DIE CUT DEVICE AND METHOD FOR SHEARING WITH SAME

CROSS REFERENCE TO RELATED PATENT

[0001]This application claims the benefit of U.S. Provisional Patent Application Serial No. 63/746,097, filed January 16, 2025, the entire disclosure of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

FIELD OF THE INVENTION

[0002] This disclosure is related to the field of construction, and more particularly shearing studs and tracks.

DESCRIPTION OF RELATED ART

[0003] Metal studs are versatile fasteners and structural components used in construction, often in commercial or industrial buildings. They are typically made from materials like steel, stainless steel, or aluminum. Metal studs are designed to provide strength and stability and provide great durability as well at fire resistance. They are used in light-gauge steel framing to build non-load- bearing walls, ceilings, and partitions. Studs are vertical framing components that support the weight of structures, such as the weight of a roof, ceiling, or an upper-level floor. Studs provide anchor points for attaching drywall, insulation, wiring, and other finishing materials. In conjunction with tracks and other components, studs form the skeleton or framework for walls and ceilings. Tracks, the horizontal components, are framing members that work in conjunction with studs to form a stable structure. Tracks are used as guides or channels in which the studs are inserted, helping to maintain alignment and stability. Together, studs and tracks are essential in steel framing, drywall installation, and partition construction, providing strength, stability, and proper alignment for construction projects.

[0004]The process of cutting studs and tracks currently involves using a saw, such as a hacksaw, a power miter saw, or a reciprocating saw. However, cutting metal studs and tracks with a saw produces considerable airborne debris and sharp edges. Other methods include manual metal shears which are made for very small scale, lightweight tasks. Punch presses are often used on an industrial scale. However, punch presses can be incredibly expensive and may result in material wastage. Steel and other metal alloys can be difficult to cut through. Burrs from saws can cause injury or difficulty in any further handling and installation. A deburring tool or file is necessary to grind off the burrs and smooth the edges after the cut. Cutting metal studs and tracks also generates substantial heat and can produce sparks, creating a potential fire hazard. In addition, producing a clean, accurate edge cut can be difficult with a manual saw and resulting burrs, which can lead to misalignment in installation as well as a waste of time, money, and materials. The powerful vibration of the power tools can also make it difficult to make a straight, accurate cut, and the stud or track has to be clamped to minimize movement.

[0005]This system, though simple in concept, can be challenging, time-consuming, and expensive. Shearing with a steel block and a battery-powered hydraulic press tool removes the difficulty in obtaining a straight, clean edge and the mess of burrs, while also conserving materials and reducing costs associated with expensive punch presses. The clean, straight edges are important in track systems where the fit and alignment need to be precise for smooth operation, such as in rail or conveyor systems. Shearing is a much faster process than sawing. This is because shearing uses a high amount of pressure to slice through the material in one smooth action, allowing it to cut multiple pieces in a short amount of time. It's especially efficient for cutting large sheets or long lengths of material, such as metal tracks. This increased speed is ideal for industrial applications where large volumes of material need to be processed quickly and efficiently, reducing downtime and increasing overall productivity. Shearing force is a force that causes part of a material to move in a direction parallel to the surface, resulting is a breaking of the material. The hydraulic press die cut assembly is more versatile, precise, and capable of handling higher forces, especially when dealing with thick, hard materials, complex shapes, or delicate operations, when compared to a punch press.

SUMMARY OF THE INVENTION

[0006] The following is a summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not intended to identify key or critical elements of the invention or delineate the scope of the invention. The sole purpose of this section is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.

[0007]Because of these and other problems in the art, described herein, is a die cut system and a method for shearing with the die cut system. At a high level of generality, the die cut system utilizes a press tool in conjunction with the die cut assembly system to shear studs and tracks, or any other rigid material in an efficient manner while occupying minimal space. These and other aspects of the die cut system are described in further detail herein.

[0008]The present invention provides a portable die cut shearing system and method for efficiently cutting rigid materials, such as metal studs, tracks, and similar construction components. The system is designed to produce clean cuts substantially free of burrs, sparks, and debris, while improving cutting speed, accuracy, and safety compared to conventional sawing and punch press methods.

