WO2013059284A2

WO2013059284A2 - Arc punch and method of using the same

Info

Publication number: WO2013059284A2
Application number: PCT/US2012/060566
Authority: WO
Inventors: Ross Exley; Mark Shainwald; Matt SWEENEY; Josh Piezas
Original assignee: Dimension Crafts Llc
Priority date: 2011-10-17
Filing date: 2012-10-17
Publication date: 2013-04-25
Also published as: EP2768641A4; WO2013059284A3; AU2012326242B2; JP6145455B2; JP2014534081A; BR112014009344A2; AU2012326242A1; EP2768641A2

Abstract

A punch guide for guiding the application of a punch to a work piece includes a base, a rotatable member coupled to the base, a punch carriage moveable along the base, and an adjustable indexing assembly for adjusting an indexed extent of angular rotation of the rotatable member with respect to the base. The rotatable member is rotatable about a rotational axis. At least one of the base and the punch carriage includes first alignment indicia for identifying a selected distance between the rotational axis and the punch carriage. The adjustable indexing assembly includes second alignment indicia corresponding to the first alignment indicia for setting the adjustable indexing assembly to provide a selected indexed extent of angular rotation that corresponds to the selected distance between the center axis and the punch carriage.

Description

ARC PUNCH AND METHOD OF USING THE SAME

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/548,116, filed October 17, 2011, the entire contents of which are hereby incorporated by reference herein.

TECHNICAL FIELD

[0002] The present disclosure generally relates to a punch system for use in punching sheet media. In particular, an arc punch is provided to make decorative cuts in a circular arrangement and of varying diameters.

BACKGROUND

[0003] Paper punches for forming decorative perforations or decorative borders in paper products are known. Such punches come in a wide variety of sizes, shapes, and

configurations. In some applications, the size of the necessary punch can often be a limiting factor of the punch or the resultant workpiece configuration. For example, if it is desired to punch a border around a relatively large sheet of paper, such as a 10" X 10" sheet, a single punch suitable for creating such a pattern would be excessively large and would require complicated mechanisms to provide a sufficient mechanical advantage to operate the punch.

[0004] Rather than providing an excessively large punch, decorative punches have been developed that are configured to be used repeatedly in a way that creates a decorative border around a sheet medium. By creating a row of evenly-spaced punches, the punch eventually "cuts out" the desired shape. While these punches solve the problem of creating punched patterns around relatively large sheets of paper, adjacent punches must be precisely aligned with one another to produce quality results. This is particularly difficult when the desired resultant shape is a circle. Not only do the punches need to be precisely located adjacent to one another, they must also be consistently spaced the same distance away from the center of the desired circle. SUMMARY

[0005] A punch guide for guiding the application of a punch to a work piece is provided. The punch guide includes a base, a rotatable member coupled to the base, a punch carriage moveable along the base, and an adjustable indexing assembly for adjusting an indexed extent of angular rotation of the rotatable member with respect to the base. The rotatable member is rotatable about a rotational axis. At least one of the base and the punch carriage includes first alignment indicia for identifying a selected distance between the rotational axis and the punch carriage. The adjustable indexing assembly includes second alignment indicia corresponding to the first alignment indicia for setting the adjustable indexing assembly to provide a selected indexed extent of angular rotation that corresponds to the selected distance between the center axis and the punch carriage.

[0006] In another embodiment, a punch guide for guiding the application of a punch to a work piece is provided. The punch guide includes a base having a center portion, a punch carriage moveably coupled to the base for movement toward and away from the center portion, and a rotatable member rotatably coupled to the center portion. The punch guide also has an adjustable indexing assembly for adjusting an indexed extent of angular rotation of the rotatable member with respect to the base.

[0007] According to another embodiment, a punch guide for guiding the application of a punch to a work piece includes a base including a center portion and an arm extending away from the center portion. The arm defines a channel. A rotatable member is detently rotatably coupled to the base for detent rotation about a rotational axis. The rotatable member is detently rotatable between a plurality of detent rotational positions, and adjacent detent rotational positions are separated by an angle (A). A punch carriage is received by and detently slidable along the channel for selective adjustment between a plurality of detent locations along the arm. A coupling member is configured for coupling the work piece to the rotatable member for rotation with the rotatable member. An adjustable indexing assembly engages the rotatable member and includes a moveable member that is moveable to change the angle (A) between the each detent rotational position of the rotatable member.

[0008] A method for punching a curved pattern in a work piece is also provided. The method includes providing a punch guide that is operable by coupling the work piece to a rotatable member. The rotatable member rotates about a rotational axis between a plurality of indexed rotational positions, and the indexed rotational positions are separated from one another by an adjustable angle (A). A distance between a punch carriage and the rotational axis is adjusted, and an adjustable indexing assembly is set to adjust the angle A to correspond to the distance between the punch carriage and the center axis. The work piece is punched a first time to form a first opening in the work piece. The rotatable member is rotated from one indexed rotational position to a next indexed rotational position, thereby rotating the rotatable member and the work piece by the angle (A). The work piece is punched a second time to form a second opening in the work piece. The second opening at least partially overlaps with the first opening.

