


138


,


148


.




As discussed above frame


20


includes slide blocks


72


,


74


which are adjustably located in channels


64


,


66


of front and rear plates


36


,


38


respectively. Each slide block


72


,


74


is adjusted upwardly or downwardly within channels


64


,


66


. Movement of slide block


72


,


74


upward toward the top the plates


36


,


38


results in movement of die assembly


22


toward the exit side of cutter


10


. Similarly, downward movement of slide blocks


72


,


74


results in movement of die assembly


22


toward the loading side of cutter


10


.




Since slide blocks


72


,


74


are independently adjustable it is possible to independently adjust each end of die assembly


22


. By independent adjustment of the slide blocks, it is possible to compensate for relative wear of blades


138


,


198


if the blades do not wear at the same rate.




The operation of cutter


10


and the interaction of the various components detailed above will now be described. For purposes of describing the various components of mini-blind cutter


10


, the front of cutter


10


is the portion that faces the operator when utilizing cutter


10


. Specifically, the operator faces front end plate


36


when operating cutter


10


. (See FIG.


5


). The rear of cutter


10


is opposite the front and includes the rear side


30




b


of base plate


30


. (See FIG.


4


). A longitudinal axis of cutter


10


extends down the center of cutter


10


from the front of the cutter


10


to the rear of cutter


10


. The loading side of cutter


10


is the side in which the headrail components are loaded into cutter


10


to be cut.




The loading side corresponds to the left side of cutter


10


when the operator is facing the front of cutter


10


. (See FIG.


2


). Similarly, the right side, the side opposite the loading side, is referred to as the exit side. This is the side from which the cut portions of the mini-blind are expelled after they are cut. The transverse direction of cutter


10


is the direction perpendicular or normal to the longitudinal axis toward the loading or exit sides. Finally, a base plane is defined by the bottom surface


30




f


of base plate


30


.




Turning now to the operation of cutter


10


itself, the two modes of operation as discussed above will be addressed. In the first mode of operation, as illustrated in

FIG. 9

, die assembly


22


is in a first or lower position such that first slot


128


of headrail die


112


and first receiving area


134


are located proximate shelf plate


94


. In this first mode of operation a mini-blind product having a first configuration is sized. As discussed above, for purposes of illustration the first configuration will include a headrail and bottom rail formed from vinyl and a plurality of slats formed of vinyl or aluminum.




In the second mode of operation as illustrated in

FIGS. 1 and 6

, die assembly


22


is in the second or raised position such that second slot


130


of headrail die


112


, second receiving area


136


and bottom die


132


are located proximate shelf plate


94


. In this second mode of operation a mini-blind product having a second configuration is sized. The exemplary mini-blind product of the second configuration includes a headrail and bottom rail formed from steel and a plurality of slats formed of aluminum or steel. It should also be noted that the first and second blind configurations also have different geometric shapes.




Die assembly


22


is moved from the first position to the second position by lifting lever


144


in the upward direction until catch


142


engages top plate


86


. (See FIG.


1


). In a similar manner die assembly


22


may be moved from the second position back to the first position by depressing catch


142


toward the loading side of cutter


10


thereby releasing lever catch from top plate


86


. Once catch


142


is released, die assembly


22


may be lowered to the first position by the operator with lever


144


.




While die assembly


22


is movable in an up/down direction transverse to the base plane, die assembly


22


is positively located in frame


20


in the other directions. This is accomplished by engagement of flanges


124


,


126


within grooves


76


,


78


of slide blocks


72


,


74


which are secured within channels


64


,


66


of front and rear plates


36


,


38


.




For both modes of operation the starting position of the drive system and carrier assembly is the same. As shown in

FIGS. 6 and 9

drive system and carrier assembly is in the start position. In this start position, follower


246


is located adjacent point A on cam


232


which represents the point of minimum radius of cam


232


. Slat carrier


146


is at a point closest to rear plate


38


. In the start position the distance between slat carrier


146


and headrail carrier


148


is maximized. Additionally, in this position the heads


176


of connecting rods


166


are located within counter bores


180


.




