Angled Die Punching Tool for Dense Creasing Plate Patterns

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Creasing machines struggle to quickly adapt to specific patterns of creases, especially when used in digital printing environments, as existing methods for manufacturing creasing tools are time-consuming and inflexible, leading to bottlenecks in production.

Innovation Solution

A punching tool with a punch and die system, where the die has a straight recess with an outer contour angled at less than 90°, allowing for close proximity of creasing projections, and an elastic ejector to prevent damage and ensure precise folding, enabling rapid manufacturing of creasing plates for various creasing jobs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional etching processes are used to manufacture creasing tools, then the creasing tool has long lifetime and high precision, but the manufacturing time takes several hours and adaptability to new creasing jobs is poor

Engineering Contradiction:

Improveadaptability to new creasing jobsVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent replaces conventional etching processes with a punching tool system that uses mechanical deformation to create creasing projections. The punch and die system mechanically forms projections by deforming the creasing plate material, eliminating the time-consuming etching process while enabling rapid adaptation to different creasing patterns through programmable punch movements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing approach from chemical etching to mechanical punching, and introduces programmable control parameters for punch position, depth, and pattern. This allows rapid reconfiguration for different creasing jobs by changing control parameters rather than physically retooling, significantly improving adaptability while reducing manufacturing time.

Inventive Principle:

Principle #35Parameter changes

2Loss of time

If plastic material is applied to form creasing projections, then the manufacturing time is shorter, but the lifetime of the creasing tool is significantly shorter

Engineering Contradiction:

Improvemanufacturing timeVSAvoidlifetime of creasing tool

Core Design Contradiction:

Loss of timeVSDuration of action of stationary object

Solution Approach 1:

The patent uses a composite approach where a metal creasing plate provides the structural base and longevity, while plastic material is applied only to the specific projection areas that require frequent reconfiguration. This composite structure combines the durability of metal with the adaptability of plastic, achieving both short manufacturing time and extended tool lifetime.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent segments the creasing tool into a permanent metal plate structure and replaceable plastic projection elements. The metal plate maintains structural integrity and longevity, while only the plastic projection portions need to be manufactured and replaced, separating the lifetime-critical components from the time-critical components.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If creasing projections are positioned close together, then precise folds can be generated, but the risk of merging projections and material damage increases

Engineering Contradiction:

Improveprecision of foldsVSAvoidmaterial damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent applies partial deformation by controlling the punch to deform only the necessary portions of material to the required depth, avoiding excessive deformation that would cause merging or damage. The system uses controlled punch travel distance and force to achieve precise projections without over-deforming the material between closely spaced creases.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent introduces an elastic ejector as an intermediary element between the punch and the creasing plate. This elastic component mediates the deformation process by providing controlled contact and release, preventing direct excessive force application that could cause material damage while still enabling precise projection formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables quick and flexible production of creasing plates with precise creases, reducing manufacturing time and increasing adaptability to different creasing patterns, thereby improving efficiency in digital printing environments.

Implementation Method 1

an elastic ejector to prevent damage and ensure precise folding

Methodology Applied

Scientific EffectElastic force: Elasticity

Implementation Method 2

punch and a die, in particular for deforming sheet metal so as to create local projections

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11484930B2Punching tool comprising a punch and a die

Publication Date: 2022.11.01 BOBST MEX SA

AI summary

A punching tool comprising a punch (42) and a die (46), in particular for manufacturing a creasing plate (24), the die having a straight recess (50) for accommodating material deformed by the punch (42), characterized in that the die (46) has an outer contour which extends, adjacent the open end of the recess (50), at an angle of less than 90° with respect to the longitudinal direction of the recess (50).