WO1998033661A2

WO1998033661A2 - Spiral-binding punch apparatus and method

Info

Publication number: WO1998033661A2
Application number: PCT/US1998/001683
Authority: WO
Inventors: Gerald L. Adams
Original assignee: Unicoil, Inc.
Priority date: 1997-01-30
Filing date: 1998-01-30
Publication date: 1998-08-06
Also published as: WO1998033661A3

Abstract

A spiral-binding punch (30) comprising a drive assembly (350) and a die assembly (40), engageable by the drive assembly, which is insertable and removable from the punch, as a unit, without disassembly of the punch or die assembly, thereby enabling easy replacement, or substitution, of the die assembly (40) by another die assembly capable of producing holes of a different size, of a different shape, of a different spacing between adjacent holes, and/or of a different distance relative to a paper edge. According to the preferred embodiment, the die assembly (40) is slidably receivable, in a lateral direction, through an opening (52) in a side of the punch (30) and includes a plurality of adjacent punch dies (300) which extend between upper and lower portions of the die assembly (40). A die assembly sensor (61), oriented so as to be contactable by a die assembly (40), interacts with the drive assembly (350) to automatically prevent operation of the punch and, hence, potential damage to the punch, when no die assembly is present within the punch.

Description

SPIRAL-BINDING PUNCH APPARATUS AND METHOD

FIELD OF THE INVENTION

This invention relates generally to the field of apparatus and methods for binding sheets of paper or other materials together and, more particularly, to the punching of holes in paper or other flat stock materials for subsequent binding with a spiral coil.

BACKGROUND OF THE INVENTION

Many methods of binding sheets of paper or other flat stock materials together as a unit have been developed in the past, including book binding, Velobinding ® , spiral binding, etc. Each method has its own advantages and disadvantages. Classic book binding, although preferred in many applications, requires equipment and manufacturing techniques that generally do not lend themselves to low volume binding, such as that required in small companies, offices, print shops, etc. Velobinding ® may be performed with equipment readily available to small offices or print shops. The bound unit produced by Velobinding requires a large margin on the left-hand side and does not allow the resulting unit to be easily laid open for viewing.

Spiral binding allows a stack of papers to be bound together as a unit that is easily opened to any page, thus making it very acceptable in the marketplace. In spiral binding, a series of equally-spaced, round holes are punched adjacent to one edge of the stack of papers by a first piece of equipment known as a punch. The diameter of the holes and the spacing between the centers of adjacent holes (and, hence, the number of holes adjacent the edge) made by the punch are determined primarily by the thickness of the stack of papers to be bound. Generally, smaller bound units (i.e., those having a relatively small thickness) enable use of a spiral coil having a smaller coil diameter and a smaller filament diameter, thereby dictating that the holes made by the punch have a smaller diameter and a smaller spacing between holes (also known as the "pitch" of the holes). Alternatively, larger bound units (i.e., those having a relatively large thickness) enable use of a spiral coil having larger coil and filament diameters, thereby dictating that the punched holes have a larger diameter and pitch. Once the holes are punched in the stack of papers, a continuous spiral coil is fed or spiraled through the holes to form a bound unit by a second piece of equipment known as a coil inserter.

The acceptance of spiral binding in the marketplace has led a number of manufacturers to produce equipment to perform spiral binding. Unfortunately, many of the manufacturers have focused their efforts to develop spiral binding equipment which is large, complex, and designed for use in assembly lines where commercially-produced spiral bound units are produced. Some manufacturers have, however, developed spiral binding equipment which is intended for use in small businesses, offices, and print shops, but such small business equipment often requires substantial table-top space, is often expensive, and is often difficult and time-consuming to use.

For instance, certain manufacturers have developed punches for small business use which punch holes using dies that lie in a horizontal plane and travel in a horizontal direction (referred to herein as "horizontal punches") within the plane. The papers or other materials to be punched are inserted in a vertical direction into the punch with the edge to be punched being received against the horizontal bottom of a vertically-extending well. Because the dies of a horizontal punch travel in a horizontal plane which is perpendicular to the surfaces of the papers, the mechanism which drives the dies typically extends in the same horizontal plane and, in most horizontal punches, extends for a substantial distance, thereby causing the horizontal punch to have a footprint requiring considerable table-top space. Due in part to the size of their footprint, horizontal punches are often unattractive for small businesses where quarters are usually cramped and table- top space is at a premium.

Other manufacturers have developed punches for small business use which punch holes using dies that lie in a vertical plane and travel in a vertical direction (referred to herein as "vertical punches") within the plane. In a vertical punch, the papers or other materials to be punched are inserted in a horizontal direction into the punch with the edge to be punched being received against a vertically-extending stop and the dies travel in a vertical direction perpendicular to the surface of the papers. In order to drive the dies in the vertical direction, most vertical punches have a complex drive mechanism positioned above the dies which results in vertical punches usually having a smaller footprint than that of their horizontal counterparts. Unfortunately, the position of the drive mechanism typically requires that much of the mechanism be disassembled, removed, and reassembled whenever it is necessary to change the size of the dies or the pitch of the dies in order for an operator to switch between punching holes for different sizes of bound units. Such disassembly, removal, and reassembly consumes valuable time, increases the cost of punching operations, and virtually requires that a small business must have an employee who is extremely well-trained with respect to the inner workings of the vertical punch.

There is a need, therefore, in the industry for a punch having a small footprint and easily changed dies which addresses these and other related, and unrelated, problems. SUMMARY OF THE INVENTION

Briefly described, the present invention comprises a punch having a drive assembly and a die assembly, engageable by the drive assembly and having a plurality of adjacent punch dies, which is insertable and removable from the punch as a unit, without disassembly of the punch or the die assembly, thereby enabling easy replacement, or substitution, of the die assembly by another die assembly capable of producing holes of a different size, of a different shape, of a different spacing between adjacent holes, and/or of a different distance relative to a paper edge. The individual punch dies of the plurality of adjacent punch dies are translatable in a first direction within a first plane, in response to operation of the drive assembly, and the die assembly is slidably translatable, as a unit, in a second direction within a second plane. A die assembly sensor, oriented so as to be contactable by a die assembly, is interactable with the drive assembly to automatically prevent operation of the punch and, hence, potential damage to the punch, when no die assembly is present within the punch. Paper sensors, strategically located within a die assembly and engageable by paper inserted into the punch, detect the presence of paper and whether or not the paper is in a proper position for punching, and interact with the drive assembly to automatically trigger a punching operation.

