Patent Grant
11413679
The subject application relates to a new design of tooling, specifically a die and die ring, for production of elongate bodies, such as nails or screws in a wire-fed nail machine.
In an existing nail-machine one of the main-issues is the wear and related replacement of dies for production of said nails, especially forming the head on the nail. The machine is continuously fed with a raw material, a wire, which is shaped into nails through pressure from a stamping, rolling or roll forming process which includes two corresponding dies.
In some nail-machines, the dies are fixated, with thread based fastening means, to a rotating ring tool within the nail-machine, the dies arranged around the ring tool. Replacing the dies on a regular basis is a labour intensive task where several fastening elements are involved to fasten each die. Furthermore, tolerances of each of the fastening elements involved in fastening of the die tend to degrade position precision of the die in the die holder, and thus in the end reduce the quality of the nails as well as introducing wear. An example of such nail producing machine can be seen e.g. in EP 1 631 400 B1.
Hence, an improved die for the manufacturing of elongate bodies would be advantageous, and in particular a more efficient and/or reliable method of replacing the dies would be advantageous.
The subject application provides a die for the manufacturing of elongate bodies that solves the above mentioned problems of existing technology with simplified replacement of dies within the die holder, such as a tool ring, reducing down-time and increasing yield from a nail-machine. At the same time, it is preferred that the die is precisely positioned in the die holder.
Thus, the above described technology includes a first aspect of the subject application by providing a die for mounting in an associated die holder for the production of heads on elongate bodies, such as a metal nail or screw, the die comprising:
In the context of the subject application, ‘die’ is to be understood as a tool or device for imparting a desired shape, form, or finish to a material or for impressing an object or material, such as shaping the head on a nail or screw from a metal wire.
In the context of the subject application, ‘recess’ is to be understood as a depression into part of a surface, such as, but not limited to, a cleft, cut or cavity. In the context of the recess for forming the head on the elongate body, the recess can be a combination of a cut out for forming a surface, e.g. a plane surface, suitable for forming the head by applying pressure on the end of the elongate body when being held by the groove. Further, the recess may comprise specific features for forming a specific head shape on the elongate body, e.g. a chamfer and/or a round etc.
In the context of the subject application, ‘head’ is to be understood as the uppermost extremity or projecting part of an object.
In the most example embodiments, the groove is perpendicular or substantially perpendicular to a central longitudinal axis through the body between top surface and bottom part of the body of the die. Preferably, the groove is perpendicular to the central longitudinal axis through the body. Especially, a small offset angle of such as 0.1° may be preferred, and thus most preferably, the groove forms an angle of 89.8°-90.2° with the central longitudinal axis through the body of the die.
In an embodiment of the subject application, the recess or protrusion serving to fix angular orientation is shaped so as to guide the die into the corresponding protrusion or recess of the associated die holder. This will reduce the time spend on aligning the die surface in respect to the direction from which the wire is fed into the groove.
In an embodiment of the subject application, the elongate body is processed into rivets.
In an embodiment of the subject application, the elongate body is processed into spokes, such as, but not limited to, spokes for a bicycle.
In an embodiment of the subject application, the wire to be fed into the machine is smooth.
In an embodiment of the subject application, the wire to be fed into the machine is profiled, such as a round, square or spline profile.
In an embodiment of the subject application, the die has a cylindrical shape, which could improve the durability of the die, as sharp edges are usually the weakest point, most prone to chipping, when using alloy-steels suitable for tools.
In general, the die can be formed by a variety of material including metals as well as non-metals.
In the context of the subject application, ‘alloy steels’ is to be understood as steels that are well-suited to be made into tools. Alloying elements such as, but not limited to Tungsten, Chromium, Vanadium or Molybdenum are added, forming carbides in the steel, to increase the hardness, corrosion and heat resistance, abrasiveness and deformation of the steel.
In an embodiment of the subject application, at least a part of the die could be made from cement carbide, or a ceramic, such as Oxide ceramics with e.g. Zirconia additives, Mixed ceramics with e.g. carbides or Silicon nitride ceramics and SiAION grade ceramics. Ceramics have excellent wear resistance which could improve the durability of the die or the die holder.
In an embodiment of the subject application, at least a part of the body of the die is tapered improving the fixation of the die within the die holder. In example embodiments, the tapered part of the body of the die, or the entire body of the die, has a circular cross section. It is to be understood that the circular cross section may likewise be slightly elliptic or lightly oval.
In an embodiment of the subject application at least a part of the body of the die has a conical shape, such as wherein a side surface of said part of the body providing an angle of 0.1°-3°, such as 0.5°-2.5°, such as 1.0°-2.0°, with a central axis of the body.
In an embodiment of the subject application, the die has at least one recess forming a shoulder, preferably with a chamfer, for guiding the die into an associated die holder, wherein the recess has a corresponding protrusion within said die holder, in order to fix angular orientation of the groove relative to the die holder.
In an embodiment of the subject application, the die has a stop surface with at least one surface on a lower part of the body of the die for engaging with a bottom surface or lower shoulder surface in the hole or bore of the associated die holder.
In an embodiment of the subject application, the top surface of the die and the surface part of the die holder are to be substantially plane in respect to each other when the stop surface of the die is abutting said bottom surface or lower shoulder surface of the die holder.
In an embodiment of the subject application, the die has one or more holes or bores in the bottom surface and the die holder has one or more pins corresponding to said holes or bores, the pins engaging with the holes or bores, in order to fix angular orientation of the groove relative to the die holder.
In an embodiment of the subject application, the stop surface of said die has an inclined groove so as to ease the extraction or ejection of said die when seated in an associated die holder, when applying pressure with an elongate tool, such as a pin, preferably with a inclined tip corresponding to the inclination of the groove thereby driving the die out of the associated die holder without damaging said die holder or elongate tool.
In an embodiment of the subject application, the inclined groove on the stop surface of the die has an angle between 1° to 40°, such as between 2° to 30°, such as 5° to 20° or such as 8° to 15°, relative to the stop surface of the die, wherein the angle reduces the pressure needed to extract said die from an associated die holder.
In the context of the subject application, inclined groove is to be understood as a narrow cut or low area in a surface angled from one area in said surface to another area in said surface and wherein the groove varies in depth, relative to said surface from one end of the groove to the opposite end of the groove.
