3D Cutting Punch for Low-Force Packaging Corner Cutting
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Solution Overview
Problem
The production of punching tools for packaging corners is costly due to high manufacturing precision requirements, and the operation of these tools necessitates high punching forces, leading to increased energy consumption and significant waste material generation.
Innovation Solution
A cutting device with a cutting punch featuring a three-dimensional cutting edge that progressively cuts through the film web with increasing depth, reducing cutting forces and eliminating the need for complex designs or narrow-tolerance recesses, allowing for efficient cutting of round packaging corners with reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional punching tools with two-dimensional cutting contours are used, then complete foil sections can be punched out, but extremely high punching forces are required and manufacturing costs are high
Solution Approach 1:
The patent transitions from traditional two-dimensional cutting contours to a three-dimensional cutting contour that extends in the longitudinal direction of the cutting punch. This dimensional change allows the cutting edge to progressively cut through the film web along a curved path, reducing the peak punching force required while simplifying manufacturing requirements.
Solution Approach 2:
The cutting process becomes dynamic as the cutting edge progressively advances through the film web along a three-dimensional contour. The cutting depth increases continuously during the punching stroke, transforming the static two-dimensional cut into a dynamic three-dimensional cutting path that reduces force requirements.
2Use of energy by moving object
If traditional punching tools are used, then packaging corners can be rounded, but energy consumption increases significantly
Solution Approach 1:
The three-dimensional cutting contour extends the cutting path in the longitudinal direction, allowing the cutting edge to progressively remove material along a curved trajectory. This reduces the peak force required at any moment while maintaining high cutting speeds, thereby lowering energy consumption without sacrificing productivity.
Solution Approach 2:
The cutting edge begins cutting from the surface of the film web and progressively advances deeper into the material along the three-dimensional contour. This preliminary action of gradually engaging the material reduces the sudden force and energy requirements compared to traditional punching that engages the entire cutting contour simultaneously.
3Loss of substance
If traditional punching tools are used, then foil sections can be cut out, but significant waste material in the form of residual skeleton is generated
Solution Approach 1:
The three-dimensional cutting contour with its longitudinal extension allows the cutting edge to progressively separate the desired foil section from the residual skeleton in a controlled manner. This reduces the interlocking and folding of residual material, minimizing waste volume and simplifying disposal despite the increased geometric complexity of the cutting tool.
4Manufacturing precision
If traditional two-dimensional cutting edges are used, then punching can be performed, but complex recess designs with narrow tolerances are required
Solution Approach 1:
By extending the cutting contour into the longitudinal dimension, the patent creates a three-dimensional cutting edge that progresses through the material along a curved path. This reduces the requirement for extremely precise two-dimensional recess geometries with narrow tolerances, as the longitudinal progression allows for more gradual material removal and less sensitive positioning requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables high-speed cutting with lower energy consumption, reduces manufacturing costs, and minimizes waste by allowing complete film cutouts without folding, resulting in improved productivity and handling of residual film.
Implementation Method 1
The cutting edge according to the invention cuts through the film web further and further with increasing penetration depth (i.e., advancing in the cutting or film plane) until the film cut is complete. The cutting edge can be pulled through the film web using comparatively low cutting forces.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a cutting device (15) designed for cutting substantially round packaging corners from a film web (F), wherein the cutting device (15) comprises at least one cutting tool (16) that includes a cutting punch (18, 18') having at least one concavity (30) on its outer surface, which is provided for forming a cutting edge (25) of the cutting punch (18, 18'). According to the invention, the cutting edge (25) has a cutting contour (26, 26') extending both transversely and longitudinally along the cutting punch (18, 18'). The invention further relates to a method for manufacturing a cutting punch (18).