[0009] The present disclosures generally relate to a punch system for use in punching sheet media. In particular, an arc punch is provided to make decorative cuts in a circular arrangement and of varying diameters. Features, advantages and embodiments of the arc punch may be set forth, or are apparent, from consideration of the following description. Moreover, it is to be understood that the following description is exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] To understand the present disclosure, it will now be described by way of example, with reference to the accompanying drawings in which embodiments of the disclosures are illustrated and, together with the descriptions below, serve to explain the principles of the disclosure.

[0011] FIG. 1 is a perspective view of an arc punch according to one embodiment.

[0012] FIG. 2 is an exploded perspective view of the arc punch of FIG. 1.

[0013] FIG. 3 is an exploded perspective view of an adjustable indexing assembly of the arc punch of FIG. 1.

[0014] FIG. 4 is a bottom view of an indexing plate of the adjustable indexing assembly of FIG. 3.

[0015] FIG. 5 is a top view of the adjustable indexing assembly of FIG. 3 in a first position.

[0016] FIG. 6 is a top view of the adjustable indexing assembly of FIG. 3 in a second position.

[0017] FIG.7 is a top view of the arc punch of FIG. 1 illustrating an arc punching operation in progress.

[0018] FIG. 8 is a perspective section view of an arc punch according to an alternative embodiment.

[0019] FIG. 9 is a perspective view of an underside of an indexing plate for the arc punch of FIG. 8. [0020] FIGS. 10-13 provide schematic illustrations of a method of using the arc punch of FIG. 8.

[0021] The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure.

DETAILED DESCRIPTION

[0022] While the arc punches discussed herein are susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail, preferred embodiments with the understanding that the present description is to be considered as an exemplification of the principles of the arc punch and are not intended to limit the broad aspects of the disclosures to the embodiments illustrated.

[0023] FIGS. 1 and 2 illustrate an arc punch 10 for punching curved, arcuate, and circular patterns into a work piece. The work piece may be, for example, one or more sheets of paper or cardstock. The arc punch 10 includes a base 14, a punch carriage 18 moveable with respect to the base 14, a punch assembly 22 coupleable to and moveable with the punch carriage 18, a rotatable member 26 (FIG. 2) rotatably coupled to the base 14 for rotation about a rotational axis 30, and a coupling member 34 for securing the work piece to the rotatable member 26.

[0024] The base 14 includes a center portion 38 that defines the rotational axis 30 and supports the rotatable member 26. The rotatable member 26 is detently rotatable about the rotational axis 30 between a plurality of detent rotatable positions. An adjustment arm 40 is moveable to adjust an indexed extent of angular rotation of the rotatable member 26 with respect to the base 14, as discussed further below. The base 14 also includes an arm 42 extending away from the center portion 38 in a radial direction with respect to the rotational axis 30. The arm 42 defines a channel 46 that receives the punch carriage 18. The arm 42 includes a pair of sidewalls 50 for guiding the movement of the punch carriage 18 with respect to the base 14. Each sidewall 50 includes at least one retention slot 54 extending generally along the length of the arm 42, and a serrated portion 58 (FIG. 2) that, in the illustrated configuration, extends along a distal portion of each sidewall 50, although other configurations may not include a serrated portion at all, or may include serrated portions 58 that extends along the entire arm 42 or along a different portion of the arm 42. The serrated portions 58 cooperate with the punch carriage 18 to provide detent sliding movement of the punch carriage 18 with respect to the base 14 between a plurality of detent locations, as discussed further below. [0025] As shown in FIG. 2, the punch carriage 18 can include at least a portion of the punch assembly 22. More specifically, in the illustrated configuration a top wall 62 of the punch carriage 18 defines a recess 66 for receiving a lower die 70 of the punch assembly 22. As understood by those skilled in the art, the lower die 70 of a punch assembly 22 generally includes one or more openings 72 that provide a female outline of the shape to be punched. Also in the illustrated embodiment, a moveable and spring-biased latch member 74 secures the lower die 70 in the recess 66 and is manually moveable to release the lower die 70 from the punch carriage 18. In other embodiments, the lower die 70 may be non-removably coupled to or formed with the punch carriage 18.

[0026] In addition to the lower die 70, the punch assembly 22 also includes a punch body 78 comprising a lower portion 82 that removably couples with the punch carriage 18, as discussed below, and an upper portion 86 that is moveable with respect to the lower portion 82. The lower portion 82 includes an upper die 90 that defines one or more openings 94 corresponding to the one or more openings 72 in the lower die 70. The upper portion 86 includes a male punch 98 including one or more projections sized and configured to fit through the one or more openings 72, 94 in the lower and upper dies 70, 90. During a punching operation, the lower die 70 is positioned below the work piece, the upper die 90 is positioned above the work piece, and the upper portion 86 of the punch assembly 22 is pressed downwardly toward the lower portion 82 of the punch assembly 22 to move the male punch 98 through the upper die 90, through the work piece, and through the lower die 70, to form openings in the work piece that generally correspond to the openings 72, 94 in the lower and upper dies 70, 90. An arrangement of links, gears, and/or the like (not shown) may be incorporated into the punch assembly 22, for example between the upper portion 86 and the male punch 98, to provide a mechanical advantage that reduces the amount of force to be applied by the user during the punching operation. The generally trapezoidal shape of the openings 72, 94 and male punch 98 shown in FIG. 2 is a generic example of a shape that may be punched by the punch assembly 22. It should be appreciated that a virtually unlimited number of decorative punched shapes can be obtained (see, e.g. , FIG. 7) by changing the configurations of the dies 70, 90 and the male punch 98, which may be provided as a set.

