Deep-Drawing Piston and Die for Crease-Free Paper Forming
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Solution Overview
Problem
Existing deep-drawing methods are limited to thermoformable materials like plastic foils, and struggle to reshape paper and cardboard without significant creasing, requiring complex edge smoothing and often using plastics for sealing.
Innovation Solution
A method using a deep-drawing piston and die with a clamping mechanism and partial or complete material penetration, combined with a die design that allows for fine deformation and sealing, including the use of a plate die with a thickness less than or equal to the deformation depth, and a mold with conical or angular side walls for shaping, along with a sealing mechanism that includes a stamp and movable mold for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If deep-drawing method is used for paper and cardboard, then three-dimensional shaping is achieved, but significant creases and wrinkles form
Solution Approach 1:
The deep-drawing process is divided into multiple sequential steps with intermediate smoothing operations. The forming process is segmented into: initial deep-drawing to create the three-dimensional shape, followed by smoothing of creases, then further forming steps. This segmentation allows surface quality to be maintained while achieving complex three-dimensional shapes that would otherwise create excessive wrinkles.
Solution Approach 2:
The material is pre-treated by smoothing creases during the forming process before final shaping is completed. The patent applies smoothing operations at intermediate stages to prevent creases from becoming permanent defects, thereby preparing the material for subsequent forming steps without compromising surface quality.
2Manufacturing precision
If complex edge smoothing is applied to formed paper and cardboard, then surface quality improves, but process complexity increases
Solution Approach 1:
The smoothing function is merged into the deep-drawing process itself rather than being a separate post-processing step. The patent integrates smoothing operations within the forming sequence, combining shaping and surface finishing into a unified process flow, thereby reducing overall process complexity while maintaining edge smoothness.
Solution Approach 2:
The deep-drawing process itself performs the smoothing function through controlled material flow and intermediate forming steps. The material is smoothed by the forming action and subsequent controlled deformation, eliminating the need for separate complex smoothing equipment and processes.
3Reliability
If plastic is applied for sealing, then sealing effectiveness improves, but material compatibility and environmental concerns worsen
Solution Approach 1:
The patent uses homogeneous sealing - sealing the paper or cardboard container with itself or with compatible materials of the same material family. This eliminates the need for plastic applications and ensures material compatibility throughout the sealing process, while maintaining effective sealing through controlled deformation and friction-based sealing mechanisms.
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
This approach effectively smooths out creases, prevents wrinkles, allows for precise shaping, and enables secure sealing of paper and cardboard materials into three-dimensional forms without the need for additional smoothing or plastic applications, ensuring a durable and efficient forming process.
Implementation Method 1
the mold in which the molding is held is movably mounted and can be depressed against a spring
Data Source
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AI summary
Method for three-dimensional forming of planar material (1) made in particular of natural fibers, such as paper or cardboard, with a deep-drawing piston (2) and a die (3) through which or into which the material is drawn, wherein the diameter of the deep-drawing piston plus the material thickness of the material to be deep-drawn corresponds at least approximately to the diameter of the die.