For illustrative purposes the operation of cutter


10


in the second mode of operation will be described first. With die assembly


22


in the second or raised position, headrail


14


, slats


16


, and bottom rail


18


of the first mini-blind configuration are loaded into cutter


10


for sizing. Facing the front plate


36


of cutter


10


the operator loads the blind into cutter


10


from the left or loading side of cutter


10


. (See FIGS.


1


and


18


).




As illustrated in

FIGS. 1 and 18

headrail


14


is slid through second slot


130


of headrail die


122


. Similarly slats


16


are slid into second receiving area


136


proximate slat shear plate


100


. Finally, bottom rail


18


is slid into bottom die slot


133


. Headrail


14


, slats


16


and bottom rail


18


are positioned such that the portion of each component to be cut extends beyond exit surface


122




f


of headrail die, exit surface of slat shear plate


100


and exit surface


132




c


respectively.




Once the blind components are loaded into cutter


10


and positioned relative to the exit side of die assembly


22


, the operator begins the cut cycle by manually rotating handle assembly


200


in a clockwise direction. Rotation of handle assembly


200


and handle arm


204


specifically occurs in a plane parallel to the base plane. It is also possible to design handle assembly


200


for counter-clockwise rotation. Counter-clockwise rotation of handle assembly


200


may be desirable to allow greater leverage for the right handed operator.




Rotation of handle assembly


200


results in the rotation of shaft


206


and worm


208


, which in turn rotates worm gear


210


and output shaft


212


, which in turn rotates cam


232


in a clockwise position. The clockwise rotation of cam


232


is defined by viewing cam


232


from the exit side of cutter


10


.




In the preferred embodiment, handle assembly


200


is rotated thirty times to complete a single rotation of cam


232


. The complete rotation of cam


232


represents one complete cutting cycle of cutter


10


. A complete cutting cycle includes translation of blades


138


,


198


from a starting position to a fully extended position in which the mini-blind components are cut and return the blades


138


,


198


are returned to the starting position.




As cam


232


is rotated, follower


246


is translated toward the front of cutter


10


which results in the forward movement of slat carrier


146


. The cam profile is configured such that the rate of forward translation of follower


246


varies for a given rotation of output shaft


212


.




In the preferred embodiment, the greatest rate of forward translation of the follower per unit of rotation of the output shaft occurs proximate the starting point A. During this initial stage of the cutting cycle, slat carrier


146


moves from the starting position to a point proximate where blade


138


engages bottom rail


16


. The force required to move the slat carrier from the start position to a position proximate bottom rail


18


is less than the force required to cut the components. The mechanical advantage required initially is less than that required during the actual cutting of the components. Accordingly, the rate of translation per degree of rotation is greater for the initial period in which blade carrier


146


moves from the start position to the position in which blade


138


engages bottom rail


18


.




Continued translation of slat carrier


146


and blade


138


results in the cutting of bottom rail


18


. The curvature of blade


138


as discussed above is preferably flush against the curved surface


132




c


of bottom rail die


132


. Once a portion of bottom rail


18


has been cut it exits cutter


10


via chute region


184


of slat carrier


146


. Further translation of slat carrier


146


results in the engagement of blade


138


with slats


16


. Slats


16


are first forced forward within second opening


136


against slat shear plate


100


thereby removing any slack between the slats


16


. The force of blade


138


further minimizes the curvature of slats


16


during the cutting operation. Each slat


16


is then sheared by blade


138


in seriatim and exits cutter


10


through chute


184


.




During the cutting of slats


16


front surface


146




b


of slat carrier


146


abuts spacer


172


and results in forward translation of headrail carrier


148


. As a result slat carrier


146


and headrail carrier


148


move forward in unison. As the remainder of uncut slats


16


are cut headrail


14


is cut by blade


198


. (See FIG.


21


).




In this manner, drive system


28


provides independent linear translation of the first blade carrier for a pre-determined first distance, and simultaneous linear translation of the first and second blade carriers for a pre-determined second distance. The pre-determined first distance being sufficient to cut the bottom rail and portions of the slats. The pre-determined second distance being sufficient to complete the cutting of the slats and headrail. This approach permits the overall length of cutter


10


along the longitudinal axis to be reduced. It is possible to include a separate third blade carrier, such that a unique blade cuts the three separate components. However this adds additional cost.