[0027] In the illustrated embodiment, the punch body 78 is magnetically coupled to the punch carriage 18. In this regard, the punch carriage 18 includes at least one, e.g. four as shown, first ferromagnetic members 102 positioned on the top wall 62 of the punch carriage 18, and the punch body 78 includes at least one, e.g. four as shown, second ferromagnetic members 106 cooperatively positioned on a lower surface 110 of the lower portion 82. Although other configurations are possible, in the illustrated configuration the first and second ferromagnetic members 102, 106 comprise cylindrical magnets inserted and secured within bores provided in the punch carriage 18 and lower portion 82 of the punch body 78. The ferromagnetic members 102, 106 may be or include rare-earth magnets, standard magnets, or a ferromagnetic material (such as iron) that is not itself magnetic but that can be attracted by a magnet.

[0028] In some embodiments, the first and second ferromagnetic members 102, 106 are configured and arranged such that the north and south poles of the various magnetic members 102, 106 generally ensure that the lower and upper dies 70, 90 are properly aligned when the punch body 78 is coupled to the punch carriage 18. For example, with the punch body 78 oriented as shown in the figures, each first ferromagnetic member 102 is attracted to its corresponding second ferromagnetic member 106. However, if the punch carriage 18 is rotated 180 degrees, thereby misaligning the upper and lower dies 90, 70, at least one of the first ferromagnetic members 102 will be repelled from the second ferromagnetic member 106 with which it is aligned. In this way it will generally be made apparent to the user when he or she does not have the punch body 78 properly aligned with the punch carriage 18, even though the user may not be able to see the orientation of the lower die 70 because it is covered by the workpiece. Although the illustrated embodiment includes four ferromagnetic members 102, 106 on each of the punch carriage 18 and the punch body 78, it is

contemplated that any number of ferromagnetic members may be used and suitably configured and arranged to couple the punch body 78 to the punch carriage 18 and also to promote proper alignment of the punch body 78 with the punch carriage 18.

[0029] By magnetically coupling the punch body 78 to the punch carriage 18, the punch body 78 can be quickly removed from and reattached to the punch carriage 18 while the work piece remains positioned over the punch carriage 18. When the punch body 78 is attached to the punch carriage 18 with the work piece positioned therebetween, the magnetic coupling between the punch body 78 and the punch carriage 18 at least partially secures the work piece for a punching operation. When the punch body 78 is removed from the punch carriage 18, the work piece can be reoriented, for example by rotating, as discussed further below.

[0030] In some embodiments, including the illustrated embodiment, the upper die 90 and male punch 98 are non-removably coupled to the punch body 78 such that providing a new punch shape involves providing a new punch body 78 and a matching lower die 70 configured to fit within the recess 66 of the punch carriage 18. In other embodiments, one or more of the upper die 90 and male punch 98 may be removably coupled to the punch body 78 such that providing a new punch shape involves providing a set that includes a lower die lower die 70 that fits in the recess 66, and an upper die 90 and a matching male punch 98 that can be installed into the punch body 78.

[0031] In alternative embodiments, rather than the magnetic coupling arrangement described above, the punch body 78 can be removably or non-removably mounted to the end of a first elongated arm that is coupled to a second elongated arm having at its end the punch carriage 18. In this alternative embodiment, the punch carriage 18 and punch body 78 are coupled to one another in a configuration similar to a conventional stapler such that the work piece can be positioned between the two elongated arms and the punch body 78 can be moved downwardly and into engagement with the work piece and the punch carriage 18 during a punching operation. The punch body 78 and/or the elongated arm to which it is connected may be spring biased into a raised position to allow the work piece to be repositions between punching operations.

[0032] Returning to the illustrated embodiment of FIGS. 1 and 2, the punch carriage 18 is received by and detently slidable along the channel 46 for selective adjustment between a plurality of detent locations along the arm 42. The punch carriage 18 can be adjusted along the arm 42 with or without the punch body 78 magnetically coupled thereto. The punch carriage 18 includes a pair of sidewalls 114 that extend downwardly from the top wall 62. Each sidewall 114 includes an outwardly protruding rib 118 that extends along a lower edge of the sidewall 114 and that is received by the retention slot 54 in the corresponding sidewall 50 of the arm 42. Detent tabs 126 are formed on opposite ends of each sidewall 114, and include a lower guide projection 130 that also fits within the retention slot 54, and an upper detent tooth 134 that engages the serrated portions 58. When the punch carriage 18 is moved along the arm, the detent teeth 134 of the detent tabs 126 detently engage the serrated portions 58 of the sidewalls 50 of the arm 42 to provide tactilely and audibly detectable detent sliding of the punch carriage 18 between a plurality of detent locations along the arm 42. In alternative embodiments, detent sliding of the punch carriage 18 may be eliminated and the punch carriage 18 and/or the arm 42 may also or alternatively be provided with a latching or locking assembly that allows the punch carriage 18 to be releasably secured in substantially any desired location along the arm 42.

