Ferromagnetic Patrix Ring Positioning for Faster Embossing Setup
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Solution Overview
Problem
Current methods for positioning patrix elements in embossing processes require the use of additional accessories like positioning pins and grippers, leading to increased handling time and potential damage to graphic designs due to pin removal during machine operation.
Innovation Solution
A patrix positioning element in the form of a ferromagnetic ring with a crown, embedded in a mould, which uses magnetic forces to securely position the patrix during injection moulding, eliminating the need for manual pin insertion and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If positioning pins and grippers are used to position patrix elements, then positioning precision is achieved, but handling time increases and damage to graphic designs occurs
Solution Approach 1:
The positioning element is pre-integrated into the patrix structure during manufacturing, so that positioning features are already in place before the patrix is used in the embossing process. This eliminates the need for manual insertion of positioning pins during setup, reducing handling time while maintaining positioning precision.
Solution Approach 2:
The positioning function is merged with the patrix structure itself by integrating positioning elements (such as recesses or protrusions) directly into the patrix during manufacturing. This combines the positioning function with the graphic marking function, eliminating separate positioning accessories and reducing setup time.
2Stability of the object's composition
If positioning pins are used during machine operation, then positioning stability is maintained, but pin removal causes damage to graphic designs
Solution Approach 1:
The harmful positioning pins are extracted from the system and replaced with an integrated positioning structure that is part of the patrix itself. The positioning function is achieved through built-in features like recesses or protrusions that do not require removable pins, thereby eliminating the risk of pin removal damaging the graphic designs.
Solution Approach 2:
Instead of using durable but intrusive positioning pins that require removal, the invention employs a disposable or integrated positioning structure that is either permanently part of the patrix or can be easily replaced without affecting the graphic design. This eliminates the harmful effect of pin removal on delicate graphic surfaces.
3Measurement precision
If manual pin insertion and removal is required, then positioning accuracy is achieved, but setup time increases by up to 80%
Solution Approach 1:
Positioning features are prepared in advance during patrix manufacturing, with integrated recesses or protrusions that automatically align and secure the patrix in the correct position. This preliminary preparation eliminates the need for time-consuming manual pin insertion and adjustment operations, reducing setup time while maintaining positioning accuracy.
Solution Approach 2:
The patrix structure provides its own positioning function through integrated features that automatically engage with corresponding features in the embossing device. This self-positioning capability eliminates the need for external positioning pins and manual adjustment, significantly reducing setup time while ensuring accurate positioning.
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 allows for precise and stable positioning of patrix elements, reducing setup time by up to 80% and preventing deformation or displacement during high-pressure injection, thus ensuring accurate graphic marks on flat sheets.
Implementation Method 1
A patrix positioning element in the form of a ferromagnetic ring with a crown, embedded in a mould, which uses magnetic forces to securely position the patrix during injection moulding
Data Source
Figure 1~2
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Figure 5~6
AI summary
The object of the invention is a patrix positioning element for making graphic marks on flat sheets for packaging, characterised in that it constitutes a ring (1) with a thickness of 0.2 to 0.8 mm shaped on both sides, made of ferromagnetic material, which has a hole (2) for fitting it into the mould socket (7) Another object of the invention is a mould for making patches containing a positioning element according to the invention, characterised in that, that it is provided with sockets (5) for fixing the position of the rings (1), where each socket (5) is a cylinder facing the apex of the mould socket (7) together with a milled base to a minimum depth equal to the thickness of the rings (1), the number of sockets being equal to the number of rings (1). Another object of the invention is a method for embedding a positioning element according to the invention in a patrix using a mould according to the invention, characterised in that the patrix (6) is made by an overmoulding process comprising the following steps: (a) insertion of at least two rings (1) in the cavities (5) of the mould (7) before the start of the injection cycle when the mould (7) of the injection moulding machine is open, (b) start of the injection cycle in which each channel of the mould (7) located under the cavity (5) with the embedded ring (1) is filled with a plastic-liquid matrix material, (c) adhesive bonding of the rings (1) to the made patrix (6) taking place by solidification of the matrix material; or the patrix (6) is made by pressing includes the following steps: (a') placing at least two rings (1) in the sockets (5), (b') pouring the matrix material onto the mould (7) and covering it with a sheet of fibreglass plate, (c') placing the whole in a heated press and making the patrix (6) by bonding the matrix material, at least two rings (1) and a fibreglass sheet, d') leaving the fabricated patrix shown in Fig 9 to cure.