FIELD OF THE INVENTION

The present invention generally relates to a tool for folding paper as a grouped operation either by hand or using pneumatic, hydraulic, or with similarly actuated devices. More particularly, the present invention relates to an apparatus and method for folding paper stock into basic shapes for assembling paper-based toys and the like.

BACKGROUND OF THE INVENTION

There is a perceived need in the art for reducing manufacturing costs in connection with the manufacture of toys and the like as such articles have become more disposable for certain applications. One way to provide a low-cost article of manufacture is to construct the article from cheaper materials as exemplified by paper and similar other stock material. To enhance the formation of toy-like articles from paper, there is a further perceived need in the art for an apparatus and method for quickly and efficiently folding stock material into certain shapes to support the assembly of the articles of manufacture. The present invention has been developed in an effort to address these perceived needs in the state-of-the-art.

SUMMARY OF THE INVENTION

The present invention provides an apparatus or tool for folding a pre-formed paper blanks or similar other sheet or stock material as a grouped operation either by hand or more preferably using pneumatic, hydraulic, or similarly actuated devices. The finally folded paper or sheet article may then be further processed for forming a final article of manufacture as exemplified by a toy. The apparatus according to the present invention quickly and efficiently provides the final folding operation as applied to the planar pre-formed paper blank for reducing the time and expense required for toy manufacture as derived from pre-formed paper-based or similar other stock material sheets.

There are two primary processing objectives of the paper-sheet folding tool or apparatus according to the present invention. A first processing objective is to pre-fold or bias the paper sheet by having peripheral portions of a paper sheet stand roughly 90 degrees relative to a central sheet portion by way of a first step according to the apparatus or tool. A second processing objective is to finally fold linear targeted fold segments 180 degrees, which targeted fold segments extend intermediate the central sheet portion and the peripheral portions of the preformed sheet article. Final folding actions are preferably performed in a group operation in that a series of final folds are performed simultaneously.

BRIEF DESCRIPTIONS OF THE DRAWINGS

Other features of the invention will become more evident from a consideration of the following brief descriptions of the illustrations submitted in support of the subject invention:

FIG. 1A is a first sequential diagrammatic cross-sectional view of an upper male press element and a lower female press element with a planar paper sheet extending therebetween before the paper sheet is folded by the upper male press element and the lower female press element. FIG. IB is a second sequential diagrammatic cross-sectional view of the upper male press element and the lower female press element pre-folding the paper sheet extending therebetween.

FIG. 2A is a third sequential diagrammatic cross-sectional view of upper linear actuable press elements opposite a lower press formation with the pre-folded paper sheet from FIG. IB extending therebetween.

FIG. 2B is a fourth sequential diagrammatic cross-sectional view of the upper linear actuable final fold press elements being linearly actuated into the pre-folded paper sheet as supported by the lower press formation for finally folding the paper sheet.

FIG. 3 is a top view of a pre-folded paper sheet showing radiating peripheral portions extending outwardly from a central sheet portion with target fold sections therebetween.

FIG. 4 is a top perspective view of the pre-folded paper sheet being partially finally folded by a linearly actuated final fold element.

FIG. 5 is a first sequential top perspective view of a paper sheet-folding apparatus according to the present invention showing an upper press element in exploded relation relative to a lower press apparatus.

FIG. 6 is a second sequential top perspective view of the paper sheet-folding apparatus according to the present invention otherwise shown in FIG. 5 showing a paper sheet supported by the lower press apparatus with the upper press element in exploded relation relative to the paper sheet and lower press apparatus. FIG. 7 is a top perspective view of an upper press element in exploded relation relative to a lower press apparatus with upper support platform removed to show otherwise hidden final fold elements of the lower press apparatus.

FIG. 8 is a third sequential top perspective view of the paper sheet-folding apparatus according to the present invention showing the paper sheet supported by the lower press apparatus with the upper press element being directed into the paper sheet.

FIG. 9 is a fourth sequential top perspective view of the paper sheet-folding apparatus according to the present invention showing the paper sheet being pre-folded by the upper press element and the lower press apparatus.

