In-Mold Insulating Sheet Placement in Composite Stamping Lines
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Solution Overview
Problem
In manual stamping processes, the inefficiencies in production line transitions and material handling lead to increased costs and extended delivery times due to the need for multiple processing stages and separate workstations for stamping and film-attaching operations.
Innovation Solution
A composite automatic production equipment integrates in-mold stamping and film-attaching processes using a continual stamping mold group and an insulating-sheet feeding device, where the punching material strip and insulating-film material strip are synchronized to adhere insulating sheets directly onto semi-finished products within the stamping process, eliminating the need for separate film-attaching workstations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple sets of molds or multiple engineering conversions are used for stamping finished products, then the stamping process can be completed, but the production line replacement and material handling time increases
Solution Approach 1:
The patent combines the stamping process and film-attaching process into a single integrated mold system. The stamping mold includes both stamping punches and film-attaching components, allowing both operations to be performed simultaneously in one workstation without line changes or material handling transfers.
2Ease of manufacture
If separate workstations are used for stamping and film-attaching operations, then each process can be specialized, but the material handling and production efficiency decreases
Solution Approach 1:
The patent merges stamping and film-attaching operations into a single workstation with an integrated mold system. The stamping mold includes both stamping punches and film-attaching components that work simultaneously, eliminating the need for separate workstations and material handling while maintaining process specialization through dedicated tooling elements.
3Adaptability or versatility
If manual management of each stage of the process is used, then flexibility is maintained, but operating efficiency reduces and material costs increase
Solution Approach 1:
The patent implements an automated material feeding system where the insulating-film material strip is automatically fed through the stamping mold and the insulating sheets are automatically attached to the semi-finished products during the stamping process. The system self-manages the film-attaching operation without manual intervention, improving operating efficiency while maintaining flexibility through programmable control.
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 integration enhances production efficiency, reduces operating costs, and shortens delivery times by completing the film-attaching process concurrently with stamping, improving overall operational efficiency and reducing material handling complexities.
Implementation Method 1
The insulating-film material strip includes a main material strip passing through the lower die plate and the punching material strip, and a plurality of insulating sheet sets which are adhesive and detachably arranged along the main material strip. When the upper die plate and the lower die plate are closed, and one of the semi-finished products overlaps with one of the insulating sheet sets, the punching material strip is pressed down to the insulating-film material strip by the upper die plate, so that the one of the insulating-film material strips and the one of the semi-finished products overlapped with each other are adhered together
Data Source
AI summary
A composite automatic production equipment for in-mold placement process includes a upper stamping mold having a upper die plate and punches, a lower stamping mold having a lower die plate, a punching strip feeding device sending out a punching material strip to the lower stamping mold, an insulating-sheet feeding device feeding out an insulating-film material strip intersecting to the punching material strip. The insulating-film material strip includes a main material strip and insulating sheet sets that are adhesive and detachably arranged along the main material strip. When the upper and lower die plates are closed, the punches punch the punching material strip to form semi-finished products arranged in sequence, and one of the semi-finished products is pressed to adhere to one of the insulating sheet sets. When they are separated, the insulating sheet set on the semi-finished product is torn off from the insulating-film material strip.