[0009] In one embodiment, the system comprises a die cut shearing assembly coupled to a powered press tool configured to generate a shearing force. The press tool may be battery-operated, hydraulic, pneumatic, or otherwise powered, and is operable to selectively translate a movable shear die relative to a fixed shear die. The fixed shear die defines at least one aperture configured to receive a rigid material, while the movable shear die is aligned with the fixed die to sever the material. A return mechanism, such as a spring or biasing element, restores the movable die to a resting position after each shearing operation.

[0010]The die cut shearing assembly may be removably attached to the press tool using an attaching system such as pins, cams, clamps, or fasteners, providing a direct linear transfer of force from the press tool to the movable shear die. The fixed and movable dies may define apertures shaped to receive specific material geometries, including studs or tracks, and may include U- shaped or other shaped apertures with substantially ninety-degree corners or apertures disposed at an acute angle relative to the longitudinal axis of the fixed die.

[0011]In some embodiments, the system further comprises a frame enclosing the fixed and movable dies, with deployable support elements such as front and rear kickstands to support the system on a work surface. The method of using the system includes inserting a rigid material into the die aperture, activating the press tool to move the movable die to shear the material, and returning the movable die to its resting position. The shearing step may be performed using hydraulic or pneumatic force and produces a clean cut edge on the rigid material. The system and method are compact, adaptable to power-limited job sites, and suitable for a variety of material types and thicknesses.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 depicts an assembled embodiment of the disclosed die cut system connected to the battery-powered hydraulic press tool.

[0013]FIG. 2 depicts an exploded diagram that depicts an embodiment of the disclosed die cut system.

[0014]FIG. 3 depicts the die cut system in resting position before the shearing cycle.

[0015]FIG. 4 depicts a shearing process using the die cut of the present disclosure at the end of the shearing cycle.

DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0016]FIG. 1 depicts an exemplary embodiment of the systems and methods described herein. In the depicted embodiment, a die cut shearing system (101) is shown, comprised of a power tool (105) and an attached die cut shearing assembly (103). The depicted die cut shearing assembly (103) comprises an attaching system (109), a frame (111), and a shearing system (113). In the depicted embodiment of FIG. 1, a metal stud (107) is shown disposed in the shearing system (113). These and other elements are further described elsewhere herein.

[0017]In the depicted embodiment of FIG. 1, the power tool (105) is a hydraulic press tool (105). The depicted tool (105) is a battery-operated, handheld tool. The purpose of the tool (105) in the system is to apply high-pressure force. The hydraulic press tool (105) is based on Pascal's Principle, which states that pressure applied to a confined fluid is transmitted equally in all directions. The tool (105) consists of several key components that work together to apply significant force with relatively small input effort. The heart of the hydraulic press tool (105) is a hydraulic cylinder consisting of a large, sealed tube, containing a piston. Hydraulic fluid is pumped into the cylinder, where it applies pressure to the piston. The fluid can be pressurized by a pump, which is connected to the hydraulic system. The particular characteristics of the selected hydraulic fluid, such as viscosity and stability, are important to ensure smooth operation and longevity of the press tool (105). The hydraulic pump is the power source that moves the hydraulic fluid. It is driven either by an electric motor or a manual handle, depending on the particular press design. The pump forces the fluid through the pipes into the hydraulic cylinder, where it pushes the piston to create the force needed for compression. In order to control the amount of pressure exerted, a pressure relief valve is typically included in the hydraulic press tool (105). This valve prevents the pressure from exceeding a safe limit, protecting both the machine and the operator. It releases excess fluid back into the reservoir when pressure reaches a certain threshold. A reservoir stores the hydraulic fluid before it enters the pump. It is generally equipped with filters to keep contaminants out of the fluid. The size of the reservoir determines how much fluid can be used in a system and supports the press's overall capacity. A control valve regulates the flow of hydraulic fluid, directing it to the appropriate side of the piston. A frame provides structural support for the press. The frame is typically made from a robust steel or other high strength material to withstand high amounts of force applied during operation. A ram or platen applies force to the material being compressed. The ram moves in response to the action of the hydraulic cylinder. Depending on the type of the hydraulic press, the ram can be flat, or shaped. Hydraulic press tools (105) can be manually operated or automatically operated. In manual operation, the hydraulic press tool relies on direct, hands-on control by an operator. This type of operation is typically simpler and requires more human interaction throughout the process. In automatic operation, the hydraulic press tool is controlled by a programmable system or automated mechanism that requires little to no human intervention after the setup. This method is typically used for mass production or continuous operations where consistency and efficiency are critical. Hydraulic press tools (105) come in different types, such as C-frame hydraulic presses, H-frame hydraulic presses, and four-post hydraulic presses. C-frame hydraulic presses have a C-shaped frame, which allows for easy access to the workpiece. H-frame presses have an H-shaped frame for heavy duty applications. Four-post presses have four posts to allow uniform pressure across the entire workpiece. Another battery powered tool (105) that can be used is a pneumatic press. A pneumatic press is a mechanical press that uses compressed air, rather than hydraulic fluid, to generate a pushing or compressive force. Pneumatic presses contain an air compressor, an air tank, pneumatic cylinders, and a frame. Although a handheld, battery-operated tool (105) is shown, in an alternative embodiment, the power tool may be a different type of tool, such as a floor-mounted tool, or it may be powered via a conventional wall receptacle.