In an embodiment of the subject application, the bottom surface of the die has an inclined groove so as to ease the extraction or ejection of said die when seated in an associated die holder, when applying pressure with an elongate tool, such as a pin, preferably with a inclined tip corresponding to the inclination of the groove thereby driving the die out of the associated die holder without damaging said die holder or tool.
In some embodiments of the die, the stop surface and the bottom surface are one and the same. In some embodiments, the stop surface may be a recess cut into the body of the die at a position above the bottom surface.
In an embodiment of the subject application, the inclined groove on the bottom or stop surface of the die has a width (W) and the die has an outer diameter (D), and where a ratio (W/D) between said width and said outer diameter is between 0.01 and 1, more preferably between 0.1 and 0.5 as these ratios are ideal for the production of dies from steel, such as from tool grade steel or other hard alloys, especially such as a hard metal, e.g. tungsten carbide, or other hard materials suitable for the production of elongate bodies, such as a nail or screw.
In another embodiment of the subject application, the inclined groove has at least a plane surface part so as to reduce friction between an elongate tool and the plane surface, thereby easing the ejection of the die from die holder, when said die is firmly seated in said die holder.
In an embodiment of the subject application, the groove is a plane surface being parallel with an axis perpendicular to a central axis of the die, so as to ease the insertion of an elongate tool for the ejection of the die from die holder, when said die is firmly seated in said die holder.
In an embodiment of the subject application, the plane surface has an inclination angle of 0.5° to 50°, such as 1° to 40° or such as 2° to 20° relative to the stop surface or bottom surface of the die.
In an embodiment of the subject application, the inclined groove has at least a curved surface part.
In an embodiment of the subject application, the outer diameter (D) of the die and an overall height (H) of the die has a ratio (D/H) between 0.1 and 5 or more preferably between 0.5 and 2.0 to optimize manufacturing costs of the die and an associated die holder, such as a tool ring.
In a second aspect, the subject application relates to an elongate tool comprising a tip shaped to match the groove of the die according to the first aspect of the subject application, wherein the elongate tool is arranged to remove the die from an associated die holder.
In the context of the subject application, it is to be understood that the elongate tool may be used as a wedge, wherein the tip of said elongate tool is wedged between a bottom surface of the die and the bottom surface of the associated die holder, so as to apply a pressure for pushing the die upwards and out of the bore or hole in the die holder.
In an embodiment of the subject application, the tip on the elongate tool has an inclined flat surface arranged for engagement with an inclined flat surface of the inclined groove of the die, so as to ease the ejection of said die seated in an associated die holder.
In a third aspect, the subject application relates to a die holder comprising:
This aspect of the subject application is particularly, but not exclusively, advantageous in that the die holder according to the subject application may be implemented by insertion in an older, less advanced machine, such as a nail manufacturing machine, as an upgrade kit. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines which can be modified or updated to include a die holder with dies according to the first aspect of the subject application.
In an embodiment of the subject application, the top surface part of the die holder is ring-shaped, and the plurality of holes or bores are evenly distributed on the ring-shaped top surface part so as to ensure structural integrity of said die holder.
In an embodiment of the subject application, the die holder comprises at least 10 holes or bores evenly distributed on the ring-shaped top surface part, such as 10-100 holes or bores, so as to maximize the amount of said bores or holes on said ring-shaped top surface. In specific embodiments, the die holder may have such as 24, 30, 36, 40, 48, or 60 holes or bores evenly distributed on the ring-shaped top surface part of the die holder, however other numbers of holes or bores may be preferred.
In an embodiment of the subject application, the body of the die holder is monolithic and made of a metals so as to decrease the amount of parts needed to fixate a die in said die holder.
In a fourth aspect, the subject application relates to a machine for producing elongated bodies, such as nails, the machine comprising:
In the context of the subject application, ‘press fit’ is to be understood as the fit of a body driven into a hole slightly smaller than itself to be held tight and motionless.
In an embodiment of the subject application, the top surface part of the die holder is substantially ring-shaped, having a central axis of rotation, the ring-shaped die holder being mounted so as to rotate about said axis.
In an embodiment of the subject application, the machine has two opposite ring-shaped die holders, the die holders angled or slanted so as to, when rotating, to bring two opposite dies close enough together to almost brush against each other.
In an embodiment of the subject application, the top surface of the ring-shaped circular die holder has a plurality of holes or bores, such as 10-100 holes or bores, arranged for mounting of respective dies according to the first aspect of the subject application.
In an embodiment of the subject application, the plurality of holes or bores are parallel and evenly distributed around the top surface part of the ring-shaped die holder.
In an embodiment of the subject application, the die holder body has an opening, such as a hole or bore, connected to a bottom part of the hole or bore shaped for receiving and holding the die, so as to allow an elongate tool to engage with a lower part of the die to push the die upwards for removal of the die from the die holder, such as by exerting a force between the bottom surface of the die and a surface of the die holder. This embodiment is particularly, but not exclusively, advantageous for fast and simple removal of a worn-down or chipped die from the die holder, which will could significantly reduce the down-time of a machine.
In an embodiment of the subject application, the opening, for the insertion of the elongate tool into the die holder body, is a hole or bore perpendicular to the hole or bore for receiving and holding the die.
In an embodiment of the subject application, the die holder is ring-shaped, and the opening for the insertion of the elongate tool into the die holder body, is located on an inner side of the ring, so as to allow removal of the die, when the die holder is mounted for normal operation.
In an embodiment of the subject application, the die holder has one or more pins located in the hole or bore, serving to engage with a corresponding protrusion or recess of the die to fix angular orientation of the groove relative to the die holder.
The machine may especially be a nail producing machine, such as for producing nails with round heads, or for producing nails with D-shaped heads. The machine may alternatively be a screw producing machine, e.g. for producing heads on threaded elongate bodies.
In a fifth aspect, the subject application relates to a method for manufacturing a head on an elongate body, such as metal nails or screws, using the die according to the first aspect. In an embodiment, the method comprising:
This aspect of the subject application is particularly, but not exclusively, advantageous in that the method according to the subject application may be implemented by providing a ring shaped die holder according to the third aspect and the die according the first aspect. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines which can be modified or updated to include a die holder with dies according to the subject application.