Depending on the increased load required by simultaneously cutting the uncut slats and headrail it is possible to alter the cam profile configuration to reduce the rate of translation per unit of rotation of handle assembly


200


. The variation in the cam profile allows for a constant input force on behalf of the operator. However, a constant rate of translation can be employed for the entire portion of the cycle in which the blades are engaged with the components.




The carriers


146


,


148


are farthest from the starting position or in the fully extended position when follower


246


is adjacent point C on cam


232


. At this point head rail


14


, slats


16


, and bottom rail


18


are fully cut. (See FIGS.


8


and


22


). Continued rotation of handle assembly


200


, results in the rotation of cam


232


from point C to starting point A. The rate of reduction in radius from point C to point A allows carriers


146


,


148


to return quickly to the starting position.




In the preferred embodiment, the return of carriers


146


,


148


from the fully extended position to the starting position is accomplished with rotation of approximately 30 to 36 degrees of cam


232


. Based upon a thirty to one ratio of rotation of handle assembly


200


to rotation of cam


232


, return of the carriers is accomplished with approximately two and one half to three turns of handle assembly


200


.




Extension springs


194


are in tension when carriers


146


,


148


are in the fully extended position and bias the carriers back to the starting position as cam


232


is rotated from point C to point A. While it would be possible to incorporate a step reduction in the radius from point C to point A this would result in the carriers “slamming” back under the tension of springs


194


. The sloped non-step reduction in the radius allows for a smoother return of carriers


146


,


148


.




Turning to the operation of cutter


10


in the first mode of operation, die assembly


22


is moved to the first or lower position such that first slot


130


of headrail die


122


and first opening


134


are located adjacent shelf plate


94


. (See FIG.


9


).




Similar to the process described above for sizing the mini-blind product having the second configuration, the mini-blind having the first configuration is loaded into blind cutter from the left or loading side of cutter


10


. (See FIG.


18


).




While, the headrail of the first configuration is slid through first slot


128


in the manner described above for the headrail of the second embodiment, the slats and bottom rail


18


of the first configuration are slid into first opening region


134


. Although a separate die is not used in the preferred embodiment for cutting the vinyl bottom rail, a die could be used to cut the bottom rail of the first configuration as well. The use of bottom die


132


for cutting the steel bottom rail increases the dimensional integrity of the bottom rail during the cutting process.




As described above with respect to the second configuration, the headrail, slats and bottom rail of the first position are positioned such that the portions to be cut extend beyond the exit surface of headrail die


122


, slat shear plate


100


, and bottom rail die


132


.




The cutting operation is substantially similar to that described above with the noted exception that slats are forced against shear plate


100


initially upon contact of bottom rail by blade


138


.




Referring now to

FIG. 23

a second preferred cutter mechanism


300


will be described. Cutter


300


is similar to cutter


10


in a number of respects. First, cutter


300


includes a frame


302


similar to frame


20


of cutter


10


. Accordingly, every element of frame


302


will not be described again. However, the differences between frame


302


and frame


20


will be outlined below as required to support the description of the various modified systems. For example, since cutter


300


includes a different drive system, frame


302


does not include a spring tower. Components that are similar in both cutter


10


and cutter


300


will be identified with a separate reference numeral for clarity.




Similarly, cutter


300


includes a die assembly


304


that is similar to die assembly


22


of cutter


10


, and a blade carrier assembly


306


and supporting structure similar to carrier assembly


24


. The differences in these systems and assemblies will be described below as required.




As discussed above with respect to cutter


10


, cutter


300


may be used to cut two different mini-blind configurations, in two different modes of operation. The first mode of operation involves sizing a mini-blind having a vinyl head rail, vinyl bottom rail and either aluminum or vinyl slats. This mini-blind configuration will be referred to as the vinyl blind. The second mode of operation involves sizing a mini-blind having a steel head rail and bottom rail and aluminum slats. This mini-blind configuration will be referred to as the aluminum blind. Of course other materials and combinations could also be sized.




The framework or frame


302


supports the movable die assembly


304


that works in cooperation with the carrier assembly


306


. Die assembly


304


is movable from a first or lowered position to cut a mini-blind having the first configuration (vinyl blind) to a second or raised position to cut a mini-blind having the second configuration (aluminum blind).




