Elastic Matrix Punching Device for Thin-Walled Materials

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Solution Overview

Problem

High-output punching tools are costly and inefficient for small quantities of labels and lids, and existing cutting solutions lead to rapid blade wear and maintenance issues.

Innovation Solution

A device with a displaceable matrix and elastic support system for the blade, using band steel tools and magnetic fastening, allows for cost-effective production and minimizes wear, enabling efficient punching on existing high-output machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-output punching tools are used for small quantities of labels and lids, then punching capability is achieved, but tool costs become excessively high

Engineering Contradiction:

Improvepunching capabilityVSAvoidtool costs

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The matrix is made elastically displaceable through an intermediate plate with elastic elements (springs or elastomers), allowing it to flex during punching operations. This dynamic capability enables the use of simpler, less expensive tooling while maintaining high-output punching performance on existing machines

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The punching system uses an elastically displaceable matrix that changes its mechanical parameters during operation. The elastic intermediate plate allows the matrix to deflect and absorb forces, enabling cost-effective tooling to achieve the same punching capability as expensive high-output tools

Inventive Principle:

Principle #35Parameter changes

2Productivity

If a locally fixed cutting blade support is used, then cutting effectiveness is improved, but blade wear increases rapidly

Engineering Contradiction:

Improvecutting effectivenessVSAvoidblade life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The elastic intermediate plate acts as a cushioning element between the matrix and the fixed support structure. This beforehand cushioning absorbs impact forces and prevents direct impingement of the cutting blade on the rigid support, thereby reducing blade wear while maintaining cutting effectiveness

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The elastic intermediate plate serves as an intermediary element between the matrix and the fixed support. It mediates the interaction by providing elastic compliance, which reduces the harmful impact forces on the cutting blade while still allowing effective cutting action

Inventive Principle:

Principle #24Intermediary (Mediator)

3Duration of action of stationary object

If a spring-loaded cutting support is used, then blade wear is reduced, but punched work pieces cannot be removed after punching

Engineering Contradiction:

Improveblade lifeVSAvoidwork piece removal

Core Design Contradiction:

Duration of action of stationary objectVSEase of operation

Solution Approach 1:

The support system is segmented into distinct functional zones: the elastic intermediate plate provides cushioning for blade protection, while the matrix plate with its recess provides a separate ejection path for work pieces. This segmentation allows both blade wear reduction and easy work piece removal to be achieved simultaneously

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If expensive high-output punching tools are used, then punching precision is maintained, but maintenance costs increase significantly

Engineering Contradiction:

Improvepunching precisionVSAvoidmaintenance costs

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The system uses a cost-effective matrix with an elastic intermediate plate that can be easily replaced or adjusted. Instead of investing in expensive high-output tools with high maintenance costs, the invention uses simpler, cheaper components that maintain punching precision while reducing maintenance expenses

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 reduces maintenance costs and extends tool life by up to 90% while allowing for quick adaptation to different label shapes, making it suitable for both high and low volume production.

Implementation Method 1

an elastic, deformable intermediate plate (47) is placed on the matrix seat (33)

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

magnets can be used in the guide sleeves (43) for contracting the fastening pins (45) and holding the matrix (55)

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS10828796B2Device for punching thin-walled materials

Publication Date: 2020.11.10 BERHALTER

AI summary

A device by which thin-walled materials, such as labels and flat lids for containers, can be punched in micro or small quantities. The device includes a band steel cutting edge (11) that is elastically mounted in the punching direction. The matrix is likewise elastically held on the matrix plate perpendicular to the punching direction by virtue of a matrix seat (33) fastened to the region in the matrix plate (27) that is adjacent to the opening (29). On the matrix seat, an elastically deformable intermediate plate (47) is placed, and the matrix (55) is placed on the intermediate plate.