According to an apparatus of the preferred embodiment of the present invention, a punch, comprising a drive assembly, a die assembly, and a base, defines a substantially laterally-extending (i.e., side to side) cavity which slidably receives the die assembly, substantially in the lateral direction of the cavity, through an opening defined in a side of the punch. The die assembly includes a laterally-extending die retaining structure and a plurality of adjacent punch dies slidably held by the die retaining structure in a vertical plane to allow translation of the punch dies in the vertical direction of the plane through a laterally and rearwardly-extending gap between members of the retaining structure which receives paper, in primarily, the longitudinal (i.e., front to back) direction, during operation of the punch. The die retaining structure includes an upper portion and a lower portion where the upper portion is biased and translatable relative to the lower portion. Individual punch dies of the plurality of adjacent punch dies extend between the upper and lower portions of the die retaining structure through coaxially-aligned holes defined by members of the upper and lower portions. The upper portion of the die retaining structure is slidably and engageably received, in the lateral direction, by elements of the drive assembly (i.e., a compression bar and extraction brackets) and the lower portion of the die retaining structure is slidably and engageably received, in the lateral direction, by elements of the base which prevent vertical movement of the lower portion of the die retaining structure during operation of the punch. The die retaining structure further includes first and second paper sensors which reside partially within, and at the rearmost extent of, the gap defined by members of the lower portion of the die retaining structure. The first and second paper sensors, when the die assembly is positioned within the cavity of the punch, extend rearward of the die assembly to contact levers of switches which are secured to the base and which are connected to the drive assembly. The punch further comprises a die assembly sensor, extending adjacent the opening in the side of the punch, which is engageable by an end-plate of the die assembly and which is, similar to the first and second paper sensors, connected to the drive assembly.

The drive assembly comprises a motor which is uniquely coupled to the compression bar by a linkage which produces translatory motion of the compression bar in response to rotary motion of the motor's shaft. The linkage includes a first shaft which extends laterally substantially between the sides of the punch and which is connected to the motor shaft by a sprocket and chain drive. The linkage further includes twin push rods, each having a crank lobe with a ball bearing, and twin compression levers, each having first and second arms. The push rods rotatively interface to the first shaft and pivotally connect, respectively, to the first arm of one of the compression levers. The compression levers are rotatively mounted about a fixed, second shaft which extends parallel to the first shaft and substantially between the sides of the punch. The second arms of the compression levers pivotally connect to the top of the compression bar. In operation, rotary motion of the motor shaft causes the push rods to rotate which, in turn, causes rotation of the compression levers about the second shaft. Due to the unique kinematic arrangement of the arms of the compression levers relative to the push rods and the compression bar, the first half of a revolution of the push rods creates a, generally, upward movement of the first arms of the compression levers and a, predominantly, downward movement of the second arms of the compression levers (and, hence, downward translation of the compression bar), while the second half of each revolution of the push rods produces a, generally, downward movement of the first arms of the compression levers and a, predominantly, upward movement of the second arms of the compression levers (and, hence, upward translation of the compression bar).

In accordance with a method of the preferred embodiment of the present invention, the cavity of the punch receives a die assembly which is slidably inserted in the lateral direction of the punch through the opening in a side of the punch. While sliding laterally into position, the die assembly engages the die assembly sensor, causing detection of the presence of the die assembly and notification to the drive assembly that a die assembly is present and, thereby satisfying one requisite for operation of the punch. When fully-received by the cavity, the upper portion of the die assembly resides predominantly in a gap defined by the compression bar and extraction brackets of the drive assembly with the extraction brackets extending partially under the upper portion and with the individual punch dies of the die assembly residing immediately below the compression bar in a vertical plane. Once the die assembly is fully-received by the cavity, the punch receives paper, first in a longitudinal direction, within the gap defined by the lower portion of the die assembly. The first paper sensor, engaged by the paper, rotates and actuates a first paper switch, thereby signaling, to the drive assembly, the detection of paper being present within the die assembly and a determination that the paper is properly positioned in the longitudinal direction for punching. The second paper sensor, slidably engaged by subsequent lateral movement of the paper toward a side of the punch while within the paper is present in the gap of the lower portion, translates and actuates a second paper switch which signals the drive assembly to note a determination that the paper is properly positioned in the lateral direction for punching.

Upon determining that paper is present and properly positioned within the die assembly, a second requisite for operation of the punch is satisfied and a punch cycle is triggered, causing the motor to start and, hence, causing downward translation of the compression bar into contact with the punch dies of the die assembly (note that in an alternate method, triggering of a punch cycle is triggerable by operation of a foot pedal). Continued operation of the motor and drive assembly causes continued downward translation of the compression bar in the vertical plane of the punch dies, downward translation of the upper portion of the die assembly toward the stationary lower portion of the die assembly (and, hence, compression of the biasing members between the upper and lower portions of the die assembly), and downward translation of the punch dies through the paper present in the gap of the lower portion of the die assembly (thereby, creating holes in the paper), until the kinematic relationship of the linkage of the drive assembly (described above) determines that the maximum downward travel of the punch dies has been reached and, hence, conclusion of the first half of the punch cycle. The compression bar then begins translating in an upward direction, still within the vertical plane of the punch dies, causing the extraction bracket to engage the upper portion of the die assembly and, in conjunction with an upward force applied to the upper portion by decompression of the biasing members, producing translation of the punch dies in the vertical direction. Continued operation of the motor and drive assembly brings about continued upward translation of the extraction brackets and of the upper portion of the die assembly until the compression bar actuates a switch which determines that the maximum upward travel of the compression bar (and, hence, the upper portion and the individual dies of the die assembly) has been reached and which signals the drive assembly that the second half of the punch cycle is complete in order to cause the drive assembly to turn- off the motor.

According to the method of the preferred embodiment, the die assembly is removable, as a unit, from the cavity of the punch by sliding translation of the die assembly in the lateral direction through the opening at a side of the punch without disassembly of the die assembly and without disassembly of the punch. Upon sufficient removing translation of the die assembly, the die assembly sensor disengages the die assembly and notifies the drive assembly that a die assembly is no longer present within the punch, thereby preventing operation of the punch. Once the die assembly (i.e., the first die assembly) is removed from the punch, a second die assembly is receivable within the cavity of the punch in a manner like that of the first die assembly, thereby enabling replacement, or substitution, of the first die assembly with a second die assembly having, perhaps, different sized punch dies (i.e., to produce different sized holes), different shaped punch dies (i.e., to produce different shaped holes), different spacing (or, "pitch") between adjacent dies (i.e., to produce different spacing between adjacent holes), and/or a different distance between the punch dies and a paper stop (i.e., to produce holes at a different distance from the paper edge) than the first die assembly.

Accordingly, an object of the present invention is to punch a plurality of adjacent holes in paper.

Another object of the present invention is to punch a plurality of adjacent holes in paper with a punch that enables replacement of a die of the punch without disassembly of the punch. Still another object of the present invention is to punch a plurality of adjacent holes in paper with a punch that enables replacement of a die of the punch without disassembly of the die.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables replacement of a first die of the punch, capable of producing a hole of a first size, with a second die of the punch capable of producing a hole of a second size.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables replacement of a first die of the punch, capable of producing a hole of a first shape, with a second die of the punch capable of producing a hole of a second shape.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables replacement of a first die of the punch, capable of producing holes at a first spacing between holes, with a second die of the punch capable of producing holes at a second spacing between holes.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables replacement of a first die of the punch, capable of producing holes at a first distance from the edge of the paper, with a second die of the punch capable of producing holes at a second distance from the edge of the paper.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that detects the presence or absence of a die within the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is controlled by the presence or absence of a die within the punch. Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables rapid replacement of a die of the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables replacement of a die of the punch by an individual who is substantially unskilled with respect to the inner workings of the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that requires minimal table-top space.

Still another object of the present invention is to punch a plurality of holes in paper with a punch that enables other devices or items to reside on top of the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch which receives paper in a horizontal direction.

