Flat Web Material Shaping With Precision Fold Alignment
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Solution Overview
Problem
Existing methods for forming flat web materials into three-dimensional structures are inefficient and lack precision, particularly in achieving complex geometries and stable core materials for composite construction.
Innovation Solution
A method involving a flat web material placed between holding dies with pre-defined fold lines, and forming dies with bending lines that correspond to the desired structure, allowing for precise deformation and shaping through a series of compression and synchronization steps, utilizing stiff and dimensionally stable materials to achieve a regular three-dimensional structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional shaping methods with multiple shaping rollers or successively actuated mold jaws are used, then three-dimensional structures can be formed, but the manufacturing precision and reliability of fold lines are insufficient
Solution Approach 1:
The device is segmented into two independent holding matrices (upper and lower), each with its own fold lines that are brought into alignment. This segmentation allows each matrix to independently define fold lines with high precision, eliminating the need for complex sequentially actuated mechanisms while achieving reliable three-dimensional structuring.
Solution Approach 2:
The holding matrices are pre-formed with precise fold lines before the forming process. The fold lines are pre-defined on both the upper and lower matrices, which are then brought into alignment and pressed together with the flat web material. This preliminary preparation of fold lines ensures high manufacturing precision without requiring complex real-time shaping mechanisms.
2Stability of the object's composition
If holding matrices made of flexible material are used, then the flat web material can be deformed, but the dimensional stability and rigidity of the formed structure are reduced
Solution Approach 1:
The holding matrices are made from a material with optimized parameters - sufficiently rigid to maintain dimensional stability and define precise fold lines, yet capable of being pressed together to transfer the fold line pattern to the flat web material. The material parameters are selected to balance rigidity for structural stability with sufficient compliance for the forming process.
3Ease of manufacture
If pre-embossing or material weakening through perforations is applied, then folding is facilitated, but the strength and integrity of the final structure are compromised
Solution Approach 1:
Instead of permanently weakening the material through perforations or deep embossing, the invention uses the holding matrices as templates that temporarily imprint fold lines onto the flat web material through controlled compression. The fold lines are created by copying the geometry of the holding matrix fold lines onto the web material, maintaining material integrity while achieving the desired foldability.
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
Enables the formation of complex, stable three-dimensional structures with precise fold lines and angles, enhancing the material's rigidity and suitability for composite construction, while maintaining high throughput and efficiency.
Implementation Method 1
The holding matrices are advantageously made of identical material, which is advantageously significantly stiffer than the flat web material to be formed. The flat material of the holding matrices can very often be kinked or deformed along the buckling lines and, as will be explained below, also deform the flat web material.
Implementation Method 2
The lower and upper forming dies have bend lines that correspond exactly to one another and are exactly opposite to one another. Bringing the shaping matrices to the holding matrices or to the closely stacked composite of the two holding matrices with the flat web material between them has the advantage that the holding matrices lying against the flat web material with the predetermined fold lines define the folds on the flat web material precisely
Data Source
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AI summary
The aim of the invention is to shape a flat web material (12) into a constant three-dimensional structure with a plurality of folds along differently oriented folding lines and with elevations and depressions. This is achieved in that the flat web material is inserted between a lower holding die (20b) and an upper holding die (20a), which are largely flat, consist of a flat material, and have pre-shaped bending lines that lie over one another in a precise manner when lying against the flat web material. A lower (30b) and an upper molding die (30a) are then guided thereto and brought into position, said molding dies consisting of a flat material with specified folding lines which oppose one another in a precise manner. The molding dies (30a, 30b) have a shape corresponding to the three-dimensional structure to be produced, and the molding die folding lines oriented towards the holding dies or pointing towards the holding dies match the bending lines of the holding dies, wherein the folding lines can lie against the holding dies.