[0033] The punch carriage 18 and the arm 42 can be provided with first alignment indicia 138a and 138b that cooperate to identify a selected location of the punch carriage 18 along the arm 42. In the illustrated embodiment, the first alignment indicia 138a comprises an arrowhead, and the first alignment indicia 138b comprises a numerical scale including scale lines at 1/4 and 1/2 of the numerical increments, similar to a standard ruler. While the ruler configuration is convenient because it corresponds to a standard unit of measurement, more arbitrary indicia such as letters, symbols, and the like may also or alternatively be used. The illustrated numerical scale ranges from a numerical value of 6 to a numerical value of 12. The numbers 6 through 12 and the 1/4 and 1/2 scale increments therebetween correspond to the resulting diameter in inches of a circular punched cutout formed when the first alignment indicia 138a is aligned with a specific number or the 1/4 or 1/2 scale increment thereof, and the punch is operated in the manner described below. Thus, for example, to form a circular punched cutout having a diameter of 8 inches, the punch carriage 18 is moved along the arm 42 to align the first alignment indicia 138a with the number 8 of the first alignment indicia 138b. In the illustrated embodiment, the configuration of the serrated portions 58 and the detent teeth 134 is such that each detent location along the arm 42 corresponds to a 1/4 inch adjustment in the diameter of the circular punched cutout and aligns the first alignment indicia 138a with one of the numbers or one of the 1/4 or 1/2 scale increments of the first alignment indicia 138b.

[0034] As best shown in Fig. 2, the coupling member 34 is removably coupleable to the rotatable member 26 for securing the work piece to the rotatable member 26. In the illustrated configuration the coupling member 34 is magnetically coupled to the rotatable member 26 in a manner similar to the manner in which the punch body 78 is magnetically coupled to the punch carriage 18. More specifically, the coupling member 34 and the rotatable member 26 each include ferromagnetic members 142 configured and arranged such that the ferromagnetic members 142 on the coupling member 34 are attracted to the ferromagnetic members on the rotatable member 26. In some embodiments, the

ferromagnetic members 142 may be rare earth magnets, but other types of magnets and/or non-magnetic but ferrous materials can also be used. When the coupling member 34 is magnetically coupled to the rotatable member 26, the magnetic attraction between the ferromagnetic members 142 is sufficiently strong such that rotation of the coupling member 34 rotates the rotatable member 26. The rotatable member 26 also includes a pair of gripper pads 146 fixed to the rotatable member and formed of a resilient and/or high friction material that helps keep the work piece fixed with respect to the rotatable member 26 and the coupling member 34 when the coupling member 34 is used to rotate the work piece and the rotatable member, as discussed further below. As illustrated, the coupling member 34 may be hollow and may include a clear circular insert 148 having a cross-hair formed thereon to aid in aligning a desired center of the work piece with the rotational axis 30. [0035] Referring also to FIGS. 3 and 4, the base 14 includes a lower portion 150 and an upper portion 154 that cooperate to house an adjustable indexing assembly 158. The adjustable indexing assembly 158 engages the rotatable member 26 and is operable to adjust an indexed extent of angular rotation of the rotatable member 26 with respect to the base 14.

[0036] As best shown in FIGS. 2 and 4, an underside 160 of the rotatable member 26 includes a plurality of detent recesses 162. Each detent recess 162 corresponds to one of the detent rotational positions of the rotatable member 26. A hollow cylindrical boss 166 extends from the underside 160 of the rotatable member 26 and receives an upwardly extending pin 170 provided on the lower portion 150 of the base 14 to rotatably support the rotatable member 26. The lower portion 150 of the base 14 also includes a plurality of upwardly extending securement pins 174 that fit into corresponding securement sleeves 175 provided on the upper portion 154 of the base 14 to couple the lower portion 150 to the upper portion 154. The lower portion 150 of the base 14 also includes a plurality of raised cam projections 176 that cooperate with the adjustment arm 40 to provide detent adjustment of the adjustment arm 40 between a plurality of detent arm positions, as discussed below.

[0037] The adjustment arm 40 includes a pivot end 178 pivotally coupled to the lower portion 150 of the base 14, and an opposite adjustment end 182 that extends from the housing 14 and that is accessible to a user for moving the adjustment arm 40. The adjustment arm 40 is curved and includes a U-shaped portion 186 adjacent the pivot end 178 that is adapted to fit around the pin 170 as the adjustment arm 40 is moved. The adjustment arm 40 also includes a detent projection 190 positioned adjacent the adjustment end 182 and extending

downwardly for engagement with the raised cam projections 176 provided on the lower portion 150 of the base 14. As the adjustment arm 40 is moved the detent projection 190 rides up and over the raised cam projections 176 and snaps back into the spaces between adjacent cam projections 176, thereby providing tactily detectable detent movement of the adjustment arm 40 between the plurality of detent arm positions. The adjustment arm 40 also includes an engaging member 192 configured for engagement with the underside 160 of the rotatable member 26 and that, in the illustrated configuration, is located along the U-shaped portion 186. Although various configurations are possible, the engaging member 192 in the illustrated construction is in the form of a steel ball supported by a cylindrical support member 193. The steel ball engaging member 192 is biased against the underside 160 of the rotatable member 26 by a spring (not shown) that is positioned within the support member 193. The engaging member 192 is biased against the underside 160 of the rotatable member 26 and detently moves into and out of engagement with the detent recesses 162 during rotation of the rotatable member 26 about the rotational axis 30.