Still another object of the present invention is to punch a plurality of holes in paper with a punch having dies which translate in a vertical direction.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is controlled automatically.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is triggerable by the presence of paper within the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is triggerable by the proper positioning of paper within the punch. Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is triggerable by the proper longitudinal-direction positioning of paper within the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is triggerable by the proper lateral-direction positioning of paper within the punch.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is controlled manually.

Still another object of the present invention is to punch a plurality of holes in paper with a punch whose operation is triggerable by actuation of a foot pedal.

Still another object of the present invention is to punch a plurality of holes in paper with a punch which detects completion of a punch cycle.

Other objects, features, and advantages of the present invention will become apparent upon reading and understanding the present specification when taken in conjunction with the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a punch in accordance with a preferred embodiment of the present invention.

FIG. 2 is a back elevational view of the die assembly of FIG. 1.

FIG. 3 is a left side elevational view of the die assembly of FIG. 1.

FIG. 4 is a right side elevational view of the die assembly of FIG. 1. FIG. 5 is a top plan view of the die assembly of FIG. 1.

FIG. 6 is a top plan, cut-away view of the die assembly of FIG. 1.

FIG. 7 is a sectional view of the die assembly of FIG. 5 taken along lines 7-7.

FIG. 8 is a front elevational view of a punch die of the die assembly of FIG. 1.

FIG. 9 is a top plan, cut-away view of the punch of FIG. 1.

FIG. 10 is a front elevational view of the punch of FIG. 1.

FIG. 11 is a sectional view of the punch of FIG. 9 taken along lines 11-11.

FIG. 12 is a top plan, cut-away view of the left front area of the punch of FIG. 1.

FIG. 13 is a partial, right side elevational view of the punch of FIG. 1 with the end plate of the die assembly removed to enable viewing inside the punch.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, in which like numerals represent like components throughout the several views, FIG. 1 displays a punch 30 in accordance with the preferred embodiment of the present invention. The punch 30 has a front 32, a back 34, a right side 36, and a left side 38 and comprises a die assembly 40, a platform 42, and a cover 44 mounted atop a base tray 46. The right and left sides 36,38 of the punch 30 define a lateral direction therebetween. A cavity 48, defined within the punch 30, extends in the lateral direction substantially between the right and left sides 36,38 of the punch 30 and slidably receives the die assembly 40 which is inserted and removed, in the lateral direction as indicated by arrow 50, through an opening 52 defined by a right side panel 54 of the cover 44. A pair of screws 56, biased relative to an end plate 58 of the die assembly 40 by springs 60, extend through holes defined by the end plate 58 and enable securement of the die assembly 40 to the remainder of the punch 30 with end plate 58 substantially occupying opening 52. A die assembly sensor 61 has an actuator 62 and a switch (not visible). The actuator 62 protrudes from the right side 36 of the punch 30 proximate to the opening 52 for contact with the end plate 58 of the die assembly 40. When the die assembly 40 is correctly positioned for operation within cavity 48 and secured by screws 56, actuator 62 is depressed, closing the switch and enabling the punch 30 to operate. Alternatively, when the die assembly 40 is withdrawn from cavity 48 by a distance which enables actuator 62 to extend fully, the switch opens and disables the punch 30 from operation, thereby avoiding potential damage to the die assembly 40 and other components of the punch 30.

The platform 42 extends in the lateral direction between the right and left sides 36, 38 of the punch 30 and extends in a longitudinal direction, at the front 32 of the punch 30, from a location beneath a front panel 64 of the cover 44 to a location distant from the front panel 64. The platform 42 has a top surface 66 which, principally, with the front panel 64 of the cover 44, support base 68a, and end plate 58, defines a channel 70 through which a paper, or stack of papers, are guided into the die assembly 40 for punching. A portion of the front panel 64, proximate to the left side 38 of the punch 30, extends downward to an elevation slightly above the top surface 66 of the platform 42 to define a stop 72 against which a paper, or stack of papers, is positioned for punching as described below.

The die assembly 40, as illustrated in FIGS. 2-7, has a first end 80, at which end plate 58 is secured to the remainder of the die assembly 40, and a second end 82, distant from the first end 80, which define a lateral axis 84 for the die assembly 40. The end plate 58 defines a slot 86 which extends in a longitudinal direction defined by a longitudinal axis 88 extending between a front 90 and a back 92 of the die assembly 40. The slot 86 aligns with channel 70 when the die assembly 40 is positioned within cavity 48. The die assembly 40 also has an upper portion 74 which translates upward and downward relative to a lower portion 76 of the die assembly 40 as described below.

The die assembly 40, according to the preferred embodiment, comprises a punch extraction plate 94 having a first end 96 and a second end 98 proximate to ends 80, 82, respectively, of the die assembly 40. The punch extraction plate 94 extends for a substantial distance (i.e., length) in the direction of the die assembly's lateral axis 84 and for a lesser distance (i.e., width) in a longitudinal direction of the die assembly's longitudinal axis 88. The punch extraction plate 94 has an upper surface 100 and a lower surface 102 and defines a plurality of holes 104 which extend between the upper and lower surfaces 100, 102. Individual holes 104 of the plurality of holes 104 are, preferably, positioned adjacent to one another in the direction of the die assembly's lateral axis 84. Each hole 104 of the plurality of holes 104 has a diameter, "A", and adjacent holes 104 define a distance, "B", between their centers (also referred to herein as "pitch"). Additionally, the punch extraction plate 94 has a front face 106 and a back face 108 which extend between the upper and lower surfaces 100, 102 and between plate ends 96, 98.

The die assembly 40 further comprises a spring retention plate 110, having an upper surface 1 12 and a lower surface 114, which resides adjacent to and beneath the punch extraction plate 94 with the upper surface 112 contacting the lower surface 102 of the punch extraction plate 94. The spring retention plate 1 10 extends primarily in the lateral direction defined by the die assembly's lateral axis 84 and has a first end 116 and a second end 1 18 located, respectively, near the first and second ends 80, 82 of the die assembly 40. Preferably, the spring retention plate 1 10 extends laterally to define a length which is greater than the length of the punch extraction plate 94 and longitudinally, in the longitudinal direction defined by the die assembly's longitudinal axis 88, to define a width which is less than the width of the punch extraction plate 94. Due, in part, to the difference between the widths of the spring retention plate 110 and the punch extraction plate 94, portions 120, 122 of the lower surface 102 of the punch extraction plate 94 are exposed forward and rearward, respectively, of the spring retention plate 110. Similar to the punch extraction plate 94, the spring retention plate 1 10 has a front face 124 and a back face 126 which extend between upper and lower surfaces 112, 114.

The spring retention plate 110 defines a pair of spacer receiving holes 128 which extend between the upper and lower surfaces 1 12, 114. Spacer receiving hole 128a is located at a site between the first end 96 of the punch extraction plate 94 and the first end 1 16 of the spring retention plate UO. Spacer receiving hole 128b is located at a site between the second end 98 of the punch extraction plate 94 and the second end 118 of the spring retention plate 1 10. The spring retention plate 110 also defines a plurality of holes 130 which extend between the upper and lower surfaces 1 12, 1 14 and which are positioned adjacent to one another in the direction of the die assembly's lateral axis 84. Preferably, each hole 130 of the plurality of holes 130 has a diameter, "C", which is identical to diameter "A" of the holes 104 of the plurality of holes 104 of the punch extraction plate 94, and adjacent holes 130 define a pitch, "D", which is identical to the pitch "B" of the holes 104 of the plurality of holes 104 of the punch extraction plate 94, thereby causing holes 130 of the spring retention plate 110 to vertically align with the holes 104 of the punch extraction plate 94. Together, the spring retention plate 110 and the punch extraction plate 94 comprise the upper portion 74 of the die assembly 40.

