Cold Forming Punch with Protrusion for Blister Packaging
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Solution Overview
Problem
The existing cold forming process for medical or pharmaceutical products into special materials like aluminum or aluminum laminate films faces challenges in achieving precise and stable positioning of products, leading to issues with product breakage and uneven deformation, which affects the sealing and removal of products in blister packs.
Innovation Solution
A forming device with a blank holder and die, featuring a punch and counter-punch with rounded or beveled edges and recesses, allows for precise clamping and deformation of the film, enabling the formation of stepped wells that improve product positioning, stability, and uniform deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cold forming process is used to form cups in aluminum or aluminum laminate films, then absolute tightness against light or water vapour is ensured, but the cups cannot achieve the same small dimensions and stable positioning as hot forming process
Solution Approach 1:
The punch is divided into multiple functional zones: a rounded edge area for initial material engagement, a protrusion for central support, and an intermediate area for controlled deformation. The counter-punch includes ridges that segment the deformation zone to control material flow and prevent pinching, enabling precise cup formation in cold-forming aluminum films
Solution Approach 2:
The rounded edge area of the punch performs preliminary action by gently engaging and pre-positioning the film material before the main deformation occurs. This preliminary engagement ensures the material is properly positioned and reduces stress concentrations during subsequent forming, achieving both precision and integrity
2Adaptability or versatility
If cold forming process is used, then products can be formed in special materials like aluminum, but the products cannot be held in stable position leading to breakage detection blurring
Solution Approach 1:
Different regions of the punch are given different local qualities: the rounded edge area provides gentle engagement to prevent material damage, while the centrally located protrusion provides localized support exactly where needed for stable product positioning. This localized differentiation ensures both material integrity and positioning precision for accurate breakage detection
Solution Approach 2:
The protrusion acts as an intermediary element between the punch and the product, providing centralized support that stabilizes the product during formation. This intermediary structure prevents product movement and positioning errors, enabling accurate breakage detection while working with special materials like aluminum films
3Ease of manufacture
If cold forming process is used, then cups can be formed in aluminum films, but there is risk that product could be pinched between formed film and cover film during sealing
Solution Approach 1:
The rounded edge areas of the punch provide beforehand cushioning by gently engaging the film material at the edges before main deformation occurs. This cushioning effect prevents sharp edges or protrusions that could pinch the product during sealing, ensuring product protection while maintaining cold forming capability
Solution Approach 2:
The cold forming process, which initially presents a risk of product pinching, is converted into a benefit through the specially designed rounded edges and protrusions. These features control material flow and prevent pinching, transforming the potential harm into a reliable sealing process that protects the product
4Adaptability or versatility
If cold forming process is used, then cups can be formed in special materials, but material elongation cannot be uniformly controlled
Solution Approach 1:
The punch design implements local quality by providing different surface characteristics in different zones: rounded edges for gentle engagement, a protrusion for centralized support, and an intermediate area for controlled deformation. This local differentiation ensures uniform material elongation throughout the cup formation process while working with special materials like aluminum films
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
The solution ensures accurate and stable positioning of products, facilitates easier removal, and allows for better control of material elongation during cold forming, resulting in improved packaging with reduced overall dimensions and enhanced product handling.
Implementation Method 1
the cold forming process is not able to provide cups with the same small dimensions as a comparable hot forming process
Implementation Method 2
allowing the elongation of the material of the film during cold forming to be better controlled and thus a uniform deformation allows
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3B
AI summary
The forming device for cold forming cups (24) for medical or pharmaceutical products into a film (6) comprises a hold-down device (2) and a die (4) for clamping the film (6) between the hold-down device (2) and the die (4) in an area around at least one stretch zone (S) of the forming device, as well as at least one punch (8) and at least one counter-punch (10) arranged in the stretch zone (S) and serving to form at least one cup (24) into the clamped film (6), wherein at least one of the punches (8) or counter-punch (10) is movable relative to the other into a closed forming position of the forming device. The punch (8) has a base body (12) with a working surface (14).wherein at least one protrusion (16) projecting towards the counter-punch (10) is arranged substantially centrally in the stretching zone (S) on the working surface (14) and the base body (12) has a rounded or chamfered edge region (18) at the edges of the working surface (14), wherein in the closed forming position of the forming device the film (6) bears against both the rounded or chamfered edge region (18) of the working surface (14) of the punch (8) and against the protrusion (16) of the punch (8), and the counter-punch (10) has at least one recess (22) surrounded by ribs (20) in which the at least one protrusion (16) of the punch (8) is received in the closed forming position of the forming device,such that the ribs (20) of the counter-punch (10) in the closed forming position of the forming device are in an intermediate area between the rounded or chamfered edge area (18) of the working surface (14) of the punch (8) and the protrusion (16) of the punch (8) on the film (6).