[0038] As shown in FIGS. 1 and 2, the upper portion 154 of the base 14 and the adjustment end 182 of the adjustment arm 40 are provided with second alignment indicia 194a, 194b that provide a visual indication to the user regarding the relative location of the adjustment arm 40. In the illustrated embodiment, the second alignment indicia 194a comprises a triangle that is alignable with the second alignment indicia 194b, which comprises a numerical scale ranging from 6 to 12. The numerical scale of the second alignment indicia 194b corresponds to the numerical scale of the first alignment indicia 138b, for reasons discussed further below. Each number of the second alignment indicia 194b generally corresponds to one of the detent arm positions defined by engagement of the detent projection 190 with the cam projections 176.

[0039] Referring to FIG. 4, the detent recesses 162 provided on the underside 160 of the rotatable member 26 are arranged in a plurality of substantially concentric rings 200a, 200b, 200c. In the illustrated, non- limiting example, the rotatable member 26 includes seven rings of detent recesses 162 however for clarity only three of the seven rings are labeled in FIG. 4 and discussed below in connection with operation of the adjustable indexing assembly 158. An inner ring 200a of detent recesses 162 includes twelve detent recesses 162 each separated by an angle Al. A middle ring 200b of detent recesses 162 includes eighteen detent recesses 162 each separated by an angle A2 that is less than the angle Al. An outer ring 200c of detent recesses 162 includes twenty-four detent recesses 162 each separated by an angle A3 that is less than the angle Al. It will be understood that other detent configurations can be used having different numbers of detent recesses and different angles. Moreover, the rotatable member 26 also can include detent recess 162 having a different configuration than the illustrated generally circular dimples shown in FIGS. 3 and 4. For example, the rotatable member 26 could include an arrangement of grooves, corrugations, pins, ratchet teeth (see, e.g. , the alternative embodiment shown in FIG. 9), and the like.

[0040] When punching a curved, arcuate, or circular cutout with the arc punch 10, as the radius of the curve, arc, or circle is increased, e.g. , by moving the punch carriage 18 away from the rotational axis 30, more individual punching operations are required to obtain a desired arc length or to complete a full circle. Consequently, the angle of rotation between adjacent punches also is reduced. The configuration of the concentric rings 200a, 200b, 200c of detent recesses 162, including the different numbers of detent recesses 162 in each ring and the different angles Al, A2, A3 between the detent recesses 162 of each ring allow for adjustment of the angle between each detent rotational position of the rotatable member 26 during operation of the arc punch 10 to accommodate the punching of cutouts having different radii and diameters.

[0041] Referring also to FIGS. 5 and 6, by moving the adjustment arm 40 between the detent arm positions provided by the cam projections 176 in the lower portion of the base 14, the engaging member 192 (e.g. the ball) of the adjustment arm 40 is moved into and out of circumferential alignment with different rings of detent recesses 162. As shown in FIG. 5, the adjustment arm 40 is shifted all the way to the right (as viewed in FIG. 5) such that the engaging member 192 is aligned for engagement with the detent recesses 162 in the outer ring 200c. Thus, when the rotatable member 26 is rotated, each detent rotational position of the rotatable member 26 will be separated by the angle A3 associated with the ring 200c, and a full rotation of the rotatable member 26 will involve rotation through all twenty-four of the detent rotational positions defined by the twenty-four detent recesses 162 in the ring 200c. As shown in FIG. 6, the adjustment arm 40 is shifted all the way to the left (as viewed in FIG. 6) such that the engaging member 192 is aligned for engagement with the detent recesses 162 in the inner ring 200a. Thus, when the rotatable member 26 is rotated, each detent rotational position of the rotatable member 26 will be separated by the angle Al associated with the ring 200c, and a full rotation of the rotatable member 26 will involve rotation through all twelve of the detent rotational positions defined by the twelve detent recesses 162 in the ring 200c. It should be appreciated that the adjustment arm 40 can be adjusted to any one of the detent arm positions provided by the cam projections 176 to align the engaging member 192 for engagement with any one of the rings of detent recesses 162 in the underside 160 of the rotatable member 26, and that each detent arm position of the adjustment arm 40 provides a different number of detent rotational positions and a different angle of rotation A between the detent rotational positions of the rotatable member 26.