The die assembly 40 additionally includes a punch guide block 140 which resides beneath the spring retention plate 1 10 and which has an upper surface 142 and a lower surface 144 extending between a first end 146 and a second end 148 in the direction of the die assembly's lateral axis 84. Preferably, the punch guide block 140 has a length (i.e., in the lateral direction) which is identical to the length of the punch extraction plate 94. The punch guide block 140 is oriented with its first end 146 aligned with the first end end 1 18 of the spring retention plate 1 10. The punch guide block 140 defines a pair of spring receipt holes 150 which extend between the upper and lower surfaces 142, 144. The spring receipt holes 150 are located near the ends 146, 148 of the punch guide block 140 in vertical alignment with the spacer receiving holes 128 of the spring retention plate 110. Spacers 152, having first ends 154 and second ends 156, extend between the spring retention plate 1 10 and the punch guide block 140. The first ends 154 of the spacers 152 extend into the spacer receiving holes 128 of the spring retention plate 1 10 and the second ends 156 of the spacers 152 extend into the spring receipt holes 150 to abut a primary guide plate 158 which is secured to the lower surface 144 of the punch guide block 140 by a plurality of screws 160. Springs 162, coiled about respective spacers 152, have first ends 164 which abut the lower surface 1 14 of the spring retention plate 1 10 and second ends 166 which abut the primary guide plate 158 within the spring receipt holes 150 of the punch guide block 140. Washers 168 are secured, by screws 170, to the first ends 154 of the spacers 162 between the heads of the screws 170 and the upper surface 1 12 of the spring retention plate 1 10.

The punch guide block 140, substantially similar to the spring retention plate 1 10, defines a plurality of holes 172 which extend between the upper and lower surfaces 142, 144. The holes 172 are adjacently positioned in a direction defined by the lateral axis 84 of the die assembly 40 and along a line extending between the spring receipt holes 150. Holes 172 have a diameter, "E", and adjacent holes 172 define a pitch, "F", which, preferably, measure identical to the diameter, "A", and pitch, "B", of thefloles 104 of the punch extraction plate 94, thereby causing the holes 172 to vertically align with holes 104 of the punch extraction plate 94 and with holes 130 of the spring retention plate 1 10.

The primary guide plate 158 resides beneath the punch guide block 140 and has upper and lower surfaces 180, 182 which extend between first and second ends 184, 186 in the direction of the lateral axis 84 of the die assembly 40. The primary guide plate 158 is oriented with the upper surface 180 in contact with and adjacent the lower surface 144 of the punch guide block 140. The first end 184 of the primary guide plate 158 is positioned closer the first end 80 of the die assembly 40 than the first end 146 of the punch guide block 140, while the second end 186 of the primary guide plate 158 is positioned closer the second end 82 of the die assembly 40 than the second end 148 of the punch guide block 140. The primary guide plate 158 also has front and back faces 188, 190 which extend between the upper and lower surfaces 180, 182 and ends 184, 186. The front face 188 includes a first portion 192 which is substantially vertical and a second portion 194 which slopes downward and rearward to connect the first portion 192 of the front face 188 with the lower surface 182. The downward and rearward slope of the second portion 194 aids in guiding a paper, or stack of papers, into a punching slot 230 which is described below. The primary guide plate 158 defines a plurality of holes 196, extending between the upper and lower surfaces 180, 182, which are adjacently located in a direction defined by the lateral axis 84 of the die assembly 40. Each hole 196 of the plurality of holes 196 has a diameter, "G", which, preferably, has a measure equal to the measure of the diameter, "A", of the holes 104 of the punch extraction plate 94. Adjacent holes 196 define a pitch, "H", which, preferably, has a measure equal to the measure of the pitch, "B", of adjacent holes 104 of the punch extraction plate 94, thereby causing the holes 196 to align with holes 172 of the punch guide block 140, with holes 130 of the spring retention plate 110, and with holes 104 of the punch extraction plate 94.

The die assembly 40 further comprises a lower die plate 200 having an upper surface 202 and a lower surface 204 which extend between first and second ends 206, 208 primarily in the direction defined by the lateral axis 84 of the die assembly 40. The first end 202 engages and is secured to end plate 58 at the die assembly's first end 80 by screws 210. The lower die plate 200 defines a front shoulder 212 and a back shoulder 214 which each extend between ends 206, 208 and interface with die support weldments 520, 522 as described below when the die assembly 40 resides within cavity 48 of the punch 30. The lower die plate 200 also defines a plurality of holes 216 adjacently positioned in the direction defined by the lateral axis 84 of the die assembly 40. Each hole 216 of the plurality of holes 216 has a diameter, "I", and adjacent holes 216 of the plurality of holes 216 have a pitch, "J", which are substantially the same as the diameters and pitches of the holes 196 of the primary guide plate 158, substantially the same as the diameters and pitches of the holes 172 of the punch guide block 140, substantially the same as the diameters and pitches of the holes 130 of the spring retention plate 1 10, and substantially the same as the diameters and pitches of the holes 104 of the punch extraction plate 94. As a result, the holes 216 align axially with the holes 196 of the primary guide plate 158, with the holes 172 of the punch guide block 140, with the holes 130 of the spring retention plate 1 10, and with the holes 104 of the punch extraction plate 94.

The lower die plate 200 is separated from the primary guide plate 158 by a slot/spacer plate 220 which extends partially from a first end 222, positioned near first end 80 of the die assembly 40, to a second end 224. The slot/spacer plate 220 has an upper surface 226 which extends between ends 222, 224 and which resides adjacent to and contacts the lower surface 182 of the primary guide plate 158. The slot/spacer plate 220 has a lower surface 228, extending between ends 222, 224, which contacts and is adjacent to the upper surface 202 of the lower die plate 200. The lower die plate 200, the slot/spacer plate 220, and the primary guide plate 158 define a slot 230 which receives a paper, or stack of papers, for punching. Note that the lower die plate 200, the slot/spacer plate 220, the primary guide plate 158, and the punch guide block 140 are secured together by screws 160 which extend through respective holes defined by the plates 200, 220, 158 and block 140.