[0018] In the depicted embodiment of FIG. 1, the power tool (105) is attached to the die cut shearing assembly (103) via an attaching system (109). The attaching system (109) is depicted in FIG. 1 as a pin engagement, but in other embodiment it could be another attaching system such as cams, clamps, or other fasteners. In a pin attachment system, the pin is inserted through holes in the both the power tool (105) and then die cut shearing assembly (103). The pin prevents any movement, rotation, or shifting of the tooling during operation, especially when the hydraulic press tool (105) applies force to the die cut shearing assembly (103). There are several different types of fastening pins that can be utilized. By way of example and not limitation, clevis pins can be utilized and are secured with a cotter pin, snap ring, or another retaining clip. Tapered pins are self-locking because of their tapered design. Once fully inserted, they create a tight interference fit, so no additional securing mechanism is needed. Roll pins are spring-loaded and expand when inserted into the hole, gripping the sides of the hole securely. No additional fasteners are required, but a punch or tool may be used to tap the pin fully into place. Alignment pins are used alongside other fastening pins, such as clevis or tapered pins, to ensure precise positioning of the attachment on the press with the main purpose of maintaining alignment rather than providing a secure locking mechanism. In an embodiment, the pin attaching mechanism (109) provides a linear push along a straight path to advance the moving shear die (120). A direct drive mechanism (109) is thus employed to transfer rotational force from the hydraulic press tool (105) to the die cut shearing assembly (103), enabling efficient and precise cutting action without the need for intermediate mechanical linkages.

[0019] In an alternative embodiment, cams, rather than pins, act as the attaching system (109) to connect the hydraulic battery-powered tool (105) to the die cut shearing assembly (103). The hydraulic battery-powered press tool (105), once triggered, engages and rotates a set of cams fastened to the tool around a central axis. These rotating cams transmit force onto a hydraulic press tool interface (116), which in turn moves the moving die surround (119) and moving shear die (120), shearing through the fed rigid material (107). The profile of the cams dictates how force is transmitted-whether gradually, suddenly, or in a complex pattern-by altering the speed and distance the follower moves. The hydraulic battery-powered tool (105) moves in response to the cams' motion, with the force being transmitted directly through the contact between the cam and hydraulic battery-powered tool (105).

[0020] As can be seen in FIG. 1, the depicted die cut shearing assembly (103) has a first axis and a second axis, the first axis being a major, lengthwise axis perpendicular to the second axis, a vertical, minor axis. When the depicted die cut shearing assembly (103) is connected to the tool (105), the major axis is generally parallel to the direction of force applied by the tool. Aligning the major axis of the tool (105) parallel to the direction of force applied to it is beneficial for several reasons, primarily related to efficiency, stability, and material performance. This alignment optimizes load distribution by allowing the strongest part of the structure to be subject to the applied force as well as less localized stress due to an even force distribution. If the major axis were perpendicular to the applied force, some regions of the material might experience more intense stress, leading to uneven wear on the tool or even potential failure. Parallel alignment also reduces the risk of deformation or buckling. In contrast, however, if the major axis was aligned perpendicularly to the applied force, the tool is more likely to bend or buckle under compression, especially longer and slender structures. Parallel alignment minimizes material fatigue and helps withstand repeated cycles without premature degradation. Additionally, parallel orientation, as opposed to perpendicular orientation, provides for more improved stability resulting in more accurate and controllable results.