In a sixth aspect, the subject application relates to a method for manufacturing a head on an elongate body, such as a nail, using the die holder according to the third aspect of the subject application.
This aspect of the subject application is particularly, but not exclusively, advantageous in that the method according to the subject application may be implemented by inserting a die holder according the second aspect, in an older, less advanced machine, such as a nail manufacturing machine, as an upgrade kit. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines, which can be modified or updated to include a die holder with dies according to the first aspect of the subject application.
In a seventh aspect, the subject application relates to a method for manufacturing a head on an elongate body, such as a nail, using the machine according to the fourth aspect of the subject application.
In an eighth aspect, the subject application relates to a method for ejecting a die according to the first aspect of the subject application from an associated die holder according to the third aspect of the subject application, wherein said method comprises:
This aspect of the subject application is particularly, but not exclusively, advantageous in that the method according to the subject application may be implemented by using an elongate tool according to the second aspect of the subject application in combination with the die according to first aspect of the subject application and the die holder according to the second aspect, in an older, less advanced machine, such as a nail manufacturing machine, as an upgrade kit. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines, which can be modified or updated so as to faster replace any damaged dies from the die holder and hence, reduce down time on the manufacturing machine.
In an embodiment of the subject application, the method comprises engaging between a tip of the elongate tool and a groove in the stop part or a bottom part of the die, wherein said tip and said groove are shaped to match so as to facilitate ejection of the die.
In an embodiment of the subject application, the groove comprises a plane surface with an inclination angle between 1° to 40° or such as between 2° to 20° relative to the stop surface or bottom surface of the die, and wherein a tip on the elongate tool has a plane surface shaped to engage with said plane surface of the groove.
In a ninth aspect, the subject application relates to the use of a die according to the first aspect of the subject application for manufacturing a head on an elongate body, such as a nail.
In a tenth aspect, the subject application relates to the use of a die holder according to the third aspect of the subject application, for manufacturing a head on an elongate body, such as a nail.
In an eleventh aspect, the subject application relates to the use of a machine according to the fourth aspect of the subject application, for manufacturing a head on an elongate body, such as a nail.
In a twelfth aspect, the subject application provides a nail manufactured according to any of the fifth, sixth or seventh aspect.
In a thirteenth aspect, the subject application provides a method of manufacturing nails comprising:
The subject application provides a die for the manufacturing of heads on elongate bodies that solves the above mentioned problems of the existing technology with and reducing down-time and increasing yield from a nail-machine.
In a fourteenth aspect, the subject application provides a die for mounting in an associated die holder for the production of heads on elongate bodies, the die comprising:
In an embodiment of the subject application, the first portion of the side surface of the die has a round shape, such as a circular or cylindrical shape, which may improve the durability of the die, as sharp edges are usually the weakest point, most prone to chipping, when using alloy-steels suitable for tools. In another embodiment, said first portion of the side surface has a conical shape, which has an advantageous shape for press fitting with a corresponding conical bore of an associated die holder.
In another embodiment of the subject application, the second portion of the side surface of the die comprises a plane portion serving to engage with a corresponding plane portion of the inner surface of the bore or hole in the associated die holder. This embodiment is particularly advantageous, as the plane portion provides a lock and key feature with a corresponding bore or hole of an associated die holder, thus preventing an operator from inserting the stop surface into said bore or hole. Thus, the flat surface provides an intuitive design for assembly. Furthermore, the plane portion, as per the inventors significant testing, has proven to provide a very durable die, thus saving time and material, when manufacturing nails.
The inventors have tested the die under normal operational conditions. Normal operational conditions is to be understood as operational conditions according to factory required and/or recommended conditions, i.e. wherein the nail manufacturing machine, wherein the die is positioned, is maintained according to factory recommendations and machine parameters are adjusted and set, according to factory recommendations.
The subject application introduces a novel die and method for fixing a die in a die holder for the forming of heads on elongate bodies, such as nails or screws. The introduction of the plane side surface portion which engages with a corresponding plane inner surface portion of the bore or hole of the die holder, the angular orientation guiding between die and die holder is handled without requiring any element which increases height of the die, and a limited height of the die helps increasing its stability under normal head forming operations and thereby eliminates or at least reduces problems with damages and wear.
The inventors have realized and verified by tests under normal nail production conditions, that the die according to the fourteenth aspect has a surprisingly long lifetime compared to the existing technology dies, including the dies disclosed in WO 2020/088823 A1. Thus, a nail-producing machine with such dies can be expected to have a very limited downtime, and thus a high yield, since it is only required to very rarely stop nail production due to worn out or damaged head forming dies.
Furthermore, compared to the existing technology dies disclosed in WO 2020/088823 A1, the dies according to the subject application are easier to mount, since they have one plane side surface only and can therefore not fit into the bore or hole of the die holder with the recess for head forming to the wrong side. This helps to reduce mounting time and eliminates damages or time spent on operating a nail producing machine with one or more dies with the head forming recess in the wrong position. The plane side surface further provides a clear, visual lock and key indication which provides an operator with an immediate information as to how the die are to be positioned respective to the bore of an associated die holder, when said operator is tasked with e.g. replacing a die in an associated die holder of a nail manufacturing machine.
Still further, compared to the existing technology dies disclosed in WO 2020/088823 A1, the dies according to the subject application are easier to manufacture, since the design is simpler and therefore can be performed with fewer manufacturing steps.
Even further, the dies can be designed with a volume of only 40-50% of the existing technology dies disclosed in WO 2020/088823 A1. Thus, the die design helps to save a significant amount of material, typically a hard metal alloy. Hereby, the dies according to the subject application are therefore also more environmental friendly than the existing technology dies.
In the context of the subject application, ‘die’ is to be understood as a tool or device for imparting a desired shape, form, or finish to a material or for impressing an object or material, such as shaping the head on a nail or screw from a metal wire.
In the context of the subject application, ‘recess’ is to be understood as a depression into part of a surface, such as, but not limited to, a cleft, cut or cavity. In the context of the recess for forming the head on the elongate body, the recess can be a combination of a cut out for forming a surface, e.g. a plane surface, suitable for forming the head by applying pressure on the end of the elongate body when being held by the groove. Further, the recess may comprise specific features for forming a specific head shape on the elongate body, e.g. a chamfer and/or a round shape etc.