The die assembly 40 also includes a y-axis switch actuator 240 (also referred to herein as a "paper sensor") pivotally mounted to the primary guide plate 158 and the lower die plate 200 proximate to the second end 224 of the slot/spacer plate 220. The y- axis switch actuator 240 has a first portion 242, residing between the primary guide plate 158 and the lower die plate 200, which defines a hole 244 through which screw 246 passes. Note that screw 246 also passes through holes 248, 250 which are, respectively, defined by primary guide plate 158 and the lower die plate 200. The first portion 242 of the y-axis switch actuator 240 has a laterally-extending face 252, between upper and lower surfaces 254, 256, which is rearward of slot 230 (and which partially defines slot 230) and engageable by paper received within the slot 230 during operation of the punch 30. The first portion 242 also has a longitudinal surface 258 which extends rearward from face 252 toward a second portion 260 of the y-axis switch actuator 240. Surface 258 faces the second end 224 of the slot/spacer plate 220 and, in conjunction with the second end 224 of the slot/spacer plate 220, limits counterclockwise rotation (as viewed in top plan view) of the y-axis switch actuator 240 during operation. The second portion 260 of the y-axis switch actuator 240 extends rearward from the first portion 242 and from the die assembly 40. The second portion 260 has a lateral surface 262 which extends from the first portion 242 toward the first end 80 of the die assembly 40 at a location adjacent to and rearward of the second end 224 of the slot/spacer plate 220. Surface 262, acting in concert with the second end 224 of the slot/spacer plate 220, limits clockwise rotation (as viewed in top plan view) of the y-axis switch actuator 240 during operation. The second portion 260 also has an arcuate surface 264 which extends toward the second end 82 of the die assembly 40 to actuate switch lever 506 as described below.

The die assembly 40 further comprises an x-axis switch actuator 270 (also referred to herein as a "paper sensor") having a first portion 272, a second portion 274, and an intermediate portion 276 connecting the first and second portions 272, 274. The first and intermediate portions 272, 276 of the x-axis switch actuator 270 reside between the primary guide plate 158 and the lower die plate 200 proximate to the second end 82 of the die assembly 40. The intermediate portion 276 defines a plurality of slots 278, extending primarily in the direction of the die assembly's lateral axis 84 and through which screws 280 pass, to slidably mount the x-axis switch actuator 270 relative to the primary guide plate 158 and the lower die plate 200. The first portion 272 of the x-axis switch actuator 276 extends forward from the intermediate portion 276 adjacent to the die assembly's second end 82 and avoiding any presence with the gap between holes 196, 216. The first portion 272 has a longitudinally-extending surface 281 adjacent to slot 230 which extends rearward from the front of die assembly 40. Surface 281 is engageable by a paper, or stack of papers, received within slot 230 to partially trigger operation of the punch 30 as described below. The second portion 274 of the x-axis switch actuator 270 extends rearward from the intermediate portion 276 and has a longitudinally-extending surface 282 which interacts with switch lever 504 as described below. Note that the punch guide block 140, the primary guide plate 158, the lower die plate 200, the slot/spacer plate 220, the y-axis switch actuator 240, and the x-axis switch actuator 270 define the lower portion 76 of the die assembly 40.

In accordance with the preferred embodiment of the present invention, the die assembly 40 additionally includes a plurality of punch dies 300 slidably held in adjacent positions. As seen in FIG. 8, each punch die 300 has a first end 302 and a sharpened, second end 304 which define a central axis 306 extending therebetween. A head portion 308 extends from the first end 302 of each punch die 300 toward the second end 304 of each punch die 300 and has a surface 310 which extends radially about central axis 306. A shank portion 312 extends between the head portion 308 and the second end 304 of each punch die 300 and has a surface 314 which extends radially about central axis 306. Surface 310 of the head portion 308 and surface 314 of the shank portion 312 define an annular shoulder surface 316 therebetween. As seen in FIGS. 2 and 7, the shank portions 312 of the punch dies 300 slidably extend through adjacent, vertically-aligned holes 216, 196, 172, 130, 104 of the lower die plate 200 (when the punch 30 operates), the primary guide plate 158, the punch guide block 140, the spring retention plate 110, and the punch extraction plate 94, respectively. The first ends 302 and head portions 308 of the punch dies 300 extend above the punch extraction plate 94, while the shoulder surfaces 316 contact the upper surface 100 of the punch extraction plate 94. Note that the punch dies 300 are not secured to the punch extraction plate 94, the spring retention plate 1 10, the punch guide block 140, the primary guide plate 158, or the lower die plate 200 so as to enable relative sliding, or translatory, motion between the punch dies 300 and the spring retention plate 1 10, the punch guide block 140, the primary guide plate 158, and the lower die plate 200 during operation of the punch 30.

Referring now to FIGS. 9-13, the punch 30 further comprises a drive assembly 350 having a drive train 352 and a motor 354 coupled to the drive train 352 by sprockets 356, 358 and chain 360. The drive assembly 350 is mounted to base tray 46 and is made inaccessible to a user during use (i.e., to prevent possible injury to the user) by cover 44 (which is cut-away in FIG. 9) which secures to the base tray 46 to substantially enclose the drive assembly 350. An on/off switch 362, a trigger mechanism select switch 364, and a foot pedal connector 366 mount to the base tray 46 at the back 34 of the punch 30. The on/off switch 362 connects to a 120-volt electrical power source via a conventional electric cord and plug (not shown) and to logic circuitry 361 which controls operation of the motor 354, as described below, when the on/off switch 362 is in the "on" position. The trigger mechanism select switch 364 also connects to the logic circuitry 361 and enables a user to select whether a single punching operation of the punch 30 is to be triggered by receipt of paper correctly positioned within slot 230 (i.e., against the x-axis switch actuator 270 and the y-axis switch actuator 240, and causing sufficient translation of the x-axis switch actuator 270 and sufficient rotation of the y-axis switch actuator 240) or by depression of a foot pedal (not shown) which connects to the foot pedal connector 366. A cover switch 368, mounted to the base tray 46 at a site adjacent the right side 36 of the punch 30, connects to the logic circuitry 361 and interacts with the cover 44 to detect the presence or absence of the cover 44. A switch lever 370, extending from the cover switch 368, is depressed if the cover 44 is present, thereby closing the cover switch 368 and enabling the punch 30 to be operated by the selected trigger mechanism (i.e., either the correct positioning of paper within slot 230 or depression of the foot pedal). If the cover 44 is absent, switch lever 370 is not depressed and cover switch 368 remains open, thereby preventing the occurrence of any punching operation.

The drive train 352 comprises a first shaft 380 which extends, in the lateral direction 50 of the punch 30, between a right side support frame 382 which is mounted to the base tray 46 at the right side 36 of the punch 30 and a left side support frame 384 which is mounted to the base tray 46 at the left side 38 of the punch 30. The right and left side support frames 382, 384 extend vertically from the base tray 46 and extend, primarily, in the longitudinal direction of the punch 30. The first shaft 380 is rotatively mounted to the right and left side support frames 382, 384 by bearings 386, 388, respectively, which orient the first shaft 380 perpendicular to the frames 382, 384. Sprocket 358 is fixedly secured to the first shaft 380 at a position adjacent to the right side support frame 382 and is in planar alignment with sprocket 356 which is fixedly secured to a shaft 390 which extends from the motor 354 in the lateral direction 50 of the punch 30. The first shaft 380 also extends perpendicularly through an intermediate support frame 390 at a location approximately midway between the right and left side support frames 382, 384. The intermediate support frame 390 is secured to the base tray 46 and extends vertically (and longitudinally) to rotatively receive the first shaft 380 within a bearing 392.