[0021]In the depicted embodiment of FIG. 1, the die cut shearing assembly (103) comprises a framing element (111) enclosing and surrounding a shearing system (113). These elements and their assembly within the shearing system (113) are shown in further detail in FIG. 2. The framing element (111) is supported with a front kickstand (102) and a rear kickstand (104). The front kickstand (102) and rear kickstand (104) are meant to support the die cut shearing assembly (103) to remain stably propped up and are retractable. The front kickstand (102) and rear kickstand (104) can be deployed or folded quickly and easily. Between the encasing framing element (111) is a fixed die holder plate (106) that is similarly shaped to the framing element (111), made to completely frame the shape of the fixed shear die (110). The fixed die holder plate (106) is fastened to a fixed die surround (103), which has two triangular-shaped pieces on one side to connect to the battery-powered tool (105) through the fastening system (109). The fixed die holder plate (106) surrounds the fixed shear die (110) which is a mostly solid rectangle with two apertures (118) at its center, shaped similarly but slightly larger than the metal stud (107) to be sheared. The fixed die surround (108) is fastened with a small tool guide (112) directly between said triangular-shaped pieces on the fixed die surround (108). The tool guide fits within a notch in the top body plate (114), which frames the fixed shear die (110) and is a paddle-shaped plate with a rectangular opening. The fixed shear die (110) has two apertures (118): one generally U-shaped with generally 900 angle and another in a U-shaped with serifs parallel to the base line, also having generally 90° angles. The apertures (118) are disposed at approximately a 450 angle within the shear die (110). The apertures (118) are just slightly larger than the size of the studs or tracks (107) needing to be sheared, just large enough to allow the material to slide in the aperture and provide for minimal movement of the stud or track within the die. The shear die (110) and tool guide (112) are fastened to the top body plate (114) with a hydraulic press tool interface block (116). The hydraulic press tool interface block (116) is a rectangular steel block encased by two triangular pieces on either side, making up the interface block guide (121) that interfaces the battery-powered tool (105) and when pressure is applied, moves the moving shear die (120). The moving shear die (120) presses into a spring return plate (115), a long, skinny rectangular piece with several return springs (117). The return springs (117) compress and move the moving shear die (120) during the shearing process and return the moving shear die (120) to resting position when the shearing process is complete. A moving die surround (119) frames the moving shear die (120) and contains a handle attached to its top side in order to easily move and carry the die cut shearing assembly (103). The next layer fastened to the system is an interface block guide (121), consisting of two rounded triangular pieces on the side of the system, and a moving shear die (120), placed in the center of the system. The moving shear die (120) is a mostly rectangular piece containing the same aperture shapes as the fixed shear die (110). The hydraulic battery-powered tool (105) engages with a steel hydraulic press tool interface block (121) that acts as the shearing medium within the die cut assembly (103) when the shearing force is transferred from the hydraulic ram to the steel hydraulic press tool interface block (116).

[0022]FIGS. 3 and 4 depict a mode of operation of the system (101). FIG. 3. depicts the system (101) in the resting position. The hydraulic press tool (105) is connected to the die cut shearing assembly (103) with an via an attaching system (109). The die cut shearing system (101) can be set up on a work bench as depicted in FIG. 1 or the front kickstand (102) and rear kickstand (104) can be deployed on a hard surface to support more mobility about the system (101) and support higher forces applied to the system. Either way, the process takes place in such a manner that it remains elevated above the ground or prevents contact with the below surface. Before a force is exerted upon the system (101), the springs (117) are extended and the fixed shear die (110) is aligned with the moving shear die (120) to allow material (107) to be inserted to desired depth. This system (101) is used in in conjunction with a pre-measured and marked metal stud or track or some other rigid material (107). The material (107) to be sheared is then inserted into the tool through the apertures (118) and pushed towards the desired marking. Once the material (107) is in the desired rotation or position to be sheared, the trigger in engaged on the battery-operated hydraulic press tool (105).