[0042] Referring also to FIG. 7, to punch a curved, arcuate, or circular cutout, a user selects a desired diameter of the finished cutout by aligning the first alignment indicia 138a on the punch carriage 18 with the corresponding numerical measurement provided by the first alignment indicia 138b on the arm 42, such as the number "8" for a punch diameter of approximately 8 inches. The user then sets the adjustable indexing assembly 158 by aligning the second alignment indicia 194a on the adjustment arm 40 with the same number (e.g. , "8") on the second alignment indicia 194b provided on the base 14. The user then positions the work piece W with the desired center of the finished cutout substantially aligned with the rotational axis 30. Aligning of the work piece can be aided by looking through the hollow coupling member 34 and aligning the desired center of the work piece with the cross-hairs provided in the clear circular insert 148. With the work piece W positioned, the coupling member 34 is magnetically coupled to the rotatable member 26 by aligning the ferromagnetic members 142. The ferromagnetic members 142 and the gripper pads 146 cooperate to secure the work piece W between the rotatable member 26 and the coupling member 34 such that when coupling member 34 is rotated the work piece W and the rotatable member 26 also rotate.

[0043] With the work piece W secured between the coupling member 34 and the rotatable member 26, the punch body 78 can be coupled to the punch carriage 18 by positioning the punch body 78 into close proximity with the punch carriage 18.

Misalignment of the punch body 78 can be discouraged by the above-described configuration of the ferromagnetic members 102, 106 provided on the punch carriage 18 and the punch body 78, which tends to repel the punch body 78 away from the punch carriage 18 when the alignment is improper, and which tends to pull the punch body 78 into engagement with the punch carriage 18 when the alignment is correct. With the punch body 78 correctly coupled to the punch carriage 18, the user forms a first punch opening 204a in the work piece by pressing down on the upper portion 86 of the punch body 78, which forces the male punch member 98 through the upper and lower dies 90, 70 and through the work piece W.

[0044] After forming the first punch opening 204, the punch body 78 is removed from the punch carriage 18 and the coupling member 34 is rotated (e.g., clockwise as shown in FIG. 7). Rotation of the coupling member 34 rotates the work piece W and the rotatable member 26 such that the rotatable member 26 moves out of its existing indexed rotational position, as established by engagement of the engaging member 192 with one of the detent recesses 162, and into the next indexed rotational position defined by engagement of the engaging member 192 with the next detent recess 162 in the selected ring of detent recesses 162.

[0045] After simultaneously rotating the coupling member 34, the work piece W, and the rotatable member 26, the punch body 78 is again coupled to the punch carriage 18 and the user forms a second punch opening 204b. With the rotatable member 26 rotated to its next indexed rotational position, the second punch opening 204b is appropriately positioned to at least partially overlap the first punch opening 204a such that repeating the punch - rotate - punch pattern of operation results in an aligned arrangement of adjacent and partially overlapping punches 204a, 204b, 204c, 204d, etc. that will eventually produce a generally circular cutout having approximately the diameter selected at the beginning of the punching operation. [0046] Thus, a method is provided for punching a curved pattern in the work piece W, and includes providing the arc punch 10, wherein the arc punch 10 is operable by coupling the work piece W to the rotatable member 26, which rotates about the rotational axis 30 between the plurality of indexed rotational positions. The indexed rotational positions being separated from one another by the adjustable angle A. The distance between the punch carriage 18 and the rotational axis 30 is adjusted, and the adjustable indexing assembly 158 is set to adjust the angle A to correspond to the distance between the punch carriage 18 and the center axis 30. The work piece W is punched a first time to form the first opening 204a in the work piece, and the rotatable member 26 is rotated from one indexed rotational position to a next indexed rotational position, thereby rotating the rotatable member 26 and the work piece W by the angle A. The work piece W is punched a second time to form a second opening 204b in the work piece W, and the second opening 204b at least partially overlaps with the first opening 204a.

[0047] By setting the adjustable indexing assembly 158 to correspond to the diameter selected by positioning the punch carriage 18 along the arm 42, the adjustable indexing assembly 158 appropriately adjusts the angle between adjacent punches and the total number of punches required to complete a circle to accommodate the selected diameter. In this way, the base 14, the rotatable member 26, the punch carriage 18, and the adjustable indexing assembly 158 cooperate to guide the application of the punch assembly 22 to the workpiece W. The first alignment indicia 138a, 138b and the second alignment indicia 194a, 194 facilitate matching the selected diameter with the appropriate setting of the adjustable indexing assembly 158. Although additional detent arm positions of the adjustment arm 40 can be provided, it has been found that setting the adjustment arm 40 to, for example, a setting of "6" provides an angle of rotation that is suitable for selected diameters ranging between 6 inches and 6 and 1/2 inches, while a setting of "7" provides an angle of rotation that is suitable for selected diameters ranging between 6 and 3/4 inches and 7 and 1/2 inches, and so on up to and including the selected diameter of 12 inches. The specific suitable ranges may depend upon the specific configuration of a particular set of upper and lower dies 90, 70 the corresponding male punch 98.

[0048] FIGS. 8-13 illustrate an alternative embodiment of an arc punch as disclosed herein. As shown in FIG. 8, the arc punch 310 is comprised of a generally circular base 312 having a central axis 314, a lower arm 316, and an upper arm 318. The lower arm 316 is slidably coupled to the base 312 and includes a punching mechanism 320, comprised of one of either a male and female punching component. [0049] The upper arm 318 is slidably coupled to the base 312. The upper arm 318 is disposed above the lower arm 16 and includes the other of a male and female punching component. According to the present disclosure, at least one of the upper and lower arms 316, 318 is rotatable about the central axis 314.