In the context of the subject application, ‘head’ is to be understood as the uppermost extremity or projecting part of an object.
In the most example embodiments, the groove is perpendicular or substantially perpendicular to a central axis through the body between top surface and a bottom surface of the body of the die. In some embodiments, the bottom surface and the stop surface of the die are the same surface, i.e. the bottom surface constitutes the stop surface. Preferably, the groove is perpendicular to the central axis through the body. Especially, a small offset angle of such as 0.1° may be preferred, and thus most preferably, the groove forms an angle of 89.8°-90.2° with the central axis through the body of the die.
In an embodiment of the subject application, the elongate body is processed into rivets.
In an embodiment of the subject application, the elongate body is processed into spokes, such as, but not limited to, spokes for a bicycle.
In an embodiment of the subject application, the wire to be fed into the machine is smooth.
In an embodiment of the subject application, the wire to be fed into the machine is profiled, such as a round, square or spline profile.
In an embodiment of the subject application, the plane portion of the side surface is parallel with a central axis of the die. This embodiment may be advantageous for further providing strength to the structure of the die, thus providing a more durable die.
In the context of the subject application, the central axis is an axis extending through a bottom plane and a top plane of the die.
In another embodiment if the subject application, the plane portion of the die forms an angle of 0.5-2.0° with a central axis of the die. This embodiment may be advantageous for providing press fit of the side surface of said die with respect to a corresponding bore or hole of an associated die holder.
In yet another embodiment of the subject application the second portion of the side surface of the die comprises a curved portion serving to engage with a corresponding curved portion of the inner surface or bore in the associated die holder.
In yet another embodiment of the subject application, the curved portion of the second portion of the side surface has a different curvature than a curvature of the first portion of the side surface.
In another embodiment of the subject application, the second portion of the side surface of the die is arranged for press fit by contact with the corresponding portion of the inner surface of the bore or hole in the associated die holder.
In another example embodiment of the subject application, the first portion of the side surface of the die has a conical shape, and wherein the conical shaped portion of the side surface forms an angle of 0.5-2.0°, such as 0.8-1.6°, such as 1.0-1.4°, such as 1.1-1.3°, relative to a central axis of the die. The above examples may provide an optimal press fit angle for providing a durable die, i.e. a die that may be operational for more than 2.000 hours, preferably more than 3.000 hours, more preferably for more than 4.000 hours, even more preferably for between 4.500 and 10.000 hours or more.
In an embodiment of the subject application, an area of the second portion of the side surface is smaller than an area of the first portion of the side surface, such as the area of the second portion of the side surface being 10-40% of an area of the first portion of the side surface. This embodiment may be particularly advantageous for providing a more durable die.
In another embodiment of the subject application, the side surface of the die has chamfered portions, interconnecting said first and second portions of the side surface. In an embodiment of the subject application wherein the side surface of the has a first and second portion, the die has a first and second chamfered portion. This embodiment may be advantageous for reducing machining time of both the die and in particular the bore or hole of the associated die holder.
In another example embodiment of the subject application, the first and second chamfered portions interconnect respective first and second sides of the second portion of the side surface and the first portion of the side surface.
In yet another example embodiment of the subject application, the chamfered portions extend from a bottom surface or stop surface of the body of the die. This embodiment may be particularly advantageous for reducing machining time of both the die and in particular the bore or hole of the associated die holder. In some embodiments of the subject application, the chamfered portions extend from a bottom surface or stop surface to the top surface of the die.
In another embodiment of the subject application, the chamfered portions occupy only a part of the side surface between the bottom surface of the body to the top surface of the body, such as 30-80%, or such as 40-70%, of the distance between the bottom surface of the body to the top surface of the body. This embodiment may be advantageous for providing a more durable die.
In an embodiment of the subject application, the chamfered portions of the side surface of the die occupy a total of 1-20% of a circumference of the body of the die, such as 2-10% of the circumference of the body.
It is to be understood, that the circumference of the body of the die is to be understood as a total length of the perimeter of the side surfaces of the die, in a plane perpendicular to the central axis and substantially parallel to the top surface of the die, e.g. the circumference of a first and second portion of a side surface of a die with only two side portions.
In another embodiment of the subject application, the chamfered portions of the side surface of the die comprise a plane portion. This embodiment may be particularly advantageous for reducing machining time of both the die and in particular the bore or hole of the associated die holder, i.e. by reducing tolerances of said bore or hole with respect to the corresponding die.
In another embodiment of the subject application, the chamfered portions comprise a curved portion. This embodiment may be advantageous for providing a more durable die.
In yet another embodiment of the subject application, the second portion of the side surface of the die extends from the top surface to a bottom surface and/or stop surface of the body. This embodiment may be advantageous for providing a more durable die as well as a bore or hole within an associated die holder, which is faster to machine.
In an another embodiment of the subject application, the recess for forming the head on the elongate body is formed as a recess in an upper part of the second portion of the side surface. In an embodiment of the subject application, the second portion of the side surface is substantially flat, extending from a bottom surface of the die to the top surface of the die and wherein the recess is formed in an upper part of the flat surface. This embodiment is particularly advantageous for providing a more durable die, as the inventors have discovered that providing an extending flat surface on a side of the die, corresponding to a pressing surface for forming the head on the elongate body, provides for a stronger and more durable die which does not crack during extensive use, such as within the first 2.000 to 3.000 hours of operation.
In another embodiment of the subject application, an axis along the through-going groove is parallel to a normal to a plane portion of the second portion of the side surface.
In the context of the subject application, it is to be understood that a normal is a defining object such an axis or vector that is perpendicular to a given object. For example, the normal line to a plane curve at a given point is the (infinite) line perpendicular to the tangent line to the curve at the point.
In another embodiment of the subject application, the groove on the top surface of the die is perpendicular or substantially perpendicular to a central axis of the die.
In an advantageous embodiment, a bottom surface of the body forms the stop surface.
In a more advantageous embodiment of the subject application, bottom surface has a plane portion serving as a stop surface. This embodiment is particularly advantageous for providing a more simple die and corresponding die holder, which are faster and more simple to manufacture.