FIG. 10 is a top perspective view of the paper sheet-folding apparatus according to the present invention with upper support platform of the lower press apparatus removed to show otherwise hidden structural relationship of the paper sheet as pre-folded by the upper press element and position thereof relative to the final fold elements of the lower press apparatus.

FIG. 11 is a top perspective view of the lower press apparatus with upper support platform removed to show otherwise hidden structural relationship of the paper sheet as prefolded by the upper press element and position thereof relative to the final fold elements of the lower press apparatus.

FIG. 12 is a top perspective view of the lower press apparatus with upper support platform removed to show otherwise hidden structural relationship of the pre-folded paper sheet being finally folded by the final fold elements of the lower press apparatus.

FIG. 13 is a top perspective view of the finally folded paper sheet removed from the paper sheet-folding apparatus according to the present invention, and showing radiating peripheral portions of the finally folded paper sheet in a resiliently relaxed state extending obliquely relative to a planar central sheet portion.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Comparatively referencing Figure Nos. 1A and IB, the reader will there consider a first set of diagrammatic drawings illustrating the first processing objective. A paper sheet blank as at 10 is positioned intermediate a diagrammatic upper press element as at 11 and a diagrammatic lower press element as at 12. The upper press element 11 is directed as at arrow 100 into the paper sheet blank 10 thereby forcing the paper sheet blank 10 into the lower press element 12 for biasing or pre-folding the planar paper sheet blank 10 such that outer peripheral portions 13 thereof become angled roughly 90 degrees relative to the plane of a central sheet portion 14 of the paper sheet blank 10.

Comparatively referencing Figure Nos. 2A and 2B, the reader will there consider a second set of diagrammatic drawings illustrating the second processing objective. Separate linearly actuated final fold elements as at 15 are directed as at arrow 101 into the peripheral portions 13 for finally folding the peripheral portions 13 along targeted fold segments 16. The final fold is preferably on the order of 180 degrees. The targeted fold segments 16 in Figure Nos. 2A and 2B extend into the page intermediate the central sheet portion 14 and the peripheral portions 13 of the pre-formed sheet article or paper sheet blank 10. A support platform 17 supports the planar central sheet portion 14 during the final fold operation. Comparatively referencing the illustrative matter made the subject of Figure Nos. 3 and

4, the reader will there consider the pre-formed paper sheet having a central sheet portion as at 14, outwardly radiating peripheral portions as at 13, and targeted fold segments as at 16. The final fold action is demonstrated in Figure No. 4 with the target fold segments 16 being finally folded using hand-driven final fold elements 15 atop a support platform 17.

The final fold mechanism, demonstrated as hand-driven final fold elements 15 in Figure No. 4, may preferably be attached to a pneumatic press for actuation, for semi automation, or for full automation. This tool, or a series of individual tools or final fold elements 15, may be attached to a pneumatic press to effect each final fold of the target fold segment(s) 16. It is contemplated that the final fold elements 15 may alternatively be actuated hydraulically or by way of spring-loaded device. An example of an exemplary spring-loaded device is generally illustrated in Figure Nos. 5 - 12.

Comparatively referencing Figure Nos. 5 and 6, the reader will there consider a preformed paper sheet blank 10 as inserted between an upper press element 18 and a lower press apparatus 19 and supported by an upper support platform 20 of the lower press apparatus 19. Under the upper support platform 20 of the lower press apparatus 19 are a series of linearly actuable final fold elements 21, each of which are linearly actuable parts for effecting each fold of the series of target fold segments 16. As prefaced above, the final fold elements 21 may be actuated by a spring, hydraulic press, pneumatic press, geared lever, etc. Figure No. 7 depicts the final fold elements 21 as configured for spring driven linear actuation. The upper support platform 20 has been removed in Figure No. 7 for ease of understanding.

Comparatively referencing Figure Nos. 5, 6, 8 and 9, the reader will there consider the first interaction of directing the upper press element 18 with a press plate 22 into a plate- receiving aperture 34 formed in the upper support platform 20 of the lower press apparatus 19.

