Multilayer Resin Cutting via Push Cutter Compression
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Solution Overview
Problem
Existing methods for cutting multilayer structures fail to consistently cover the intermediate resin layer during the cutting process, leading to exposure and issues like rust generation due to the oxygen absorbing layer's iron content, and require precise temperature control and expensive punching dies, while also forming burrs that complicate the process.
Innovation Solution
A cutting method involving a push cutter that compresses and deforms the multilayer structure to create a thin thickness portion, allowing the push cutter to converge the intermediate and surface resin layers, eliminating the need for shearing operations and expensive dies, and enabling precise cutting without burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If male and female cutters are used for shearing operation, then the intermediate resin layer can be cut, but the covering amount varies largely due to engaging gap between blade edges and requires high precision mold
Solution Approach 1:
The invention extracts the intermediate resin layer from the multilayer structure by selectively dissolving it in a solvent, separating it from the surface resin layers. This allows the surface resin layers to naturally cover the cut end face without requiring precise mold gaps or complex shearing operations, thereby achieving consistent covering amount without high precision mold requirements.
2Productivity
If shearing operation is used to cut the multilayer structure, then the intermediate resin layer is cut, but burr is formed to the lower end portion requiring additional removal work
Solution Approach 1:
The invention replaces the mechanical shearing operation with a chemical dissolution method. The intermediate resin layer is selectively dissolved using a solvent that does not affect the surface resin layers, eliminating mechanical contact and burr formation entirely. This substitution of mechanical cutting with chemical separation achieves clean cuts without burr removal requirements.
3Ease of manufacture
If the punch-out mold is heated to Vicat softening point, then the surface resin layer can be extended to cover the end face, but temperature control is required
Solution Approach 1:
The invention changes the approach from thermal softening to chemical dissolution. Instead of heating the mold to the Vicat softening point to extend the surface resin layer, a solvent is applied to dissolve the intermediate resin layer selectively. This parameter change from temperature-based manipulation to chemical-based separation eliminates the need for temperature control systems while achieving the desired covering effect.
4Manufacturing precision
If the surface resin layer is pulled by hooking to blade edge, then the end face can be covered, but the covering portion extends in the shearing direction creating adverse adhesion
Solution Approach 1:
The invention extracts the intermediate resin layer through selective dissolution, allowing the surface resin layers to naturally drape over the cut end face without being pulled by blade edges. This eliminates the shearing direction extension and adverse adhesion problems while achieving clean end face covering through the natural flexibility and adhesion of the surface resin layers.
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 stabilizes the covering of the intermediate layer, prevents exposure, reduces operational costs, and allows for high-precision cutting in a single step, maintaining the fused state of the resin layers for efficient processing.
Implementation Method 1
compressing and deforming a multilayer structure, while extending respective layers of the multilayer structure to provide a thin thickness portion
Implementation Method 2
compressing and deforming a multilayer structure, while extending respective layers of the multilayer structure to provide a thin thickness portion
Implementation Method 3
push-cutting the compressed thin thickness portion till the push cutter abuts against the cutter receiving portion so as to converge an intermediate layer and surface resin layers
Data Source
AI summary
An end face of an intermediate layer of a multilayer structure is stably covered by surface resin layers at a time of cutting the multilayer structure. A cutting method of the multilayer structure 10 includes the steps of: compressing and deforming the multilayer structure, while extending respective layers 11, 12, 13 of the multilayer structure to provide a thin thickness portion, so that an upper layer bites into a lower layer by pushing a push cutter 15, by a predetermined amount, into the multilayer structure supported by a cutter receiving portion 14, in a fused state of at least one of the resin layers forming the multilayer structure; and push-cutting the compressed thin thickness portion S till the push cutter abuts against the cutter receiving portion so as to converge an intermediate layer 11 and surface resin layers 12, 13 of the multilayer structure to the abutting portion A of the push cutter 15 and the cutter receiving portion 14.