In an embodiment of the subject application, the die further comprises a dummy element or an associated dummy element, such as a monolithic element, arranged for position at a bottom part of the hole or bore of the associated die holder, wherein the dummy element comprises a top surface arranged to engage with a bottom surface of the body of the die, so as to form the stop surface in cooperation with the bottom part of the hole or bore of the associated die holder.
In an embodiment, a bottom surface or stop surface of the die has a groove, so as to allow an associated tool to engage with the groove in order to push the die upwards for removal of the die from an associated die holder.
In an embodiment of the subject application, the bottom or stop surface of said die has an inclined groove so as to ease the extraction or ejection of said die when seated in an associated die holder, when applying pressure with an elongate tool, such as a pin, preferably with a inclined tip corresponding to the inclination of the groove thereby driving the die out of the associated die holder without damaging said die holder or the associated elongate tool.
In another embodiment of the subject application, the groove is an inclined groove with an inclination angle between 2° to 20° relative to a bottom surface of the die.
In another embodiment of the subject application, the inclined groove on the stop surface of the die has an angle between 1° to 40°, such as between 2° to 30°, such as 5° to 20° or such as 8° to 15°, relative to the stop surface of the die, wherein the angle reduces the pressure needed to extract said die from an associated die holder.
The above embodiments are advantageous, as an inclined groove at a bottom or stop surface of the die may provide easier extraction or ejection of said die when seated in an associated die holder, when applying pressure with an elongate tool, such as a pin, preferably with a inclined tip corresponding to the inclination of the groove thereby driving the die out of the associated die holder without damaging said die holder or tool.
In the context of the subject application, inclined groove is to be understood as a narrow cut or low area in a surface angled from one area in said surface to another area in said surface and wherein the groove varies in depth, relative to said surface from one end of the groove to the opposite end of the groove.
In some embodiments of the die, the stop surface and the bottom surface are one and the same. In some embodiments, the stop surface may be a recess cut into the body of the die at a position above the bottom surface.
In an embodiment of the subject application, the inclined groove on the bottom or stop surface of the die has a width (W) and the die has an outer diameter (D), and where a ratio (W/D) between said width and said outer diameter is between 0.01 and 1, more preferably between 0.1 and 0.5 as these ratios may be ideal for the production of dies from steel, such as from tool grade steel or other hard alloys, especially such as a hard metal, e.g. tungsten carbide, or other hard materials suitable for the production of elongate bodies, such as a nail or screw.
In another embodiment of the subject application, the inclined groove has a width (W) and the die has an outer diameter (D), and where a ratio (W/D) between said width and said outer diameter is between 0.1 and 0.5.
In another embodiment of the subject application, the inclined groove has at least a plane surface part. This embodiment may be advantageous for reducing friction between an associated elongate tool and the plane surface, thereby easing the ejection of the die from die holder, when said die is firmly seated in said die holder.
In an embodiment of the subject application, the groove is a plane surface being parallel with an axis perpendicular to a central axis of the die, so as to ease the insertion of an associated elongate tool for the ejection of the die from die holder, when said die is firmly seated in said die holder.
In an embodiment of the subject application, the plane surface has an inclination angle of 0.5° to 50°, such as 1° to 40° or such as 2° to 20° relative to the stop surface or bottom surface of the die.
In an embodiment of the subject application, the inclined groove has at least a curved surface part.
In the context of the subject application, it is to be understood that the associated elongate tool may be used as a wedge, wherein the tip of said elongate tool is wedged between a bottom surface of the die and the bottom surface of the associated die holder, so as to apply a pressure for pushing the die upwards and out of the bore or hole in the associated die holder.
In an embodiment of the subject application, the tip on the associated elongate tool has an inclined flat surface arranged for engagement with an inclined flat surface of the inclined groove of the die, so as to ease the ejection of said die seated in the associated die holder.
In another embodiment of the subject application, the groove of the bottom surface is parallel with the through-going groove of the top surface.
In yet another embodiment of the subject application, the groove of the bottom surface forms a recess in a bottom part of the second portion of the side surface.
In yet another embodiment of the subject application, the body of the die has a symmetry plane, which is parallel with an axis along the through-going groove.
In another embodiment of the subject application, the body of the die is monolithic and made of a metal or a ceramics. This embodiment is particularly advantageous for providing a stronger and more durable die, which is faster to manufacture. In general, the die can be formed by a variety of material including metals, alloy steels as well as non-metals.
In the context of the subject application, ‘alloy steels’ is to be understood as steels that are well-suited to be made into tools. Alloying elements such as, but not limited to Tungsten, Chromium, Vanadium or Molybdenum are added, forming carbides in the steel, to increase the hardness, corrosion and heat resistance, abrasiveness and deformation of the steel.
In an embodiment of the subject application, at least a part of the die could be made from cemented carbide, or a ceramic, such as Oxide ceramics with e.g. Zirconia additives, mixed ceramics with e.g. carbides or Silicon nitride ceramics and SiAION grade ceramics. Ceramics have excellent wear resistance which could improve the durability of the die or the die holder.
In another embodiment of the subject application, an outer diameter (D) and an overall height (H) of said die has a ratio between 0.5 and 2.0, such as between 0.7 and 1.5.
In another example embodiment of the subject application, the height of the die between the top surface and a bottom surface is 5-20 mm, such as 8-18 mm, such as 10-16 mm, such as 12-15 mm.
In yet another example embodiment of the subject application, the overall length of the through-going groove of the top surface of the die is 5-30 mm, such as 10-20 mm, such as 10-18 mm, such as 10-17 mm or such as 11-17 mm.
In yet another example embodiment, the through-going groove on the top surface of the die has a width of 1.2-5.5 mm or such as 1.8-4.5 mm.
In an embodiment of the subject application, at least a part of the body of the die, such as the first portion of the side surface of the die, is tapered, improving the fixation of the die within the die holder, i.e. providing a die, which is suitable for press-fit in a die holder with a corresponding tapered geometry. In some embodiments, the tapered part of the body of the die or the entire body of the die may have one or more a circular cross sections. It is to be understood that the circular cross section may likewise be slightly elliptic or slightly oval.
