Cutting Frame for Simultaneous Optical Directivity Rectangular Pieces
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Solution Overview
Problem
Current methods for cutting base material sheets to produce rectangular unit pieces with varying optical properties result in low cutting efficiency and high scrap rates, leading to increased manufacturing costs, especially when the sheet and piece dimensions are not in constant proportion.
Innovation Solution
A cutting frame is designed with cutters arranged to cut unit pieces with optical directivity parallel and perpendicular to the base material sheet, allowing for simultaneous production of two types of rectangular unit pieces with different optical properties from the same sheet, optimizing cutter arrangement and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cutters are arranged to manufacture unit pieces with optical directivity perpendicular to base material sheet, then optical directivity requirement is met, but cutting loss increases
Solution Approach 1:
The patent combines two types of cutters (first cutter for parallel optical directivity and second cutter for perpendicular optical directivity) into a single cutting frame. This allows both types of unit pieces to be manufactured simultaneously from the same base material sheet, reducing cutting loss by utilizing the entire sheet area more effectively while meeting diverse optical directivity requirements.
Solution Approach 2:
The cutting frame is designed with multi-functionality to manufacture both types of unit pieces (with parallel and perpendicular optical directivity) using the same base material sheet. This universal approach eliminates the need for separate cutting processes for different optical directivity requirements, thereby reducing overall cutting loss and improving material utilization.
2Adaptability or versatility
If base material sheet width is not in constant proportion to unit piece width, then manufacturing flexibility is improved, but cutting loss increases
Solution Approach 1:
The patent employs a dynamic cutter arrangement where the positions and orientations of cutters can be adjusted to match varying base material sheet widths and unit piece dimensions. This dynamic adaptability allows the system to optimize the cutting pattern for different proportions, maintaining manufacturing flexibility while minimizing cutting loss through efficient material utilization.
3Reliability
If multiple types of unit pieces are manufactured from different base material sheets, then optical directivity requirements are met, but manufacturing efficiency decreases
Solution Approach 1:
The patent merges the manufacturing process for multiple types of unit pieces (with different optical directivity) into a single cutting operation using one base material sheet. By integrating both cutting functions in one frame, the system achieves high manufacturing efficiency while reliably producing unit pieces with the required optical directivity properties.
Solution Approach 2:
The cutting frame enables continuous manufacturing of both types of unit pieces from the same base material sheet without requiring separate cutting processes. This continuity of useful action improves manufacturing efficiency by eliminating idle time and material handling between separate cutting operations, while maintaining the required optical directivity for each unit piece type.
Data Source
AI summary
Disclosed herein is a method of manufacturing two kinds of rectangular unit pieces having different optical properties from a base material sheet through cutting using a cutting frame including a cutter, the method including preparing a base material sheet having a large length to width ratio, the base material sheet exhibiting optical directivity in a longitudinal direction or in a lateral direction, preparing a cutting frame including at least on first cutter for cutting a first unit piece exhibiting optical directivity parallel to that of the base material sheet and at least one second cutter for cutting a second unit piece exhibiting optical directivity perpendicular to that of the base material sheet, the first cutter and the second cutter being arranged adjacent to each other in the lateral direction of the base material sheet, and sequentially cutting the base material sheet using the cutting frame in the longitudinal direction of the base material sheet to simultaneously manufacture the first unit piece and the second unit piece.