Die Cutting Blanket Insert with Segmented Ribs
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Solution Overview
Problem
In rotating-type die cutting machines, the inserts used to provide rigidity to the counter-die cylinder blanket often warp or become misaligned during manufacturing, leading to issues with centred positioning and adhesion, which affects the quality of the die cutting process and the bond between the insert and the polyurethane band.
Innovation Solution
A stiffening insert with a prismatic configuration and separating ribs is used, which facilitates centred positioning and separation from the mould walls, preventing contamination and ensuring correct adhesion during the moulding process, and can include grooves and rough surfaces for enhanced bonding, along with a handling area for easy insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an insert is used to provide rigidity to the blanket, then the rigidity of the key is improved, but the insert may warp or become misaligned during manufacturing
Solution Approach 1:
The insert is segmented into a body and multiple separating ribs that extend from the faces of the body. These ribs divide the insert into distinct sections that can be independently positioned and stabilized during the moulding process, preventing warping and ensuring centred positioning within the key seat.
2Ease of manufacture
If clearance is present for insert embedding during hot pouring, then the insert can be introduced, but it may displace within the key seat
Solution Approach 1:
The separating ribs are pre-configured on the insert before the hot pouring process. These ribs preliminarily establish the correct positioning and orientation of the insert within the key seat, ensuring that when the insert is introduced during hot pouring, it maintains its centred position and does not displace.
3Reliability
If the insert is introduced in the key seat during blanket manufacturing, then adhesion between insert and band material is achieved, but direct contact with demoulding agent may prevent correct adhesion
Solution Approach 1:
The separating ribs segment the insert surface, creating distinct zones. The rib surfaces that contact the demoulding agent are separated from the body surfaces that need to bond with the band material. This segmentation prevents demoulding agent contamination from reaching the bonding surfaces, ensuring correct adhesion between the insert and the band material.
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 ensures precise centring and adhesion of the insert within the mould, minimizing warping and contamination, resulting in improved bonding and reduced defects in the die cutting process, such as air traps and incomplete vulcanization.
Implementation Method 1
a correct adhesion would be produced of the insert in the key
Data Source
AI summary
Counter-die cylinder blanket of die cutting machine comprising a band (3) of soft plastic material provided with a key (4), and an insert (5) of stiffening material housed in the key (4), wherein the insert (5) additionally comprises separating ribs (11) which extend from the top face (8) and/or from a bottom face (9) to facilitate the positioning of the insert (5) in the key (4) during the forming by moulding of the band (3) inside of a mould (16), and it preferably incorporates separating ribs (11) which extend from its side faces (10).