In another embodiment of the subject application, first portion of the side surface has a conical shape and occupies more than 180°, such as 200-280°, such as 230-260°, such as 240-250°, of an angular portion of a cross sectional area of the die.
In an embodiment of the subject application at least a part of the body of the die has a conical shape, such as wherein a side surface of said part of the body providing an angle of 0.1°-3°, such as 0.5°-2.5°, such as 1.0°-2.0°, with a central axis of the body.
In an embodiment of the subject application, the top surface of the die and the surface part of the associated die holder are to be substantially parallel in respect to each other when the stop surface of the die is abutting said bottom surface or lower shoulder surface of the associated die holder.
In an embodiment of the subject application, the outer diameter (D) of the die and an overall height (H) of the die has a ratio (D/H) between 0.1 and 5, preferably between 0.5 and 2.0, even more preferably between 0.5 to 1.0, even more preferably between 0.7 to 1.0, even more preferably between 0.8 to 1.0 and even more preferably between 0.9 to 1.0, to optimize manufacturing costs of the die and an associated die holder, such as a tool ring.
In a fifteenth aspect, the subject application relates to a die holder comprising:
In the context of the subject application, ‘press fit’ is to be understood as the fit of a body driven into a hole slightly smaller than itself to be held tight and motionless or substantially motionless.
In another embodiment if the subject application, the die holder is ring-shaped.
In another example embodiment of the subject application, the plurality of holes or bores have parallel central axes and radially distributed on the die holder.
In yet another example embodiment of the subject application, the die holder comprises at least 10 holes or bores, such as 20-60 holes or bores, evenly distributed on a ring-shaped top surface part of the die holder. This embodiment is particularly advantageous for ensuring structural integrity of said die holder.
In some embodiment of the subject application, the die holder comprises at least 10 holes or bores evenly distributed on the ring-shaped top surface part, such as 10-100 holes or bores, so as to maximize the amount of said bores or holes on said ring-shaped top surface. In specific embodiments, the die holder may have such as 24, 30, 36, 40, 48, or 60 holes or bores evenly distributed on the ring-shaped top surface part of the die holder, however other numbers of holes or bores may be preferred.
In another embodiment of the subject application, the plurality of holes or bores are axially distributed on an inner or outer surface part of the die holder.
In an advantageous embodiment of the subject application, the body of the die holder is monolithic and made of a metal.
In another advantageous embodiment of the subject application, each of the plurality of holes or bores of the die holder has a conical shaped inner surface portion with an angle of 0.5-2.0° relative to a central axis of the hole or bore. This embodiment of the subject application is particularly advantageous for providing a bore, which is suitable for press fit, when inserting an element into said bore, which has a corresponding conical shape, such as the die according to the fourteenth aspect of the subject application.
In another embodiment of the subject application, each of the plurality of holes or bores has a plane inner side surface portion. This embodiment of the subject application is particularly advantageous for providing a die holder, which is fast to manufacture while still maintaining a sufficient fixation of an element inserted into said hole or bore, such as the die according to the fourteenth aspect of the subject application.
In an embodiment of the subject application, the plane inner side surface portion is parallel with a central axis of the hole or bore.
This aspect of the subject application is particularly, but not exclusively, advantageous in that the die holder according to the subject application may be implemented by insertion in an older, less advanced machine, such as a nail manufacturing machine, as an upgrade kit. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines which can be modified or updated to include a die holder with dies according to the fourteenth aspect of the subject application.
In a sixteenth aspect, the subject application relates to a machine for producing heads on elongated bodies, the machine comprising
In another embodiment of the subject application, a top surface part of the die holder is ring-shaped, having a central axis of rotation, the ring-shaped die holder being mounted so as to rotate about said axis.
In another example embodiment of the subject application, the top surface of the ring-shaped circular die holder has a plurality of holes or bores, arranged for mounting of respective dies.
In an embodiment of the subject application, the top surface of the ring-shaped circular die holder has a plurality of holes or bores, such as 10-100 holes or bores, arranged for mounting of respective dies according to the fourteenth aspect of the subject application.
In an embodiment of the subject application, the plurality of holes or bores are parallel and evenly distributed around the top surface part of the ring-shaped die holder.
In an embodiment of the subject application, the machine has two opposite ring-shaped die holders, the die holders angled or slanted so as to, when rotating, to bring two opposite dies close enough together to almost brush against each other.
In an advantageous embodiment of the subject application, the die holder body has an opening, connected to a part of the hole or bore shaped for receiving and holding the die, so as to allow an elongate tool to engage with a lower part of the die to push the die upwards for removal of the die from the die holder.
In an embodiment of the subject application, the die holder body has an opening, such as a hole or bore, connected to a bottom part of the hole or bore shaped for receiving and holding the die, so as to allow an associated elongate tool to engage with a lower part of the die to push the die upwards for removal of the die from the die holder, such as by exerting a force between the bottom surface of the die and a surface of the die holder. This embodiment is particularly, but not exclusively, advantageous for fast and simple removal of a worn-down or chipped die from the die holder, which will could significantly reduce the downtime of a machine.
In another embodiment of the subject application, the die holder is ring-shaped, and wherein said opening is located on an inner side of the ring, so as to allow removal of the die, when the die holder is mounted for normal operation.
In an embodiment of the subject application, the opening, for the insertion of the associated elongate tool into the die holder body, is a hole or bore perpendicular to the hole or bore for receiving and holding the die.
In another embodiment of the subject application, the machine comprises a head forming mechanism arranged to apply a force onto the elongate body at the recess end of the groove of the die, when the elongate body is fixated by the groove of the die, so as to form a head on the elongate body shaped according to the recess of the die.
In another example embodiment of the subject application, the first portion of the side surface of the at least one die has a conical shape, wherein the conical shaped portion of the side surface forms a first angle relative to a central axis of the die, and wherein each of the plurality of holes or bores of the die holder has a first inner side surface portion with a conical shape which forms a second angle relative to a central axis of the holes or bores.
In an embodiment of the subject application, the first and second angles differ by less than 0.02°.
In another embodiment of the subject application, the first angle is larger than the second angle, such as the first angle being 0.02°-0.10° larger than the second angle.