The directed movement of the press plate 22 into the plate-receiving aperture 34 preferably folds each radiating peripheral portion or flap 13 roughly 90 degrees at the target fold segments 16. Figure No. 10 is presented with the upper support platform 20 removed to depict the pre-fold or 90-degree fold action by the press plate 22.

Comparatively referencing Figure Nos. 11 and 12, the reader will see that the upper press element 18 and press plate 22 have been removed from the lower press apparatus 19. With the upper support platform 20 removed for ease of understanding, the reader will there consider the linearly actuated final fold elements 21. Figure No. 11 depicts the 90-degree pre-fold of the paper sheet moments before the linearly actuated final fold elements 21 complete the 180-degree final fold. Figure No. 12 depicts the linearly actuated final fold elements 21 finally folding over the radiating peripheral portions 13 at the target fold segments 16. Accordingly, Figure No. 12 shows peripheral portions 13 of the paper sheet blank 10 folded over 180 degrees (fully folded) inside the lower press apparatus 19 of the paper sheet- folding apparatus according to the present invention.

Figure No. 13 depicts the finally folded paper sheet blank 10 as finally folded by way of the paper sheet- folding apparatus according to the present invention. The peripheral portions 13 of the paper sheet blank 10, having an inherent material resiliency, return to a relaxed oblique configuration relative to the planar central portion 14 when disengaged from the paper sheetfolding apparatus. The reader will note that the apparatus according to the present invention is not limited in the number of folds that can be performed. Further, several of the apparatuses can be simultaneously implemented for further enhancing efficiency of the folding operations. Once the pre-formed paper sheet(s) 10 are finally folded and sitting in the folded position as generally depicted in Figure No. 13, the finally folded paper sheet (i.e. a pre-formed paperbased toy) may preferably be nested with subsequently finally folded paper sheets and thus made ready for subsequent operations. An example of such an operation is adhesively fastening the tabs or radiating portions simultaneously using a serial glue process. As prefaced above, the primary objective of the present invention is to significantly increase efficiency in folding preformed paper sheets for the purpose of finally forming or assembling paper-based toys from the finally folded paper sheets.

It will be understood the paper sheet-folding apparatus 30 according to the present invention basically operates to fold peripheral portions 13 of a paper sheet 10 or similar other stock material. The peripheral portions 13 of the paper sheet 10 preferably comprise target fold segments as at 16 serially arranged in side-by-side relation to one another with radiating portions extending outwardly from the target fold segments 16 opposite a planar central sheet portion as at 14.

The paper sheet-folding apparatus 30 according to the present invention preferably comprises an upper press element as at 18 and a lower press apparatus as at 19. The upper press element 18 preferably comprises a press plate as at 22, which press plate 22 preferably comprises an outer plate periphery 31 comprising a series of pre-fold plate sections as at 32. The lower press apparatus 19 preferably comprises an upper support platform as at 20, a lower support platform as at 33, and a series of final fold elements as at 21. The series of final fold elements 21 are movable intermediate the upper and lower support platforms 20 and 33. The upper support 20 platform preferably comprises a plate-receiving aperture as at 34. The plate-receiving aperture 34 preferably comprises a series of pre-fold aperture sections as at 23. The paper sheet 10 is supported by the upper support platform 20 such that the target fold segments 16 are aligned with the pre-fold plate aperture sections 23. The press plate 22 of the upper press element 18 is directed into the lower press apparatus 19 thereby directing the paper sheet 10 into the plate-receiving aperture 34. The target fold segments 16 are pre-folded thereby such that the radiating peripheral portions 13 extend obliquely relative to the planar central sheet portion 14. The series of final fold elements 21 are each preferably linearly actuable to and from the target fold segments 16 and comprise a forward fold edge as at 35. The final fold elements 21 are linearly actuated for finally folding the radiating peripheral portions 13 at the target fold segments 16 by way of the forward fold edges 35.