Referring to

FIGS. 23-26

, cutter


300


includes a drive assembly


308


having a rack and pawl mechanism. The rack


310


is driven forward by a driving pawl


312


coupled to an actuation handle


314


by means of a four bar linkage


316


. The rack


310


is attached to the rear side


318


of a rear blade carrier


320


, such that translation of the rack


310


results in translation of the rear blade carrier


320


.




A roller


322


supported in a drive cradle


324


supports the rack


310


as it drives the rear blade carrier


320


forward. Additionally, the rack


310


is supported laterally by a pair of supports


326


secured to the drive cradle


324


and positioned on opposite sides of the rack


310


. The drive cradle


324


is secured to the base plate


328


of the frame


302


. The drive assembly is further includes a top bar


330


supported by the front plate


332


of the frame


302


and a rear support member


334


extending from the base plate


328


at the rear (R) of the cutter


300


. The base plate


328


and the top bar


330


of the frame


302


are fixed relative to one another and serve as the ground of the four bar linkage


316


.




As illustrated in

FIGS. 23-26

, the handle


314


is secured to the four bar linkage


316


at a first link


336


. The first link


336


is pivotally attached to the drive cradle


324


at a first pivot


338


. A second link


340


is pivotally attached to the first link


336


at a second pivot


342


a predetermined distance from the first pivot


338


. The second link


340


in turn is pivotally attached to a third link


344


at a third pivot


346


. The third link


344


is pivotally attached to the top bar


330


at a fourth pivot


348


. In this manner the four bar linkage


316


is completed. The driving pawl


312


is pivotally attached to the third link


344


at a fifth pivot


352


. Movement of the handle


314


toward the front (F) of the cutter


300


results in forward movement of the driving pawl


312


which in turn engages and drives the rack


310


and rear blade carrier


320


forward.




The driving pawl


312


includes a driving pawl release bar


354


attached thereto. The release bar


354


extends from the driving pawl


312


to a point above the top bar


330


. Rearward movement of the driving pawl release bar


354


pivots the driving pawl


312


about the fifth pivot


352


thereby disengaging the teeth of the driving pawl


312


from the rack


310


.




The driving mechanism further includes a holding pawl


356


to prevent the rack


310


from moving rearward during the cutting of the blind components. An extension bar


358


is secured to and extends downward from the top bar


330


. The holding pawl


356


is pivotally attached to the extension bar


358


at a sixth pivot


360


. A holding pawl release bar


362


extends from the holding pawl


356


to a point above the top bar


330


. Similar to the release bar


354


of the driving pawl


312


, movement of the holding pawl release bar


362


toward the rear of the cutter disengages the holding pawl


356


from the rack


310


thereby permitting the rack


310


to be moved rearward.




A cutter engagement/release switch


364


is slidably attached to the top bar


330


. The switch


364


includes a first end


366


having a knob


368


attached thereto, and a second opposing end


370


. Movement of the knob


368


in a direction rearward, causes the second end


370


of the switch


364


to contact and push rearward the holding pawl release bar


362


. Continued movement of the switch


364


, results in the holding pawl release bar


362


which in turn contacts the driving pawl release bar


354


thereby releasing the driving pawl


312


. In this manner the switch


364


can be moved rearward to release the driving and holding pawls


312


,


356


from the rack


310


. Once the driving and holding pawls


312


,


356


have been released from the rack


310


, the rack


310


may be manually moved rearward or forward.




Similarly, movement of the switch


364


toward the front of the cutter, results in the engagement of the driving and holding pawls


312


,


356


with the rack


310


. While the switch


364


does not directly pull the driving and holding pawls


312


,


356


into engagement with the rack


310


, the driving and holding pawls


312


,


356


are pivotally attached to the four bar linkage


316


and top bar


330


respectively such that gravity acts to pivot the pawls into engagement with the rack


310


.




Referring to

FIGS. 24 and 28

the blade carrier assembly


306


includes a head rail blade carrier


372


, a bottom rail blade carrier


320


, and a latch mechanism


374


for coupling the head rail blade carrier


372


and bottom rail blade carrier


320


together. The bottom rail blade carrier


320


includes a blade member


376


(see

FIG. 27

) having a first opening


378


for receiving a metal bottom rail of the second configuration as outlined above. The first opening


378


has a predetermined profile similar to the outer shape of the metal bottom rail. The front edge


380


of the blade member


376


includes an arcuate blade portion


382


for cutting the slats independently of the metal bottom rail in the second mode of operation. The front edge


380


of the blade


376


is also employed for cutting both the bottom rail and slats of the vinyl blind in the first mode of operation.