[0050] The upper arm 318 includes a first magnetic surface and the lower arm 316 includes a second magnetic surface. The first and second magnetic surfaces are oppositely polarized. Accordingly, the upper and lower arm, and their corresponding punching components, can only come into rotational alignment when the arms are rotated in a first direction. It is contemplated in one embodiment of the disclosure that both the upper and lower arms 316, 318 are rotatable about a central axis 314. In such an embodiment the rotating arms 316, 318 are coupled by the magnetic surfaces, and thus remain aligned when they are rotated about the central axis.

[0051] It is contemplated that the punching mechanism 320 that includes the male and female punching components may be a scissor action/lever system that reduces the force needed to push the punching head through the paper or sheet media in the punching plate. For example, the punching mechanism may include the type described in U.S. Patent No. 7,690,121, the entire contents of which are hereby incorporated by reference herein.

Alternatively, the punching mechanism 320 of the present disclosure can use any punch mechanism suitable for use with paper or other sheet media and still fall within the scope of the present disclosure. It is also contemplated by the present invention that a jig system be employed, whereby alternative cutting tools may be employed in a circular motion.

[0052] According to one disclosed embodiment of the arc punch 310, the arc punch further includes an adjustable indexing assembly in the form of a ratchet system 322. As shown in FIGS. 8 and 9, the ratchet system is comprised of a disc 324 and pawl 326. The disc 324 of the ratchet system 322 is disposed on the base312. The disc 324 has a top surface comprised of a plurality of tracks 328. The tracks 328 are radially positioned relative to an adjacent track 328. Accordingly, the tracks 328 form pathways of increasing circumference as they are positioned radially outward, one from the other. Each of the tracks 328 traverses at least a portion of the disc 324 varying circumferences as defined by that track 28. Each track 328 also includes a plurality of canted surfaces 330 disposed at predetermined distances in tracks 328. The pawl 326 is biased toward the disc 324 and is permitted to traverse the track 328 in which it is engaged in a single direction and prevented from traversing the track 328 in the opposed direction. Moreover, the canted surfaces 330 are positioned at predetermined increments along each of the tracks 328 to accommodate variable punch positioning points depending on the diameter of the desired punch pattern.

[0053] A channel 332 extends radially along the top surface of the disc 324 and generally perpendicular to the plurality of tracks 328. When the upper arm 318 is rotated to a predetermined point, the pawl 326 is permitted to travel radially in the channel 332. As a result, the upper arm 318 is permitted to slidably move along an axis perpendicular to the central axis 314, thereby altering the distance from the central axis 314 to the punching mechanism 320. In this manner, the punching mechanism 320 of the arc punch 310 is adjustable to provide arc punching along paths of varying diameter. It is contemplated that the housing on the arc punch 310 will include alignment indicia that indicates to a user that the channel is in a position to accommodate slidable movement of the upper arm 316.

[0054] FIGS. 10-13 illustrate at least one method of using the arc punch 310. The method comprises: placing a sheet media between the upper and lower arms; magnetically coupling the upper arm to the lower arm with the sheet media disposed therebetween such that the upper and lower arms are positioned in a first punching location; rotating the upper arm in a first direction to a predetermined rotational degree; and rotating the upper arm back into alignment with the lower arm such that the upper and lower arms are positioned in a second punching location.

[0055] While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the disclosure, and the scope of protection is only limited by the scope of the accompanying claims.

Claims

CLAIMS What is claimed is:

1. A punch guide for guiding the application of a punch to a work piece, the punch guide comprising:

a base;

a rotatable member coupled to the base, the rotatable member being rotatable about a rotational axis;

a punch carriage moveable along the base toward and away from the rotational axis, at least one of the base and the punch carriage including first alignment indicia for identifying a selected distance between the rotational axis and the punch carriage;

an adjustable indexing assembly for adjusting an indexed extent of angular rotation of the rotatable member with respect to the base, the adjustable indexing assembly including second alignment indicia corresponding to the first alignment indicia for setting the adjustable indexing assembly to provide a selected indexed extent of angular rotation that corresponds to the selected distance between the center axis and the punch carriage.

2. The punch guide of claim 1, wherein the adjustable indexing assembly adjusts the indexed extent of angular rotation of the rotatable member without changing a location of the rotational axis with respect to the base.

3. The punch guide of claim 1, wherein the punch carriage is detently slidable along the base for selective adjustment between a plurality of detent locations along the base.

4. The punch guide of claim 1, wherein the rotatable member is detently rotatably coupled to the base for detent rotation about the center axis between a plurality of detent rotational positions, each detent rotational position separated by an angle A that corresponds to the selected indexed extent of angular rotation.

5. The punch guide of claim 4, wherein the adjustable indexing assembly is adjustable to change the angle (A) between each detent rotational position of the rotatable member.

6. The punch guide of claim 1, wherein the adjustable indexing assembly includes an adjustment arm moveably coupled to the base and engaging the rotatable member, and wherein movement of the adjustment arm changes the selected indexed extent of angular rotation.