Certain other features of the paper sheet-folding apparatus 30 according to the present invention are briefly discussed hereinafter. The series of final fold elements 21 of the paper sheet-folding apparatus 30 according to the present invention are preferably linearly actuable by way of a spring, a hydraulic press, a pneumatic press or a geared lever (not specifically illustrated). Comparatively referencing Figure Nos. 11 and 12 the reader will note the relative linear displacements of the final fold elements 21 for finally folding the radiating peripheral portions 13 at the target fold segments 16 by way of the forward fold edges 35. The forward fold edges 35 are preferably linear in form for enhancing the folding action of the target fold segments 16. The series of final fold elements 21 further preferably each comprise a planar surface as at 40 that extends obliquely relative to the forward fold edge 35.

The upper press element 18 further preferably comprises an alignment plate edge as at 36 and the plate-receiving aperture 34 of the upper support platform 20 preferably comprises an alignment aperture edge as at 37. Further, the lower press apparatus 19 preferably comprises a sheet alignment element as at 38. The alignment plate edge 36 and the alignment aperture edge 37 preferably align with a paper sheet alignment edge as at 39. The sheet alignment element 38 functions to engage the paper sheet alignment edge 39 in alignment therewith during folding actions. The press plate 22 and the central sheet portion 14 are preferably planar in formation. The planar press plate 22 fully contacts the planar central sheet portion 14 for enhancing prefolding actions.

The series of pre-fold plate sections 32 preferably define a press plate polygon. The series of pre-fold aperture sections 23 are preferably and respectively parallel to the series of prefold plate sections 32. The target fold segments are preferably pre-folded 90 degrees when the paper sheet 10 is directed into the plate-receiving aperture 34 such that the radiating peripheral portions 13 extending orthogonally relative to the planar central sheet portion 14 before being finally folded by the series of final fold elements 21.

The final fold elements 21 are linearly actuated for finally folding the radiating peripheral portions 13 at the target fold segments 16 substantially 180 degrees by way of the forward fold edges 35. The forward fold edges 35 of the final fold elements 21 each preferably comprise laterally opposed termini as at 41. The laterally opposed termini 41 of adjacent final fold elements 21 engage one another during final fold actions thereby forming an elemental polygon in cooperation with the sheet alignment element 38 as generally depicted in Figure No. 12.

Viewed from a methodological perspective, the present invention provides a paper sheetfolding method for folding the peripheral portions 13 of a paper sheet 10. The paper sheetfolding method may be said to preferably comprises the initial step of forming radiating peripheral portions 13 at a periphery of the paper sheet 10. The radiating peripheral portions 13 preferably extend outwardly from target fold segments 16 opposite a (planar) central sheet portion as at 14. The target fold segments 16 are preferably serially arranged in side-by-side relation to one another.

The paper sheet 10 may then be positioned at a paper-sheet folding apparatus 30 according to the present invention as described in detail hereinabove. The paper-sheet folding apparatus 30 preferably comprises an upper press element as at 18 and a lower press apparatus as at 19. The upper press element 18 preferably comprises a press plate 22, which press plate 22 comprises an outer plate periphery comprising a series of pre-fold plate sections as at 32. The lower press apparatus 19 comprises an upper support platform 20, a lower support platform 33, and a series of final fold elements 21 movable intermediate the upper and lower support platforms 20 and 33. The upper support platform 20 comprises a plate -receiving aperture as at 34 having a series of pre-fold aperture sections 23.

The paper sheet 10 may then be supported by the upper support platform 20 such that the target fold segments 16 are aligned with the pre-fold plate and aperture sections 32 and 23. The press plate 22 may then be directed into the lower press apparatus 19 thereby further directing the paper sheet 10 into the plate-receiving aperture 34 such that the target fold segments 16 are pre-folded thereby with the radiating peripheral portions extending obliquely relative to the (planar) central sheet portion. The series of final fold elements 21 may then be linearly actuated for finally folding the radiating peripheral portions 13 at the target fold segments 16 by way of forward fold edges 35 of each final fold element 21.

While the invention has been disclosed with reference to certain preferred and alternative embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the invention, as defined in the appended claims and their equivalents. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the claims appended to these specifications.