Referring to

FIGS. 28 and 29

, a latch


384


is secured to the top


386


of the head rail blade carrier


372


and extends rearward. The latch


384


includes a notch


388


proximate the rearward end. The bottom rail blade carrier


320


includes a pivotal catch


390


that can be rotated from a first disengaged position (see

FIG. 28

) to a second engaged position (see FIG.


33


). The catch


390


includes a tab portion


392


that is received within the notch


388


when the catch


390


is in the first position. When the head rail and bottom rail blade carriers are adjacent one another and the die assembly is raised to the second position, movement of the catch


390


to the second position engages the tab


392


within the notch


388


, thereby coupling the two blade carriers together.




Similarly, when the catch


390


is pivoted to the first position, the tab


392


is disengaged from the notch


388


and the blade carriers are free to move independent of one another. Of course the movement of the blade carriers are still linked through the connectors as described above with respect to cutter


10


.




The catch


390


is automatically pivoted by engagement of the top plate


394


of the die assembly


304


as the die is moved to or from the first position. When the die assembly


304


is raised from its first or lower position to its second or upper position, the upper surface


396


of the top plate


394


of the die assembly contacts the underside


398


of the tab


392


thereby rotating the catch


390


such that the tab


392


is located within the notch


388


. In this manner, the head rail and bottom rail blade carriers are coupled together.




Similarly, when the die assembly


304


is moved from the upper or second position to the first or lower position, the under side


400


of the top plate


394


engages an extension portion


402


on the catch


390


thereby pivoting the catch


390


to the disengaged position.




Additionally, the bottom rail blade carrier


320


includes a handle


404


for manually moving the blade carriers either to a first fully extended position to receive the components of a blind to be sized or to a second retracted position in which the blades have moved past the corresponding die portions toward the front plate


332


.




Die assembly


304


includes a safety block


406


attached to the exit side of the support side plate


408


of the die assembly. In this manner the safety block is proximate the carrier assembly


306


. The safety block


406


prohibits the die assembly


304


from being moved from the lower position to the upper position, when the bottom rail blade carrier


320


is in the fully extended position. This prevents the bottom rail blade member


376


from being damaged by ensuring that the bottom rail die block


410


does not hit the cutting edge


380


of the bottom rail blade as the die


304


is being raised. The safety block


406


is positioned such that if a user attempts to move the die assembly


304


when the bottom rail blade carrier


320


is in the extended position, the safety block


406


safely contacts the under side of the bottom rail blade member


376


where no damage to the cutting blade


380


can occur.




The operation of the cutter


300


will now be described, including the steps required to operate the cutter


300


in both the first and second mode of operation.




The first step required to use cutter


300


is to move the die assembly


304


to the first or second position depending on the blind configuration to be sized. Movement of the die assembly


304


is accomplished by pushing the switch


364


in a rearward direction thereby disengaging the driving and holding pawls


312


,


356


from the rack


310


. With the rack


310


free to move, the handle


404


attached to the rear blade carrier


320


is manually pulled in a forward direction until the blade member


376


of the rear blade carrier


320


clears both the safety block


406


and the bottom rail die block


412


.




With the rear blade carrier


320


clear of the safety block


406


and bottom rail die block


412


, the die assembly


304


can be either raised or lowered by activation of a lever


414


pivotally attached to the top plate of the frame at a pivot


416


. The lever


414


in turn is pivotally attached to a spring biased link


418


that retains the lever


414


in a first or second position representing the lower and upper positions of the die assembly


304


. In the embodiment disclosed in the figures, when the lever


414


is pivoted toward the rear of the cutter, the die assembly


304


is lowered to the first die position. Similarly when the lever


414


is pivoted toward the front of the cutter


300


, the die assembly


304


is raised to the second position.