[0023]FIG. 4 depicts the system (101) during the shearing process. When the press tool (105) is activated, either manually or automatically, a force is exerted from the tool (105) to the hydraulic press tool interface (116). The force exerted pushes the hydraulic press tool interface (116), which moves the moving die surround (119) and consequently the moving shear die (120). The fixed die surround (108) and the fixed shear die (110) remain in place and motionless. The fixed shear die (110) is no longer aligned with the moving shear die (120), having sheared the material. The spring return plate (115) is pressed by the moving die surround (119) and the moving shear die (120). The spring return plate (115) compresses the return springs (117). Once the material (107) is sheared, the press tool (105) releases pressure, the springs (117) extended, converting elastic potential energy is converted into kinetic energy, and move the spring return plate (115), which in turn moves the moving die surround (119) and the moving shear die (120) as well as the hydraulic press tool interface (116) back to its resting position. The shearing force causes two adjacent parts of a material to slide or deform in opposite directions along a plane. Shearing occurs when a material is subjected to a force that acts parallel or tangential to its surface, typically between two parallel surfaces, resulting in the material being sheared. This process does not generate sparks or burrs, like other methods, and it shears the rigid material (107) with a clean edge.

[0024]The operator then removes the sheared section from the rear of the die cut shearing assembly (103) and removes the stud, track, or other rigid material (107) from the front of the die cut shearing assembly (103). The apertures (118) of the die cut shearing assembly (103) are then ready to be loaded with more material (107) and operate again in the same fashion as described herein. Each piece of the die cut system is preferably made from a material that is hard, wear resistant, and able to maintain sharp cutting edges over time. The chosen material should also be able to withstand the impact and pressure applied during the shearing process. By way of example and not limitation, some acceptable choices of material are steel, tungsten carbide, copper, aluminum, or another alloy that would provide strength and durability necessary to shear a rigid material. The tool is compact and portable with the handle fastened to the top side making it easily carried from one location to another and can easily accommodate various sizes of studs and tracks. Because the die cut assembly system is space-efficient and is a cordless operation, the die cut assembly system is incredibly versatile and ideal for use in a wide range of environments, for example in a warehouse or outside work spaces where outlets may not be readily available. The portable handle feature also allows for quicker set up and operation, which significantly reduces the required amount of time to complete a project. By cutting down on time, this assembly system could reduce overall project costs, increase efficiency and allowing time for refining and improving the quality of the work, provide a significant competitive advantage, and even increase customer satisfaction.

[0025] In an alternative embodiment, the aperture shape is modified to accommodate the shearing of a different shape and material, offering enhanced versatility compared to the original embodiment. Die cut apertures can be crafted in a variety of shapes, tailored to the specific design requirements and intended application. By way of example and not limitation, the aperture can be wider than the ones described herein. The apertures can also feature thinner, straighter lines or more curved shapes with softer, less angular transitions. Each embodiment of apertures can vary in terms of its size, angle, and edge style. In addition, custom dies can be made for unique designs or to meet particular constraints.

[0026] Throughout this disclosure, geometric terms may be used to characterize, among other things, sizes, shapes, dimensions, angles, distances, and relationships. These terms may be used with qualifiers such as "generally," "about," and "approximately." One of ordinary skill in the art will understand that, in the context of this disclosure, these terms are used to describe a recognizable attempt to conform a device or component to the qualified term. For example "mostly rectangle" is where the shape may not be a perfect rectangle by way of rounded corners or irregular edges. Variations from geometric descriptions are unavoidable due to, among other things, manufacturing tolerances resulting in shape variations, defects, imperfections, non-uniform thermal expansion, natural wear, minor variations that are nevertheless recognizable as the qualified term, and other deformations. One of ordinary skill in the art will understand how to apply geometric terms, whether or not qualified by relative terms such as "generally," "about," and "approximately," to describe a reasonable range of variations from the literal geometric term in view of these and other considerations appropriate to the context. Additionally, the use of the conjunctive and disjunctive should not necessarily be construed as limiting, and the conjunctive may include the disjunctive, and vice versa.

[0027] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.