The drive train 352 further includes first and second push rods 394a,b which are mounted about the first shaft 380. The first push rod 394a is positioned along first shaft

380 near sprocket 358 between sprocket 358 and the intermediate support frame 390. The second push rod 394b is positioned along first shaft 380 near the left side support frame

384 at a location between the left side support frame 384 and the intermediate support frame 390. Each push rod 394 defines a circular-shaped opening 396 and receives a crank lobe 398 within the opening 396. Each crank lobe 398 includes a ball bearing 397 which fits around first shaft 380 and rotatively interfaces a respective crank lobe 398 and, hence, a respective push rod 394 to the first shaft 380. Each push rod 394 has a connection portion 400 which extends, when the drive train 352 is not in operation, in a longitudinal direction toward the front 32 of the punch 30 and in a plane defined by the push rod 394 perpendicular to the direction of the first shaft 380. Each connection portion 400 defines a hole 402 which extends between sides 404, 406 of a respective push rod 394.

According to the preferred embodiment, the drive train 352 also comprises a second shaft 408 which extends laterally between and is held stationary by the right and left side support frames 382, 384 at a location forward of (and, elevated above) the first shaft 380. Rotatively coupled to the second shaft 408, by bearings 410a and 410b, are first and second compression levers 412a and 412b. Each compression lever 412 has a shaft interface portion 414 which extends around the second shaft 408 and which defines an opening 416 that receives a bearing 410. Each compression lever 412 also has a first arm 418 and a second arm 420 which extend in a common plane defined by the shaft interface portion 414 and the arms 418, 420. The arms 418, 420, preferably, define an angle, α, therebetween and further define holes 422, 424, extending between sides 426, 428 of a compression lever 412, at locations near the ends of the arms 418, 420, respectively. When the punch 30 is not operating, the first arm 418 of each compression lever 412 extends generally downward from the shaft interface portion 414 and slightly forward of a vertical axis extending through the center of opening 416. The second arm 420 of each compression lever 412, while the punch 30 is idle, extends generally forward from the shaft interface portion 414 and slightly above a horizontal axis extending through the center of opening 416. The first compression lever 412a is positioned about the second shaft 408 of the drive train 352 so that the plane of the first compression lever 412a is positioned adjacent to the plane of push rod 394a and between the plane of push rod 394a and the right side support frame 382. With such relative positioning of the first compression lever 412a and the push rod 394a, a portion of the first arm 418a of the first compression lever 412a is adjacent to a part of the connection portion 400a of the push rod 394a and hole 422a of compression lever 412a is aligned with hole 402a of push rod 394a. Shoulder bolt 430a extends through holes 402a, 422a and is received by the female threads of compression lever 412a to pivotally connect push rod 394a and compression lever 412a together. The second compression lever 412b is positioned about the second shaft 408 of the drive train 352 so that the plane of the second compression lever 412b is positioned adjacent to the plane of push rod 394b with the plane of the push rod 394b being between the plane of the second compression lever 412b and the left side support frame 384. Substantially similar to the first compression lever 412a and first push rod 394a, a portion of the first arm 418b of the second compression lever 412b is adjacent to a part of the connection portion 400b of push rod 394b and hole 422b of compression lever 412b is aligned with hole 402b of push rod 394b. A shoulder bolt 430b, extending through holes 402b, 422b and engaging the female threads of compression lever 412b, pivotally couples push rod 394b to compression lever 412b.

The drive train 352 additionally includes a compression bar 440 which extends, in the lateral direction of the punch 30, between the right and left side support frames 382, 384. The compression bar 440 has a first end 442 slidably received between bearing blocks 444a,b and a second end 446 slidably received between bearing blocks 448a,b. End bearing shims 450, 452 are positioned between the first and second ends 442, 446 and the right and left side support frames 382, 384. The bearing blocks 444, 446, end bearing shims 450, 452, and right and left side support frames 382, 384 substantially limit movement of the compression bar 440 to the vertical direction. The compression bar 440 has a top surface 454 to which cam followers 456a,b are rigidly attached beneath strike plates 458a,b. The strike plates 458a,b extend laterally above the top surface 454 of the compression bar 440 and are spaced above the cam followers 456a,b by spacers 460a,b, 461a,b. The strike plates 458a,b and spacers 460a,b are secured to the compression bar 440 by bolts 462a,b, 463a,b which extend downward within the spacers 460a,b, 461a,b and into tapped holes (not visible) defined by the compression bar 440. The ends of the second arms 420a,b of the compression levers 412a,b extend beneath the strike plates 458a,b and adjacent to the cam followers 456a,b, thereby aligning holes 464a,b of the cam followers 456a,b with holes 424a,b of the second arms 420a,b. Bolts 466a,b, extending through holes 464a,b and holes 424a,b, and nuts 468a,b pivotally secure the second arms 420a,b (and, hence, the compression levers 412a,b) to the cam followers 456a,b (and, hence, to the compression bar 440).

The compression bar 440 has a front surface 470 and a back surface 472 which extend between the first and second ends 442, 446 and the top and bottom surfaces 454, 474 of the compression bar 440. Extraction brackets 476 are rigidly mounted to the front and back surfaces 470, 472 of the compression bar 440 by bolts 478. The extraction brackets 476 extend substantially between the ends 442, 446 of the compression bar 440 in the lateral direction of the punch 30 with each extraction bracket 476 having a first portion 480 adjacent to either the front or back surface 470, 472 of the compression bar 440. The first portion 480 of each extraction bracket 476 extends downward to an elevation lower than that of the compression bar's bottom surface 474. A second portion 482 of each extraction bracket 476 extends from the respective first portions 480 for a small distance beneath the bottom surface 474 to define shoulders 484 and to define, in conjunction with the bottom surface 474 of the compression bar 440 and the first portions 480, a laterally-extending cavity 486 beneath the compression bar 440. The second portions 482 of the extraction brackets 476 define a gap 488 therebetween which receive dies 300 as described below. The punch 30 additionally comprises (as illustrated in FIG. 12 where portions of the die assembly 40 and drive train 352 have removed to expose various elements) an x- axis paper switch 500 and a y-axis paper switch 502 mounted to the base tray 46 near the left side support frame 384. The x-axis paper switch 500 has a switch lever 504, extending forward from the switch 500, which is contactable and deflectable by the longitudinally-extending surface 282 of the second portion 274 of the x-axis switch actuator 270 when the die assembly 40 is present within cavity 48 of the punch 30 and when a paper is correctly positioned within slot 230 pressing against the longitudinally- extending surface 281 of the first portion 272 of the x-axis switch actuator 270 (i.e., thereby fully sliding the x-axis switch actuator toward the left side support frame 384). Similarly, a switch lever 506 extends from the y-axis paper switch 502 and is contactable and deflectable by the arcuate surface 264 of the second portion 260 of the y-axis switch actuator 240 when a paper is correctly positioned within slot 230 of the die assembly 40 pressing against the laterally-extending face 252 of the y-axis switch actuator 240. The x- axis and y-axis paper switches 500, 502 connect to the logic circuitry 361 of the punch 30 and trigger punching when switch levers 504, 506, respectively, are deflected sufficiently to close the switches 500, 502 and when the trigger mechanism select switch 364 is in a position which selects control of punching operations by the paper switches 500, 502.