FIGS. 27-31

illustrate the die assembly


304


in the lower position, while

FIGS. 32-36

illustrate the die assembly


304


in the raised position. As discussed above, the raising and lowering of the die assembly


304


engages or disengages respectively the tab


392


within the notch


388


. As shown in

FIGS. 28 and 29

the tab


392


is disengaged from the notch


388


when the die assembly


304


is in the first or lower position. In contrast,

FIGS. 33 and 34

illustrate the tab


392


engaged with the notch


388


when the die assembly


304


is in the second or raised position.




The sizing of a vinyl blind will be described first. The die assembly


304


is moved to the first or lower position as discussed above. Once the die assembly


304


has been lowered, the rear die assembly


304


is manually moved rearward utilizing the rear blade carrier handle


404


. Since, the rear blade carrier


320


and the front blade carrier


372


are not coupled with the tab and notch


388


, the rear blade carrier


320


will travel a predetermined distance independently of the front blade carrier


372


. Connecting rods


420


operate as connecting rods


166


in cutter


10


described above, such that once the rear blade carrier


320


has traveled rearward a predetermined distance, the connecting rods


420


act to move the front and rear blade carriers


320


,


372


rearward together beyond the predetermined distance.




Once the rear blade carrier


320


has been fully extended rearward, the bottom rail, slats and head rail of the vinyl blind are placed within the die assembly as described above with respect to cutter


10


. The rear blade carrier


320


may then be moved forward via the rear carrier handle


404


until the rail and slats are pressed against the slat shear plate


422


. In this manner the bottom rail and slats are located securely between the blade member and the slat shear plate


422


. Since cutter


300


may be used to size a mini-blind having a variety of number of slats, movement of the rear blade carrier


320


acts to take up excess space between the blade member


376


and the slat shear plate


422


.




Once, the bottom rail and slats are secured, the switch


364


is then moved forwardly to disengage the end of switch from the holding and driving pawl release bars


362


,


354


. In this manner the holding and driving pawls


356


,


350


are engaged with the rack


310


.




The handle


314


is then moved in a forward direction via pivot


338


, resulting in forward translation of the driving pawl


350


via the four bar linkage


316


. The handle


314


can only move as far forward as the first link


336


will permit. After the handle


314


has traveled as far as it can, the handle


314


is rotated back to its starting position, and as a result the driving pawl


350


is also returned rearwards. Of course an operator need not pivot the handle as far as it can before returning it rearwards. The angle of the teeth in the rack and the driving pawl, permit the driving pawl


350


to move rearward independently of the rack


310


. However, due to the pressure that builds up in the bottom rail, slats being cut, the holding pawl


356


is required to prevent the rack


210


from moving in a rearward direction while the driving pawl


350


is returned rearwards.




The handle


314


is pivoted forward and back until the bottom rail, slats and head rail are sized. As discussed above with respect to cutter


10


after a predetermined distance, the rear blade carrier


320


and the head rail blade carrier


372


move together thereby sizing the remaining uncut components.




Once all of the components have been sized, the rear blade carrier


320


and the front blade carrier


372


are in the forward position. Accordingly, the die assembly


304


can be raised for cutting the second blind configuration. Raising the die assembly


304


automatically pivots the catch


390


such that the tab


392


is engaged within the notch


388


. (See FIGS.


33


and


34


).




After the die assembly


304


has been raised, the switch


364


is moved rearward to release the driving and holding pawls


350


,


356


as discussed above. The rear blind carrier


320


and the front blind carrier


372


are moved manually rearward via the rear blind carrier handle


404


. Since the rear blade carrier


320


and the front blade carrier


372


are coupled with the catch


390


and latch


384


they move together. A stop located on the frame positively locates the blade carriers relative to the die assembly.




Unlike cutter


10


, the bottom rail of the aluminum blind is located within the aperture


378


of the blade member


372


, and the slats are located between the cutting surface


382


and the shear slat plate. In this manner, the bottom rail is sized by the rear edge of the aperture, or a third blade in a shearing motion while the slats are sized by the cutting surface


382


of the blade member.




Once the aluminum blind components have been located within the die assembly and blade carriers, the switch


364


is moved forward to permit engagement of the driving and holding pawls


350


,


356


with the rack


310


. Similar to the sizing of the vinyl blind, the handle


314


is pivoted forward and back a number of times to size the bottom rail, slats and head rail.