7. The punch guide of claim 6, wherein the second alignment indicia is provided on the base and the arm to identify a selected relative position of the arm with respect to the base.

8. The punch guide of claim 1, further comprising a coupling member for coupling the work piece to the rotatable member for rotation with the rotatable member.

9. The punch guide of claim 8, wherein at least one of the coupling member and the rotatable member includes a magnet for magnetically coupling the coupling member to the rotatable member, and wherein when the coupling member is magnetically coupled to the rotatable member the coupling member is substantially rotatably fixed with respect to the rotatable member.

10. A punch guide for guiding the application of a punch to a work piece, the punch guide comprising:

a base including a center portion;

a punch carriage moveably coupled to the base for movement toward and away from the center portion;

a rotatable member rotatably coupled to the center portion; and,

an adjustable indexing assembly for adjusting an indexed extent of angular rotation of the rotatable member with respect to the base.

11. The punch guide of claim 1, wherein the adjustable indexing assembly is operable to adjust the indexed extent of angular rotation of the rotatable member without substantial movement of the rotatable member.

12. The punch guide of claim 10, further comprising first alignment indicia provided on at least one of the base and the punch carriage for identifying a selected distance between the center portion and the punch carriage.

13. The punch guide of claim 12, further comprising second alignment indicia provided on at least one of the base and the adjustable indexing assembly, the second alignment indicia corresponding to the first alignment indicia for setting the adjustable indexing assembly to provide a selected indexed extent of angular rotation that corresponds to the selected distance between the center portion and the punch carriage.

14. The punch guide of claim 10, wherein the punch carriage is detently slidable along the base for selective adjustment between a plurality of detent locations along the base.

15. The punch guide of claim 10, wherein the rotatable member is detently rotatably coupled to the base for detent rotation between a plurality of detent rotational positions, each detent rotational position separated by an angle A that corresponds to the selected indexed extent of angular rotation.

16. The punch guide of claim 15, wherein the adjustable indexing assembly is adjustable to change the angle A between each detent rotational position of the rotatable member.

17. The punch guide of claim 10, wherein the adjustable indexing assembly includes an adjustment arm moveably coupled to the base and engaging the rotatable member, and wherein movement of the arm adjusts the indexed extent of angular rotation of the rotatable member with respect to the base.

18. A punch guide for guiding the application of a punch to a work piece, the punch guide comprising:

a base including a center portion and an arm extending away from the center portion, the arm defining a channel;

a rotatable member detently rotatably coupled to the base for detent rotation about a rotational axis, the rotatable member being detently rotatable between a plurality of detent rotational positions, and adjacent detent rotational positions being separated from one another by an angle (A);

a punch carriage received by and detently slidable along the channel for selective adjustment between a plurality of detent locations along the arm; a coupling member for coupling the work piece to the rotatable member for rotation with the rotatable member; and,

an adjustable indexing assembly engaging the rotatable member and including a moveable member that is moveable to change the angle (A) between the each detent rotational position of the rotatable member.

19. The punch guide of claim 18, wherein the punch carriage includes at least a portion of the punch.

20. The punch guide of claim 18, wherein the moveable member is pivotably coupled to the base and engages an underside of the rotational member.

21. The punch guide of claim 20, wherein the underside of the rotational member includes a plurality of substantially concentrically arranged rings of detent recesses, each detent recess corresponding to one of the detent rotational positions of the rotatable member.

22. The punch guide of claim 18, further comprising first alignment indicia provided on at least one of the arm and the punch carriage for identifying a selected detent location of the punch carriage along the arm.

23. The punch guide of claim 22, further comprising second alignment indicia provided on at least one of the center portion and the moveable member, the second alignment indicia corresponding to the first alignment indicia for setting the moveable member in a location that adjusts the angle A to a value that corresponds to the selected detent location of the punch carriage along the arm.

24. A method for punching a curved pattern in a work piece, the method comprising:

providing a punch guide, wherein the punch guide is operable by:

coupling the work piece to a rotatable member that rotates about a rotational axis between a plurality of indexed rotational positions, the indexed rotational positions separated from one another by an adjustable angle (A);

adjusting a distance between a punch carriage and the rotational axis; setting an adjustable indexing assembly to adjust the angle A to correspond to the distance between the punch carriage and the center axis;

punching the work piece a first time to form a first opening in the work piece; rotating the rotatable member from one indexed rotational position to a next indexed rotational position, thereby rotating the rotatable member and the work piece by the angle (A); and,

punching the work piece a second time to form a second opening in the work piece, wherein the second opening at least partially overlaps with the first opening.

25. The method of claim 24, wherein adjusting the distance between the punch carriage and the center axis includes sliding the punch carriage along a channel formed in a base that is rotatably coupled with the rotatable member.

26. The method of claim 24, wherein adjusting the distance between the punch and the carriage includes aligning first alignment indicia provided on the punch carriage and a base that is rotatably coupled with the rotatable member.

27. The method of claim 26, wherein setting the adjustable indexing assembly includes aligning second alignment indicia provided on a moveable member of the adjustable indexing assembly and the base.