In accordance with a preferred method of the present invention, a user determines the diameter and pitch of the holes which must be punched in paper in order to bind the paper with a spiral coil. Based upon the diameter and pitch determined, the user selects an appropriate die assembly 40 having the desired die diameter and pitch. With the punch's on/off switch 362 in the "off position, the user determines whether or not a die assembly 40 is present within the punch 30. If the user determines that a die assembly 40 is present, the user loosens screws 56 and pulls on end plate 58 in a lateral direction 50 (i.e., in the horizontal direction) away from the punch 30 to slide the lower die plate 200 of the die assembly 40 relative to the front and back die support weldments 520, 522, thereby removing the die assembly 40 from cavity 48. If the user determines that a die assembly 40 is not present, the user inserts the second end 82 of the selected die assembly 40 through opening 52 of the right side panel 54 of the cover 44. The user then positions the front and back shoulders 212, 214 of the lower die plate 200 at the second end 82 beneath the front and back die support weldments 520, 522, respectively, and positions forward and rearward portions of the lower surface 102 of the punch extraction plate 94 atop the second portions 482a,b of the extraction brackets 476 (i.e., thereby positioning the punch extraction plate 94 and the head portions 308 of the dies 300 between the first portions 480a, b of the extraction brackets 476 and within the cavity 48 beneath the compression bar 440). Once the die assembly 40 is so aligned, the user applies a pushing force to end plate 58 toward the left side 38 of the punch 30 to slide the die assembly into cavity 48 and continues application of the force until the end plate 58 resides within opening 52 of cover 44. Sliding of the die assembly 40 into cavity 48 depresses actuator 62 of the die assembly sensor 61 , causing a signal to be sent to the logic circuitry 361 of the punch 30 which notes that a die assembly 40 is present in the punch 30 (i.e., thereby enabling operation of the punch 30). When the die assembly 40 is correctly positioned within cavity 48, the top surfaces of the head portions 308 of the dies 300 reside immediately beneath the bottom surface 474 of the compression bar 440 and the spring retention plate 1 10 occupies the gap 488 between the second portions 482 of the extraction brackets 476 with the front and back faces 124, 126 of the spring retention plate 1 10 abutting the second portions 482 of the extraction brackets 476 (i.e., thereby positioning the upper portion 74 of the die assembly 40 between the extraction brackets 476 and beneath the compression bar 440 to enable application of downward and upward vertical forces to the upper portion 74 of the die assembly 40 during a punch operation cycle). Additionally, the front and back shoulders 212, 214 of the lower die plate 200 reside adjacent and beneath die support weldments 520, 522 to prevent vertical movement of the lower portion 76 of the die assembly 40 during punch operation. The user then tightens screws 56 to secure the die assembly 40 in place.

With the die assembly 40 secured in position, the user decides whether to trigger a punching operation by manually depressing a foot pedal or by appropriately inserting the paper into channel 70 and slot 230 to sufficiently deflect switch levers 504, 506 of the x- axis and y-axis paper switches 500, 502 to close the switches 500, 502. If the user decides to utilize a foot pedal, the user, at the back 34 of the punch 30, positions the trigger mechanism select switch 364 to the "foot pedal" position and attaches the foot pedal to the foot pedal connector 366. If the user decides to appropriately insert the paper, the user positions the trigger mechanism select switch 364 to the "automatic" position. The punch 30 is now ready to punch paper.

If the user has selected "foot pedal" triggering, the user rests the paper atop platform 42, feed the paper into channel 70 and slot 230 toward the back of the punch 30 until rearward motion of the paper is thwarted by the slot spacer plate 220 and then slides the paper toward the left side 38 of the punch 30 until the paper abuts stop 72. The user then pushes the foot pedal to signal the logic circuitry 361 of the punch that the user is ready to punch paper, thereby triggering operation the punch 30. If the user has selected "automatic" triggering, the user similarly positions the paper atop the platform 42 and slides the end of the paper rearward into channel 70 and slot 230 until the paper sufficiently presses against the laterally-extending face 252 of the y-axis switch actuator 240 to cause the arcuate surface 264 of the second portion 260 of the y-axis switch actuator 240 to substantially deflect switch lever 506 of the y-axis paper switch 502 and close the switch 502. Once the y-axis paper switch 502 is closed, the user slides the paper toward the left side 38 of the punch 30 until the side of the paper abuts stop 72 and sufficiently presses against the longitudinally-extending surface 281 of the first portion 272 of the x-axis switch actuator 270 to cause longitudinally-extending surface 282 to substantially deflect switch lever 504 of the x-axis paper switch 500 and close the switch 500. The closing of the x-axis paper switch 500, after the closing of the y-axis. paper switch 502, signals the logic circuitry 361 of the punch 30 that paper is present with slot 230 and that the paper is correctly positioned for punching, thereby triggering operation of the punch 30.

Once the punch 30 is triggered, the motor 354 starts running and the sprockets 356, 358 and chain 360 transfer the rotary motion of the motor shaft 390 to the first shaft 380. Rotation of the first shaft 380 causes the crank lobes 398 and, hence, the push rods 394 (and their connection portions 400) to rotate. The movement of the connection portions 400 of the push rods 394 is imparted to the first arms 418 of compression levers 412 through shoulder bolts 430, thereby causing the compression levers 412 to rotate about the second shaft 408. Such rotation of the compression levers 412 causes the second arms 420 of the compression levers 412 to move in a generally downward vertical direction. Since the second arms 420 are connected to the compression bar 440 via the cam followers 456 and bolts 466, the compression bar 440 moves in a downward vertical direction between bearing blocks 444, 448 in response to the generally downward movement of the second arms 420 of the compression levers 412. The downward vertical movement of the compression bar 440 applies a downward-acting vertical force to the top surfaces of the head portions 308 of the punch dies 300 slidably held in the die assembly 40. Application of the downward-acting vertical force causes the individual punch dies 300 to slide, or translate, downward in unison causing the annular shoulder surfaces 316 to transfer a portion of the vertical force to the punch extraction plate 94 and the spring retention plate 110, thereby causing the punch extraction plate 94 and the spring retention plate 110 to move downward sliding relative to spacers 152 and compressing springs 162. The shank portions 312 of the punch dies 300 translate downward relative to the punch guide block 140 and the primary guide plate 158 through vertically-aligned holes 172, 196, respectively, and the second ends 304 of the punch dies 300 enter slot 230 to encounter the paper positioned therein. The second ends 304 of the punch dies 300 continue to move downward as the second arms 420 of the compression levers 412 continue to move in a generally downward vertical direction. While moving downward, the second ends 304 of the punch dies 300 (and part of the shank portions 312 near the second ends 304 of the dies 300) pass through the paper and through holes 104 of the lower die plate 200, thereby punching holes in the paper. The paper removed by the punch dies 300 falls into a collector drawer 524 positioned below cavity 48.