Cutter


300


provides a method for cutting two different blind products on the same piece of equipment, utilizing the same drive system. As discussed above, cutter


300


accommodates two mini-blind products of different geometry and or different material composition. Additionally, the number of slats may also vary for a given blind type. Since the vinyl slats are thicker than an aluminum slat, the region of the die assembly


304


to receive the vinyl slats must be wider than the region to receive a similar number of aluminum slats.




Additionally, the rear blade carrier


320


must be able to move further rearward in the extended direction in order to accommodate the greater thickness of the vinyl slats. In the preferred embodiment of cutter


300


the front edge


380


of the blade member


376


also is used to size the vinyl bottom rail. Accordingly, the rear blade carrier


320


must move further rearward than when the metal bottom rail of the aluminum blind is located within the aperture


378


of the blade member


376


.




The cooperation of the drive system


308


and blade carrier assembly


306


permits the rear blade carrier


320


to move to two different extended positions for sizing the first vinyl blind product and for sizing the second metal blind product. As discussed above the rear blade carrier


320


is moved further rearward for the sizing the vinyl product, since the front edge


380


of the rear blade member


376


cuts both the bottom rail and slats. Additionally, the width of the compressed vinyl slats is greater than compressed aluminum slats.




The location of the front blade carrier


372


in the extended position is the same for both the first and second modes of operation. However, in the first mode of operation for sizing the vinyl blind, the location of the rear blade carrier


320


is set by the connecting rods


420


while, in the second mode of operation for sizing the aluminum blind, the rear blade carrier


320


is set by the catch


390


and latch


384


. The connecting rods


420


permit independent travel of the rear blade carrier


320


, while the catch


390


and latch


384


allow for simultaneous translation throughout the translation of the blade carriers.




The first region of the die assembly


304


may also include a bottom rail die block (not shown), such that the portion of the bottom rail of the vinyl mini-blind would be located within the opening in the rear blade member. However, in order to accommodate the thickness of the vinyl slats the rear blade carrier


320


would be located further rearward in the extended position.




Although the invention has been described in conjunction with specific embodiments thereof, it is evident that alternatives, modifications and variations will be apparent to those skilled in the art. It is intended that the claims embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.



