Creasing Plate Projections for Fast Sheet Pattern Changeovers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Creasing machines struggle to quickly adapt to different creasing patterns, especially when used in digital printing environments, due to the time-consuming process of manufacturing new creasing tools, which limits their flexibility and efficiency.
Innovation Solution
A method using a metal creasing plate with projections formed by punching, allowing for quick manufacturing and minimal wear, combined with a counter element and adjustable cylinders for varying sheet types, and a driving fillet for consistent sheet engagement, enabling rapid pattern changes and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional etching process is used to manufacture creasing tools, then the creasing tool has long lifetime and wear resistance, but the adaptation time to new creasing patterns becomes very long (several hours)
Solution Approach 1:
The creasing tool is segmented into a reusable carrier structure and replaceable creasing plates. The carrier maintains long-term reliability through its durable construction, while the creasing plates can be quickly swapped to adapt to different creasing patterns without re-manufacturing the entire tool.
Solution Approach 2:
Multiple creasing plates with different creasing patterns are pre-manufactured and stored. When a new creasing pattern is needed, a pre-manufactured plate is simply selected and mounted onto the carrier, eliminating the need for time-consuming on-site manufacturing or etching.
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 becomes significantly shorter
Solution Approach 1:
The creasing plate uses a composite structure combining a metal base plate with plastic creasing projections. The metal base provides durability and long lifetime, while the plastic projections enable easier and faster manufacturing compared to traditional etching methods.
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 efficient adaptation to different creasing patterns, extends tool lifespan, and maintains consistent sheet engagement, enhancing the flexibility and efficiency of creasing machines, particularly in digital printing settings.
Implementation Method 1
a creasing plate blank is provided with at least one creasing projection by plastically deforming the material of the blank so as to form a creasing plate
Implementation Method 2
The creases are formed by locally applying a pressure onto the sheet. To this end, creasing knives are known which are pressed onto the surface of the sheet so as to generate the crease
Data Source
AI summary
The invention relates to a method of creasing sheets (12) by using a creasing tool (14, 20, 21) cooperating with a counter element (22, 23), comprising the following steps:a creasing plate blank (24′) is provided with at least one creasing projection (26) by plastically deforming the material of the blank (24′) so as to form a creasing plate (24),the creasing plate (24) is mounted to a creasing tool (14, 20, 21),sheets (12) to be provided with at least one crease are advanced through a gap between the creasing tool (14, 20, 21) and the counter element (22, 23).