After the holes are punched in the paper (i.e., signifying completion of the first half of a punch cycle), the motor 354 continues to run and continues to impart rotation to the first shaft 380. The continued rotation of first shaft 380 causes the crank lobes 398 and, hence, the push rods 394 (and their connection portions 400) to continue their rotation. However, the geometrical relationship of the push rods 394 and the compression levers 412 now causes the second arms 420 of the compression levers 412 to move in a generally upward vertical direction, thereby applying an upward-acting vertical force, through the cam followers 456 and bolts 466, to the compression bar 440. In response, the compression bar 440 slides upward between bearing blocks 444, 448 and exerts an upward-acting vertical force through extraction brackets 476 on the punch extraction plate 94, thereby pulling the punch dies 300 out of the holes 104 of the lower die plate 200 and withdrawing the punch dies 300 from slot 230. Continued rotation of the motor shaft 390 causes the punch dies 300 to continue their upward translation relative to the holes 196 of the primary guide plate 158 and relative to the holes 172 of the punch guide block 140. As the compression bar 440 continues its upward vertical translation, springs 162 apply an upward vertical force on the spring retention plate 110 which is imparted to the annular shoulder surfaces 316 of the punch dies 300, thereby pressing the top surfaces of the head portions 308 of the punch dies 300 against the compression bar 440. Eventually, the compression bar 440 travels upward sufficiently to compress an actuator 526 of a switch 528, attached to the intermediate support frame 390, causing the switch 528 to open (i.e., thereby informing the logic circuitry 361 that the compression bar 440 has reached its maximum upward travel and that the punch cycle is complete). Upon detection of the open switch 528 (which is connected to the logic circuitry 361), the logic circuitry 361 cuts the power supplied to the motor 354 to stop the upward vertical movement of the punch dies 300. The user then removes the punched paper from the punch 30.

Whereas this invention has been described in detail with particular reference to its most preferred embodiments, it is understood that variations and modifications can be effected within the spirit and scope of the invention, as described herein before and as defined in the appended claims.

Claims

CLAIMSI claim:

1. An apparatus for creating a plurality of holes in paper, said apparatus comprising:

a drive assembly including a motor and a drive train connected to said motor;

an enclosure substantially enclosing said drive assembly; and,

a die assembly including a die retaining structure and a plurality of punch dies;

wherein said die assembly is insertable into a position enabling engagement of said die assembly and said drive train absent removal of said enclosure;

wherein said die assembly is removable from a position enabling engagement of said die assembly and said drive train absent removal of said enclosure.

2. The apparatus of Claim 1 , wherein

said die assembly is a first die assembly, and

said apparatus further comprises a second die assembly including a die retaining structure and a plurality of punch dies,

wherein said second die assembly is insertable into a position enabling engagement of said second die assembly and said drive train absent removal of said enclosure, wherein said second die assembly is removable from a position enabling engagement of said second die assembly and said drive train absent removal of said enclosure, and

wherein said first die assembly is replaceable by said second die assembly.

3. The apparatus of Claim 2, wherein

said punch dies of said plurality of punch dies of said first die assembly are of a first size, and

said punch dies of said plurality of punch dies of said second die assembly are of a second size, said first size being different than said second size.

4. The apparatus of Claim 2, wherein

said punch dies of said plurality of punch dies of said first die assembly define a first spacing between adjacent punch dies, and

said punch dies of said plurality of punch dies of said second die assembly define a second spacing between adjacent punch dies, said first spacing being different than said second spacing.

5. The apparatus of Claim 1 , wherein

said die assembly has a first end and a second end,

said die assembly defines an axis extending between said first and second ends, and

said die assembly is translatable relative to said drive assembly in the direction of said axis.

6. The apparatus of Claim 5, wherein said punch dies of said plurality of punch dies are translatable in a direction different than the direction of said axis of said die assembly.

7. The apparatus of Claim 6, wherein said punch dies of said plurality of punch dies are translatable relative to said die retaining structure.

8. The apparatus of Claim 1, wherein

said die retaining structure has a first portion and a second portion, and

said first portion is translatable relative to said second portion.

9. The apparatus of Claim 8, wherein

said apparatus further includes a biasing member, and

said first portion of said die retaining structure is biasedly positioned by said biasing member relative to said second portion of said die retaining structure.

10. The apparatus of Claim 1, wherein

said enclosure defines an opening therethrough, and

said die assembly is movable through said opening.

11. The apparatus of Claim 1 , wherein said apparatus further includes a sensor means for detecting the presence of said die assembly.

12. The apparatus of Claim 11, wherein said sensor means is engageable by said die assembly.

13. The apparatus of Claim 11 , wherein

said sensor means electrically connects to said motor,

said sensor means includes means for signaling a status of said sensor means to said motor, and

said motor is operable based in part upon said status of said sensor means.

14. An apparatus for creating a plurality of holes in paper, said apparatus comprising:

a drive assembly;

a first member extending in a first direction and a second direction, said first member extending more substantially in said first direction than said second direction;

a second member extending in said first direction and said second direction, said second member extending more substantially in said first direction than said second direction, said second member being disposed opposite said first member;

a plurality of punch dies movable relative to said second member, said plurality of punch dies being engageable by said drive assembly;

a slot defined between said first member and said second member; and,

a trigger means for initiating operation of said drive assembly in response to the presence of paper within said slot.

15. The apparatus of Claim 14, wherein said trigger means is at least partially located within said slot.

16. The apparatus of Claim 14, wherein said trigger means includes means for detecting an orientation of paper within said slot.

17. The apparatus of Claim 16, wherein said means for detecting includes means for detecting a lateral position of paper within said slot.

18. The apparatus of Claim 17, wherein a portion of said means for detecting a lateral position is slidable within said slot.

19. The apparatus of Claim 16, wherein said means for detecting includes means for detecting a longitudinal position of paper within said slot.

20. The apparatus of Claim 19, wherein a portion of said means for detecting a longitudinal position is rotatable within said slot.

21. A method of enabling the creation of a plurality of holes in paper, the method comprising the steps of:

providing a punch having an enclosure and including a drive train and a die assembly receivable by the punch, the die assembly defining a slot therein and including a plurality of adjacent punch dies spaced apart from one another at a distance;

enabling insertion of the die assembly by a user as a unit into a position within the punch which renders the plurality of adjacent punch dies engageable by the drive train;

allowing receipt of paper in the slot; and,

enabling operation of the drive train to engage and move the punch dies of the plurality of adjacent punch dies relative to the paper.

22. The method of Claim 21, wherein the step of enabling insertion includes a step of enabling insertion of the die assembly by translation of the die assembly relative to the drive train of the punch.

23. The method of Claim 22, wherein

the method further includes a step of providing an opening defined by the enclosure, and

the step of enabling insertion includes a step of enabling insertion of the die assembly through the opening of the enclosure.

24. The method of Claim 21 , wherein the method further includes the steps of

providing the die assembly as a first die assembly,

providing a second die assembly defining a slot therein and including a plurality of adjacent punch dies, and

enabling replacement of the first die assembly with the second die assembly by a user of the punch without removal of the enclosure.

25. The method of Claim 24, wherein the step of enabling replacement includes a step of enabling removal of the first die assembly by translation of the die assembly relative to the drive train of the punch.

26. The method of Claim 21, wherein the step of enabling operation of the drive train includes a step of enabling operation of the drive train in response to the presence of paper within the slot.

27. The method of Claim 21, wherein the step of enabling operation of the drive train includes a step of enabling operation of the drive train in response to a position of paper within the slot.

28. The method of Claim 21, wherein the step of enabling operation of the drive train includes a step of enabling operation in response to actuation of a foot controller connected to the punch.