Perforating Apparatus Tape Cushioning Mechanism
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Solution Overview
Problem
Conventional perforating apparatuses require frequent replacement of resin sheets due to punched mark-induced irregularities, leading to waste and increased costs, and complicate the transition to subsequent processes like embroidery, as the resin sheet must be removed and repositioned.
Innovation Solution
A perforating apparatus with a cushioning material feed mechanism that uses a tape-like material wider than the processing area, allowing for downstream feeding and independent replacement without removing the workpiece, reducing waste and maintaining consistent perforation quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a resin sheet is reused multiple times for cushioning material, then cost is reduced, but punched marks cause irregularities that deepen recesses and lead to sheet warping, ultimately deteriorating perforation quality
Solution Approach 1:
The patent divides the cushioning material function into two separate components: a reusable receiving base and a disposable resin sheet. The receiving base retains the punched marks and structural integrity, while the resin sheet is replaced when quality deteriorates. This segmentation allows the expensive receiving base to be reused multiple times while only the cheaper resin sheet needs replacement, reducing overall waste and cost.
Solution Approach 2:
The receiving base acts as an intermediary between the punching blade and the workpiece. It absorbs the impact and provides cushioning, while its rigid structure prevents deformation. The resin sheet serves as a sacrificial intermediary layer that can be replaced when punched marks cause quality issues, protecting the expensive receiving base from damage.
2Manufacturing precision
If the resin sheet is made the same size as the leather sheet to be overlaid in the holder frame, then complete coverage is achieved, but the entire sheet must be discarded even when only the processed area shows wear
Solution Approach 1:
The patent segments the cushioning material system into a permanent receiving base and a replaceable resin sheet. The receiving base is sized to match the holder frame and is reused indefinitely, while only the smaller resin sheet portion that contacts the punching blade is replaced when worn. This eliminates the waste of discarding entire large sheets when only small processed areas show wear.
3Adaptability or versatility
If the resin sheet is removed from the holder frame for subsequent embroidery processes, then the workpiece can be reset, but the process becomes complicated and errors may occur
Solution Approach 1:
The patent segments the cushioning material into a permanent receiving base that remains in the holder frame and a removable resin sheet. After perforation, only the resin sheet is removed and discarded, while the receiving base and workpiece remain in place for subsequent embroidery processes. This eliminates the complexity of completely removing and repositioning the workpiece, as only the thin resin sheet needs to be taken off.
4Ease of operation
If a conventional perforating apparatus is used with a receiving base, then perforation can be performed, but the machine size increases when adding a cushioning material feed mechanism
Solution Approach 1:
The patent merges the cushioning material feed mechanism with the existing holder frame structure. The resin sheet is fed from a roll that is integrated into the holder frame assembly, and the feeding action utilizes the same mechanical movements already present in the perforating apparatus. This integration avoids adding separate bulky feeding mechanisms, keeping the machine compact while enabling automatic cushioning material supply.
Data Source
AI summary
An embroidery sewing machine including: a perforation head having a plurality of vertically reciprocating bars and punches where each punch includes a perforation head; a receiving base having a receiving member configured to receive the punch; a holder frame for supporting a workpiece in an expanded state between the punch and the receiving base, the holder frame being configured to be controlled to move in two-dimensional planar directions; and a tape feed mechanism feeding a tape-like cushioning material having a wider width than at least a processing area of the punch, wherein the material is fed from the front/rear direction and between the workpiece supported in the holder frame and an upper surface of the receiving member, and wherein an upstream portion of the material is shifted downstream to where the receiving member is located according to the vertically reciprocating motion of the punch.