Claims
  • 1. A blind cutter for in-store sizing a mini-blind product including a head rail, a plurality of slats, and a bottom rail, the blind cutter comprising:a framework; a die assembly coupled to the framework having a region for receiving a portion of each of the head rail, plurality of slats, and bottom rail; a blade carrier assembly attached to the framework, the blade carrier assembly including at least one blade carrier movable from a first extended position in which the mini-blind product is loaded into the blind cutter for sizing and a second retracted position in which the mini-blind product has been sized; and a drive system being connected to the framework and blade carrier assembly to provide linear translation of the at least one blade carrier to size the mini-blind product, the drive system including a driving pawl and track; the drive system including a switch for releasing the driving pawl from the track to permit manual movement of the first blade carrier from the retracted to the extended position; the die assembly including a first region for receiving a portion of the head rail, plurality of slats and bottom rail of the mini-blind product, and a second region for receiving a portion of the head rail, plurality of slats and bottom rail of a second mini-blind product, the die assembly being movable from a first position for sizing the first mini-blind product and to a second position for sizing the second mini-blind product; and the drive system translating the first blade carrier independent of the second blade carrier for a first distance, and translating the first and second blade carriers for a second distance, when the die assembly is in the first position.
  • 2. A blind cutter for in-store sizing a mini-blind product including a head rail, a plurality of slats, and a bottom rail, the blind cutter comprising:a framework; a die assembly coupled to the framework having a region for receiving a portion of each of the head rail, plurality of slats, and bottom rail; a blade carrier assembly attached to the framework, the blade carrier assembly including a first blade carrier having a first blade member attached thereto, and a second blade carrier having a second blade member attached thereto; and a drive system being connected to the framework and blade carrier assembly to provide linear translation of the first blade carrier independent of the second blade carrier for a pre-determined first distance, and simultaneous linear translation of the first and second blade carriers for a pre-determined second distance.
  • 3. The blind cutter of claim 2, wherein the first blade member includes a first opening for receiving the portion of the bottom rail to be sized, and a front blade portion for cutting the portion of slats to be cut.
  • 4. The blind cutter of claim 2, wherein the first blade carrier includes a third blade, wherein the second blade is configured to size the slats, and the third blade is configured to size the bottom rail.
  • 5. The blind cutter of claim 2 wherein the framework includes a slat shear plate, the first blade carrier being movable independently of the second blade carrier to compress a variable number of slats between the second blade member and the slat shear plate, such that a first of the plurality of slats is in contact with the second blade and the last of the plurality of slats is in contact with the slat shear plate.
  • 6. The blind cutter of claim 2, wherein the die assembly includes a second region for receiving a portion of a second head rail, plurality of slats and bottom rail of a second mini-blind product, the die assembly being movable from a position for cutting the first mini-blind product and to a second position for cutting the second mini-blind product.
  • 7. The blind cutter of claim 6, wherein the die assembly is slidable from a fixed first position to a fixed second position, the first blind product being sized while the die assembly is in the fixed first position, and the second blind product being sized while the die assembly is in the second fixed position.
  • 8. The blind cutter of claim 7, wherein the first region of the die assembly is proximate the first and second blade members when the die assembly is in the first position, and the second region of the die assembly is proximate the first and second blade members when the die assembly is in the second position.
  • 9. The blind cutter of claim 1, wherein the blade carrier assembly includes a latch mechanism for connecting the first and second blade carriers to provide for simultaneous linear translation of the first and second blade carriers throughout the translation of the first blade carrier, when the die assembly is in the second position.
  • 10. The blind cutter of claim 1, wherein the first blade carrier includes a handle.
  • 11. The blind cutter of claim 1, wherein the drive system includes a driving pawl and track;the drive system including a switch for releasing the driving pawl from the track to permit manual movement of the first blade carrier to the extended position.
  • 12. A blind cutter for in-store sizing a mini-blind product including a head rail, a plurality of slats, and a bottom rail:;a framework; a die assembly coupled to the framework, the die assembly including a region for receiving a portion of the head rail, plurality of slats and bottom rail of the mini-blind product; a first blade carrier including a first blade carrier having a first blade member attached thereto, and a second blade carrier having a second blade member attached thereto; and a drive system being connected to the first blade carrier assembly to provide translation of the first blade carrier independently of the second blade carrier for a first distance and to provide simultaneous translation of the first and second blade carriers for a second distance.
  • 13. The blind cutter of claim 12, wherein the die assembly includes a second region for receiving a portion of a second mini blind product including a head rail, plurality of slats and bottom rail, the second mini blind product having a geometry different than the first mini-blind product, the die assembly being movable from a first position for cutting the first mini-blind product and to a second position for cutting the second mini-blind product; the drive system translating the first blade carrier independent of the second blade carrier for a first distance, and simultaneous linear translation of the first and second blade carriers for a second distance, when the die assembly is in the first position.
  • 14. The blind cutter of claim 13, wherein the drive system translates the first blade carrier and second blade carrier simultaneously, when the die assembly is in the second position.
  • 15. The blind cutter of claim 13, wherein the blade carrier assembly includes at least one connecting rod connecting the first and second blade carriers, the connecting rod being fixedly secured to the second blade carrier and slidably coupled to the first blade carrier, to permit independent translation of the first blade carrier for a predetermined distance when the die assembly is in the first position.
  • 16. The blind cutter of claim 12, wherein the blade carrier assembly includes a catch to couple the first and second blade carriers together for constant simultaneous translation when the die assembly is in the second position.
  • 17. The blind cutter of claim 13 wherein the first blade carrier includes a first blade member, the second region of the die assembly including a head rail die block, a bottom rail die block, and a safety block, the safety block prohibits the die assembly from being moved from the first position to the second position when the first blade carrier is a region that would allow for contact of the cutting surface of the first blade member with the bottom rail die block, such that the first blade member is prevented from being damaged by the bottom rail die block.
  • 18. The blind cutter of claim 12, wherein at least one of the first and second blade carriers includes a blade.
  • 19. The blind cutter of claim 18, wherein at least one of the first and second blade carriers includes an aperture for receiving the bottom rail.
Parent Case Info

This application is a continuation-in-part of U.S. patent Ser. No. 08/900,987 filed Jul. 25, 1997 now abandoned.

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Continuation in Parts (1)
Number Date Country
Parent 08/900987 Jul 1997 US
Child 09/321674 US