Creasing Plate with Plastically Deformed Projections for Rapid Tooling
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 and the limited lifetime of existing tools.
Innovation Solution
A creasing machine with a metal creasing plate featuring small, plastically deformed areas that merge to form creasing projections, allowing for quick manufacturing and long tool lifetime, integrated with a punching module and handling system for automated plate exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If creasing projections are formed by etching a steel plate, then the tool lifetime is extended, but the manufacturing time increases to several hours
Solution Approach 1:
The creasing projection is segmented into multiple small, plastically deformed areas that merge together to form the complete projection. This segmentation allows the tool to be manufactured quickly through automated punching processes while maintaining the functional integrity of the creasing projection, thereby reducing manufacturing time without sacrificing tool lifetime
Solution Approach 2:
The invention changes the manufacturing parameter from etching (a slow, precision removal process) to plastic deformation through punching (a fast, formative process). This parameter change enables rapid tool manufacturing while the strain hardening effect during punching ensures the deformed areas maintain sufficient durability for extended tool lifetime
2Loss of time
If plastic material is applied to a carrier to form creasing projections, then the manufacturing time is reduced, but the tool lifetime is significantly shortened
Solution Approach 1:
The invention creates a composite structure by plastically deforming a metal creasing plate to form projections. The strain hardening during deformation creates a composite microstructure within the metal that combines the ductility needed for formation with the hardness required for durability, achieving both quick manufacturing and extended tool lifetime
Solution Approach 2:
The plastically deformed areas are formed with curved, rounded profiles rather than sharp edges. This curvature distributes stress more evenly during creasing operations, reducing stress concentration and preventing premature failure, thereby extending tool lifetime while maintaining quick manufacturing through automated punching processes
3Adaptability or versatility
If a new creasing tool is manufactured for each creasing pattern, then the adaptability to different creasing patterns is improved, but the productivity decreases due to repeated manufacturing cycles
Solution Approach 1:
The invention enables dynamic adaptability by allowing the creasing plate to be quickly reconfigured for different patterns through automated punching. The plate transitions from a static, permanently etched tool to a dynamic, rapidly reconfigurable component, maintaining high adaptability while eliminating the productivity loss associated with manual manufacturing cycles
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 rapid adaptation to various creasing patterns and extends tool lifetime by minimizing wear through strain hardening, reducing manufacturing time and effort, and eliminating the need for external machinery.
Implementation Method 1
a punching machine for applying a plurality of small deformations to a creasing plate sheet, the deformations constituting at least one creasing projection
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
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a creasing machine having a creasing tool (14, 20, 21), a counter element (22, 23) cooperating with the creasing tool, and a transportation system (10) for advancing sheets (12) through a creasing area between the creasing tool (14, 20, 21) and the counter element (22, 23), the creasing tool having a creasing plate (24) provided with at least one creasing projection (26), characterized in that the creasing projection (26) on the creasing plate is constituted by a plurality of small, plastically deformed areas which merge into each other so as to form the creasing projection (26). The invention also relates to a creasing plate (24) adapted for being used in a creasing machine according to any of the preceding claims, the creasing plate (24) being made from sheet metal and comprising at least one creasing projection (26) formed from a plurality of small, plastically deformed areas which merge into each other so as to form the creasing projection. Further, the invention relates to a method for creasing sheets (12), in particular made from paper, cardboard or foil, comprising the following steps: data regarding folding creases (30) to be applied to the sheet (12) is provided. A control (60) determines if a suitable creasing plate (24) is available in an inventory or if a new creasing plate (24) is to be manufactured. Based on the determination of the control (60), either an existing creasing plate (24) is retrieved from the inventory (62) or a new creasing plate (24) is manufactured by using a punching module (40) for applying a plurality of small deformations to a creasing plate blank (24'), the deformations constituting at least one creasing projection (26). The creasing plate (24) is mounted on a creasing tool (20, 21), and the creasing tool (20, 21) cooperates with a counter element (22, 23) for applying folding creases (30) to sheets (12) advanced through a creasing area between the creasing tool (20, 21) and the counter element (22, 23).