3D Cutting Punch Contour for Low-Force Film Corner Cutting
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Solution Overview
Problem
The production of round packaging corners using existing cutting tools incurs high manufacturing costs due to high accuracy requirements, necessitates complex constructions that consume significant energy, and generates substantial waste material, including a large residual grid that is costly to dispose of, and results in increased film consumption.
Innovation Solution
A cutting device with a cutting punch featuring a three-dimensional cutting edge that extends both transversely and longitudinally, allowing for a gradual cutting process with lower forces and reduced material input, eliminating the need for close-tolerance recesses and hold-down devices, and enabling efficient cutting of film cutouts with a star-shaped contour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional punching tools with two-dimensional cutting contours are used, then complete film cutouts can be achieved, but high manufacturing costs incur due to high manufacturing accuracy requirements and complex construction
Solution Approach 1:
The patent transitions from traditional two-dimensional cutting contours to three-dimensional cutting contours that extend in the longitudinal direction of the cutting punch. This dimensional change allows the cutting edge to engage the film progressively along its length, reducing the required manufacturing precision at any single cross-section while maintaining overall cutting accuracy, thereby resolving the contradiction between manufacturing precision and device complexity
2Force
If traditional punching tools are used, then film cutting can be achieved, but extremely high punching forces result which require complex construction to absorb
Solution Approach 1:
The three-dimensional cutting contour effectively segments the cutting action along the longitudinal direction of the cutting punch. Instead of applying force across the entire cutting contour simultaneously, the force is distributed progressively as the punch advances, reducing peak forces and eliminating the need for complex force-absorbing construction
3Loss of substance
If traditional punching tools are used, then packaging corners can be punched, but considerable waste material is produced in the form of residual grid
Solution Approach 1:
The patent changes the geometric parameters of the cutting contour from two-dimensional to three-dimensional, with the cutting edge extending longitudinally and featuring curved profiles in both horizontal and vertical projection planes. This parameter change enables more efficient material utilization by allowing progressive cutting that reduces residual grid waste while maintaining high cutting speed and productivity
4Use of energy by moving object
If traditional two-dimensional cutting contours are used, then cutting can be achieved, but increased energy consumption occurs on the packaging machine
Solution Approach 1:
By extending the cutting contour into the longitudinal dimension, the cutting action is distributed over time and distance rather than occurring instantaneously. This dimensional extension reduces the power peak requirements while maintaining cutting speed, thereby lowering overall energy consumption without sacrificing productivity
Data Source
AI summary
The disclosure relates to a cutting device which is adapted for cutting substantially round packaging corners from a film web, wherein the cutting device has at least one cutting tool comprising a cutting punch which has at its outside at least one concavity provided for forming a cutting edge of the cutting punch. According to the disclosure, the cutting edge has a cutting contour extending both transversely and longitudinally along the cutting punch. The disclosure further relates to a method for manufacturing a cutting punch.