Metal Card Manufacturing with Cooling Alcohol CNC Cutting
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Solution Overview
Problem
The mass production of metal cards is challenging due to the differences in characteristics between metal and plastic materials, making it difficult to achieve uniform cutting and alignment of individual card outlines using conventional plastic card processes.
Innovation Solution
A metal card manufacturing method involving the preparation of large-scale sheets with holes for alignment, lamination with a metal sheet, and CNC cutting with cooling alcohol to efficiently cut individual card outlines while preventing sheet twisting, allowing for the simultaneous production of multiple metal cards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic card processes are used for metal cards, then manufacturing can be simplified, but cutting uniformity and alignment precision deteriorate due to material characteristic differences
Solution Approach 1:
The patent modifies the cutting process parameters by introducing cooling alcohol and adjusting cutting speed to accommodate metal material characteristics, thereby achieving precise cutting uniformity while maintaining ease of manufacture through adapted conventional processes
Solution Approach 2:
Cooling alcohol is introduced as an intermediary substance between the cutting tool and metal sheet, serving as a mediator to reduce heat generation and improve cutting precision without fundamentally changing the manufacturing process complexity
2Manufacturing precision
If individual metal cards are cut one by one, then cutting precision can be maintained, but manufacturing productivity deteriorates
Solution Approach 1:
The patent merges multiple individual cutting operations into a single batch processing operation by stacking multiple metal sheets and cutting them simultaneously, thereby improving productivity while maintaining precision through the introduced cooling mechanism and process parameters
Solution Approach 2:
The cutting process is made continuous by processing multiple sheets in one operation rather than performing separate discrete cutting actions for each card, thereby eliminating idle time and improving manufacturing efficiency
3Productivity
If multiple sheets are stacked for batch cutting, then productivity improves, but heat generation increases causing cutting stability to deteriorate
Solution Approach 1:
The patent converts the harmful effect of heat generation into a beneficial cooling process by introducing cooling alcohol, which absorbs heat during evaporation and transforms the thermal problem into a controlled cooling mechanism that enhances cutting stability
Solution Approach 2:
The patent uses fluid (cooling alcohol) delivery system to provide continuous cooling during the cutting process, utilizing hydraulic principles to distribute the cooling medium effectively across the cutting zone and maintain thermal stability
4Reliability
If cooling alcohol is injected during cutting, then cutting stability improves, but process complexity increases
Solution Approach 1:
Cooling alcohol serves as a simple intermediary substance that provides cooling functionality without requiring complex equipment, using basic fluid delivery mechanisms to achieve cutting stability while minimizing process complexity
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 enables stable and uniform cutting of individual card outlines, improving manufacturing efficiency by allowing multiple metal cards to be produced at once with precise alignment and cooling to manage heat generation during the cutting process.
Implementation Method 1
injecting cooling alcohol, while cutting the individual card outlines by means of a cutting tool in a CNC process
Implementation Method 2
forming a metal card sheet through lamination among the metal sheet and the stacked sheets
Data Source
AI summary
The present invention relates to a metal card manufacturing method including the steps of: preparing a metal sheet having a given size capable of accommodating a plurality of individual cards; forming holes on at least one or more edges of stacked sheets formed by stacking a plurality of sheets inclusive of adhesive sheets and an inlay sheet on which antenna coils are printed, the plurality of sheets having the same size capable of accommodating the plurality of individual cards as each other; fitting the holes formed on the stacked sheets to pins located on a loading plate; placing the metal sheet on top of the stacked sheets; forming a metal card sheet through lamination among the metal sheet and the stacked sheets; and cutting the metal card sheet along individual card outlines of the plurality of individual cards.