Die Cutter Rule With Drop-Shaped Nick Profile

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Solution Overview

Problem

Conventional methods for manufacturing die cutter rules, such as punching, struggle to create nicks with small longitudinal extent efficiently, while techniques like milling and grinding are time-consuming and limited to rectangular profiles.

Innovation Solution

A die cutter rule with a drop-shaped nick profile and a corresponding punch with a tubular shape featuring drop-shaped and circular/semi-circular punching portions, allowing for precise and efficient creation of nicks with minimal longitudinal extent, enhancing torsion stiffness and wear resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If punching is used to create nicks on die cutter rules, then manufacturing speed is maintained, but nicks with small longitudinal extent cannot be created efficiently

Engineering Contradiction:

Improvenick longitudinal extentVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The punching tool is segmented into multiple independent punching portions (first punching portion, second punching portion, third punching portion) arranged at different angular positions around the tubular body. Each portion can create nicks at different locations on the rule, allowing precise control over nick positioning and dimensions while maintaining high-speed punching operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from conventional single-point punching to multi-point simultaneous punching by arranging punching portions in a circular pattern around the tubular body. This dimensional arrangement enables creation of multiple nicks with small longitudinal extent in a single operational cycle, achieving both precision and productivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If milling or grinding is used to create nicks, then nicks with small longitudinal extent can be created, but manufacturing time increases significantly

Engineering Contradiction:

Improvenick longitudinal extentVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The invention replaces time-consuming milling or grinding operations with high-speed punching. The punching portions are designed with precise geometries that directly form nicks with small longitudinal extent through shearing action, achieving the same precision as milling/grinding but at much higher speed comparable to conventional punching.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If conventional rectangular punches are used, then manufacturing is simple, but nicks with small longitudinal extent and improved torsion stiffness cannot be achieved

Engineering Contradiction:

Improvenick profile accuracyVSAvoidpunch structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The punching portions incorporate curved and rounded geometries (circular arcs, rounded corners) instead of simple rectangular shapes. This curvature design enables creation of nicks with optimized profiles that improve torsion stiffness while the modular tubular structure keeps the overall device complexity manageable.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

Different punching portions have different local geometries optimized for specific nick locations and requirements. The first, second, and third punching portions are designed with specific shapes and sizes appropriate for their respective positions on the rule, achieving local optimization of nick quality.

Inventive Principle:

Principle #3Local quality

4Productivity

If multiple punching portions are added to the punch, then productivity and precision are improved, but device complexity increases

Engineering Contradiction:

Improvenick creation speedVSAvoidpunch structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The tubular punch body serves multiple functions: it provides structural support, acts as a mounting platform for multiple punching portions, and enables rotational positioning. This universal design allows the single punch tool to perform multiple nick-creation operations simultaneously, improving productivity without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables the production of die cutter rules with improved structural resistance and extended tool life, capable of withstanding over 20,000 punches, while achieving accurate and rapid nick creation not possible with conventional methods.

Implementation Method 1

The combined action of the punch and the die causes the sharp splitting of a portion of material on the base of the rule opposite to the cutting edge

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentEP2851169B1Die cutter rule, machine manufacturing said rule and related manufacturing method

Publication Date: 2016.03.23 PROFORM

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AI summary

A band rule of die cutter comprising a base and a cutting edge is described. At the cutting edge at least one recess, or cut-out, or notch, hereinafter named 'nick', is provided, extending longitudinally for a length corresponding to the missing length of the cutting edge (14) and extending transversely through at least part of the base. The nick has a substantially drop-shaped profile as the rule is observed laterally.