In yet another embodiment of the subject application, both of the first and second angles are within 0.5-2.0°, such as 0.8-1.6°, such as 1.0-1.4°, such as 1.1-1.3°.
In another embodiment of the subject application, the second portion of the side surface of the at least one die comprises a plane portion, and wherein the second inner side surface portion of the holes or bores of the die holder comprise corresponding plane side surface portions.
In an embodiment of the subject application, the plane portion of the at least one die is parallel with a central axis of the at least one die, and wherein said plane side surface portions of the inner side surface of the holes or bores of the die holder are parallel with a central axis of the holes or bores of the die holder.
In an advantageous embodiment of the subject application, a bottom surface of the at least one die forms said stop surface of the at least one die, and wherein a bottom surface of the holes or bores of the die holder form said stop part in the holes or bores of the die holder.
In some embodiments of the subject application, the machine comprises a dummy element arranged between a bottom surface of the at least one die and a bottom surface of the holes or bores of the die holder. This embodiment of the subject application may be advantageous for providing a more durable die within the nail manufacturing machine.
In another embodiment of the subject application, a distance between a bottom surface and the top surface of the at least one die is equal to a distance between a bottom surface of the holes or bores and a surface part of the die holder.
The machine may especially be a nail producing machine, such as for producing nails with round heads, or for producing nails with D-shaped heads. The machine may alternatively be a screw producing machine, e.g. for producing heads on threaded elongate bodies.
In a seventeenth aspect, the subject application relates to a die for the manufacture of heads on elongate bodies, such as nails, in a machine according to the sixteenth aspect of the subject application.
In a eighteenth aspect, the subject application relates to a die holder for the manufacture of heads on elongate bodies, such as nails, in a machine according to the sixteenth aspect of the subject application.
This aspect of the subject application is particularly, but not exclusively, advantageous in that the method according to the subject application may be implemented by inserting a die holder according the fifteenth aspect, in an older, less advanced machine, such as a nail manufacturing machine, as an upgrade kit. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines, which can be modified or updated to include a die holder with dies according to the fourteenth aspect of the subject application.
In a nineteenth aspect, the subject application relates to a method for manufacturing a head on an elongate body using the die according to the fourteenth aspect of the subject application.
In another embodiment of the subject application, the method comprises mounting the die in a hole or bore of a die holder by means of press fitting, and forming the head of the elongate body with the die, when the die is mounted in the die holder.
In another example embodiment of the subject application, the method comprises mounting the die in the hole or bore of the die holder in a tool-less mounting process. This embodiment is particularly advantageous for easy and fast fixation of the die within the die holder.
In the context of the subject application, tool-less is to be understood as a method wherein a die can be inserted into the bore of a die holder without the use of any other tools, than the hands of an operator. I.E., the operator does not need a hammer, measuring tool or any other tools, to successfully complete the mounting process.
In yet another example embodiment of the subject application, the method comprises operating a machine to produce heads on elongate bodies using the die mounted in the die holder in a second step, after mounting the die in the hole or bore without the use of tools, in a first step. This embodiment is particularly advantageous for the production of nails, the process of inserting a new die into the hole or bore of a die holder is fast and only requires few steps, e.g. two steps, after which the production of nails can immediately continue.
It is to be understood that any service hatches needs to be opened/closed before/after the insertion of any dies.
In an embodiment of the subject application, the method comprises:
In an embodiment of the subject application, the method comprises ejecting the die from a hole or bore in a die holder.
In an embodiment of the subject application, the method comprises:
This embodiment of the subject application is particularly, but not exclusively, advantageous in that the method according to the subject application may be implemented by using an elongate tool in combination with the die according to the fourteenth aspect of the subject application and the die holder according to the fifteenth aspect, in an older, less advanced machine, such as a nail manufacturing machine, as an upgrade kit. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines, which can be modified or updated so as to faster replace any damaged dies from the die holder and hence, reduce down time on the manufacturing machine.
In another embodiment of the subject application, the method comprises engaging between a tip of the elongate tool and a groove in a bottom part of the die, wherein said tip and said groove are shaped to match so as to facilitate ejection of the die.
This aspect of the subject application is particularly, but not exclusively, advantageous in that the method according to the subject application may be implemented by providing a ring shaped die holder according to the fifteenth aspect and the die according the fourteenth aspect. The subject application is advantageous for new nail or screw manufacturing machines, as well as existing machines, which can be modified or updated to include a die holder with dies according to the subject application.
In a twentieth aspect, the subject application relates to a method for manufacturing a head on an elongate body, such as a nail, using the die holder according to the fifteenth aspect of the subject application.
In an sixtieth twenty-first, the subject application relates to a method for manufacturing a head on an elongate body, such as a nail, using the machine according to the sixteenth aspect of the subject application.
In a twenty-second aspect, the subject application relates to a method of manufacturing nails comprising:
In a twenty-third aspect, the subject application relates to a nail manufactured according to any one of the sixth to sixty-first aspect of the subject application.
In an twenty-fourth aspect, the subject application relates to the use of a die according to the fourteenth aspect of the subject application, for manufacturing a head on an elongate body, such as a nail.
In a twenty fifth aspect, the subject application relates to the use of a die holder according to the fifteenth aspect of the subject application, for manufacturing a head on an elongate body, such as a nail.
In a twenty-sixth aspect, the subject application relates to the use of a machine according to the sixteenth aspect of the subject application, for manufacturing a head on an elongate body, such as a nail.
In a twenty-seventh aspect, the subject application relates to a method of forming a manufacture comprising:
The die according to the subject application will now be described in more detail with regard to the accompanying figures. The figures show one way of implementing the subject application and is not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set.
S2 providing first and second dies, each of the first and second dies comprising:
S3 bringing the top surface of the first die so near to the top surface of the second die that the grooves of the first and second dies hold the elongate body, and
S4 providing force onto the elongate body at the recess end of the grooves so as to form a head on the elongate body.
In a further embodiment, the method may comprise the step of removing the die by pushing a bottom part of the die, such as by a dedicated tool, through an opening in the die holder.
On the bottom surface 7, a groove 75 has been cut into the body 2 of the die 1. The purpose of this groove 75 is to allow an elongate tool with a tip matching the groove 75 to engage with the groove in order to push the die 1 upwards, when press fit mounted in a die holder. Especially, such elongate tool can be inserted in an opening in the die holder and thus facilitate removing the die for replacement.
