Flexible Sheet Cutting Partitioning for Inflatable Cushion Defects

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Solution Overview

Problem

In the process of cutting out small, irregular parts for inflatable safety cushions using cutter machines, defects often occur in boundary zones due to reduced suction effect, leading to material loss and inefficiency, as existing methods either fail to prevent defects or increase material consumption.

Innovation Solution

A method that partitions the layout by grouping parts based on their geometrical position and associating each group with a single cutter tool and cutting window, applying spacings only between groups to prevent defects while minimizing material loss, using a computer program to automate the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If spacings are added between each part in the optimized layout to prevent cutting defects, then cutting quality is improved, but material loss increases significantly

Engineering Contradiction:

Improvecutting qualityVSAvoidmaterial loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The layout is segmented into multiple groups, with spacings applied only between groups rather than between every individual part. This selective segmentation maintains cutting quality at group boundaries while preserving material efficiency within groups.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Spacings are applied locally only at group boundaries where cutting defects occur, rather than uniformly between all parts. This localized application prevents defects in sensitive zones while minimizing overall material loss.

Inventive Principle:

Principle #3Local quality

2Device complexity

If the cutting window size is reduced to limit machine size, then device complexity is reduced, but cutting speed decreases due to intermittent material advancement

Engineering Contradiction:

Improvemachine sizeVSAvoidcutting speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The layout is divided into groups that can be processed sequentially by a single cutter tool within a compact cutting window. This segmentation enables efficient use of limited window space while maintaining reasonable cutting speed through optimized group arrangement.

Inventive Principle:

Principle #1Segmentation

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

This method effectively prevents cutting defects in sensitive zones while maintaining high cutting speed and minimizing material loss, optimizing the cutting process for efficient production.

Implementation Method 1

the effect of suction applied to the material, which normally serves to hold the material against the working table during cutting

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS11090828B2Method for partitioning a predetermined placement of parts intended to be cut in a flexible sheet material

Publication Date: 2021.08.17 LECTRA SA (FR)

AI summary

A method of partitioning involves a predetermined layout of parts that are to be cut out from a sheet of flexible material by moving at least one cutter tool along two directions in at least two distinct and determined cutting windows along which the material is advanced in succession. Starting from a predetermined layout of the parts in the material, the method comprises: automatically creating mutually distinct groups of parts by allocating each part to a single group of parts as a function of its geometrical position, each group of parts being associated, for cutting out, with a single cutter tool and with a single cutting window; and applying spacings between the various groups of parts.