On the bottom surface 7, an inclined groove 75 has been cut into the body 2 of the die 1. In the present embodiment, the inclined groove 75 is a plane surface being parallel with an axis 300 perpendicular to a central axis/length axis 200 of the die 1. The angle of inclination is preferably 2°-20°. The inclined plane surface helps to provide a force in an upward direction to drive out the die 1 from a die holder. The tool preferably has a tip with an inclination angle matching the inclination angle of the plane surface of the groove 75. An example of such tool will be given below.
Preferably, the die holder 20 is a monolithic element made of metal, preferably a metal which is softer than the metal or other material which forms the associated dies to be press fit in the holes or bores 30. The dies are preferably made of a hard material, e.g. a hard metal, to provide a long life time. By the press fitting principle, the hard material die is securely fastened in the hole or bore 30, thus providing optimal support of the edge of the hard material die, thereby providing a long life time of the die.
The holes or bores 30 each has an inner surface shaped for receiving a die and for press fit by contact with the side surface of the die. In the hole or bore 30, a stop part is formed so as to allow engagement with a stop surface of the die when the die is being pressed into the hole or bore, so as to fix a height of a top surface of the die in relation to the top surface part of the die holder 20. Further, the die holder 20 has a protrusion or recess serving to engage with a corresponding recess or protrusion of the die, in order to fix angular orientation of the die relative to the die holder, thereby facilitating precise angular orientation of the die during the mounting in the die holder 20, e.g. after replacement of the die.
Examples of the stop part and protrusion or recess for angular orientation fixing of the die can be seen in
To sum up, the subject application provides a die (1) for mounting in an associated die holder (20) for the production of heads on elongate bodies such as nails or screws. The die has a body (2) with a top surface (3) provided with a through-going groove (4) for receiving and holding an elongate body longitudinally in said groove. Furthermore, the die has a recess in the form of a cut-out (9) on one side merging into the groove (4) at one end of the groove (4) suitable for forming the head of a nail or screw. The die is preferably shaped tapered or conical for press fit by contact with the inner surface of a bore or hole (30) in the associated die holder. The top surface (3) of the die (1) is plane in relation to the top surface (21) of the die holder (20) through a stop or bottom surface (7) which engages with a stop or bottom part (28) within the hole or bore (30) of the die holder (20). Furthermore, the bottom portion of the die has at least one recess (8) or protrusion serving to engage with a corresponding protrusion (27) or recess of the associated die holder, in order to fix angular orientation of the groove (4) relative to the die holder (20). In order to produce a nail or screw from an elongate body (40), two opposite dies are brought together by two opposite die holders, the dies together forming the head (41) with their combined recesses.
In some embodiments, the inclined groove 175 is a plane surface being parallel with an axis perpendicular to the central axis, as shown in
Preferably, the die holder 120 is a monolithic element made of metal, preferably a metal, which is softer than the metal or other material which forms the associated dies to be press fit in the holes or bores 130. The dies are preferably made of a hard material, e.g. a hard metal, to provide a long lifetime. By the press fitting principle, the hard material die is securely fastened in the hole or bore 130, thus providing optimal support of the edge of the hard material die, thereby providing a long life time of the die.
The holes or bores 130 each has an inner surface shaped for receiving a die and for press fit by contact with the side surface of the die. In the hole or bore 130, a stop part is formed so as to allow engagement with a stop surface of the die when the die is being pressed into the hole or bore, so as to fix a height of a top surface of the die in relation to the top surface part of the die holder 120. Further, the die holder 120 has a protrusion or recess serving to engage with a corresponding recess or protrusion of the die, in order to fix angular orientation of the die relative to the die holder, thereby facilitating precise angular orientation of the die during the mounting in the die holder 120, e.g. after replacement of the die.
To sum up, the subject application provides a die 101 for mounting in an associated die holder 120 for the production of heads on elongate bodies such as nails or screws. The die has a body 102 with a top surface 103 provided with a through-going groove 104 for receiving and holding an elongate body longitudinally in said groove. Furthermore, the die has a recess 105 on one side merging into the groove 104 at one end of the groove 104 suitable for forming the head of a nail or screw. The die has a side surface portion, e.g. conical, shaped for press fit by contact with a corresponding inner surface portion of a bore or hole 130 in the associated die holder. Further, a second side surface portion (9), e.g. a plane portion, of the die serves to engage with a corresponding inner surface portion of the bore or hole of the die holder. Hereby, it is ensured, that angular orientation of the groove 104 is fixed relative to the die holder 120, and it has been proven that the two different side surface portions of the die, e.g. with a conical portion and a plane portion, provides an efficient press fit which ensures a long lifetime of the die. Further, the die is very simple to mount in the die holder, e.g. by hand, and it is simple to eject by a tool. Thus, altogether a highly efficient nail production can be obtained with such die and die holder system.
Although the subject application has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the subject application is set out by the accompanying claim set. In the context of the claims, the terms “comprising” or “comprises” do not exclude other possible elements or steps. Also, the mentioning of references such as “a” or “an” etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the subject application. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.
This patent application is a continuation-in-part of U.S. patent application Ser. No. 17/154,235 filed on Jan. 21, 2021, which was a continuation of U.S. patent application Ser. No. 16/778,670 filed on Jan. 31, 2020 (now U.S. Pat. No. 10,906,087), which was a continuation of PCT/EP2019/073650 filed on Sep. 5, 2019. This patent application is also a continuation-in-part of PCT/EP2021/073975 filed on Aug. 31, 2020, the disclosures of which are hereby incorporated by reference herein in their entirety and made part of the present U.S. utility patent application for all purposes.
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| Number | Date | Country | |
|---|---|---|---|
| 20220062971 A1 | Mar 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16778670 | Jan 2020 | US |
| Child | 17154235 | US | |
| Parent | PCT/EP2019/073650 | Sep 2019 | US |
| Child | 16778670 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17154235 | Jan 2021 | US |
| Child | 17524444 | US | |
| Parent | PCT/EP2021/073975 | Aug 2020 | US |
| Child | 17154235 | US |
