Plotter Creasing Unit Using Extruded Profiles for Packaging

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Solution Overview

Problem

Existing packaging production methods, such as die cutting and flatbed plotters, are costly and inefficient for producing short runs or customized packaging due to the need for custom dies and imprecise creasing, leading to poor quality and lengthy manual processes.

Innovation Solution

A plotter with a creasing unit that includes an extruder to precisely extrude profiles onto the work surface and a creasing tool with a groove to couple with these profiles, allowing for precise and high-quality creasing, replacing the traditional male and female creasing elements and simplifying the creasing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If die cutters are used for each packaging type, then cutting precision is improved, but device complexity and production costs increase

Engineering Contradiction:

Improvecutting precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The plotter employs a universal cutting system with a single blade that can cut various packaging materials (cardboard, card, plastic films, foils) by adjusting cutting parameters, replacing the need for multiple specialized die cutters for different packaging types

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces traditional mechanical die cutters with a plotter system that uses a movable blade guided by digital patterns, substituting complex mechanical die structures with a more flexible and programmable cutting mechanism

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional male and female creasing elements are used, then creasing is achieved, but creasing precision and quality deteriorate

Engineering Contradiction:

Improvecreasing qualityVSAvoidcreasing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent inverts the traditional creasing mechanism by using a female creasing element (groove in the plate) instead of a male element, allowing the blade to create precise creases by following the groove path rather than pressing through a rounded tool

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces an intermediary creasing plate with precisely machined grooves that mediate between the cutting blade and the material, ensuring consistent and accurate crease placement while protecting the blade and improving crease quality

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If custom die cutters are manufactured for each packaging type, then cutting accuracy is improved, but production time and costs increase

Engineering Contradiction:

Improvecutting accuracyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent implements a dynamic and reconfigurable cutting system where the blade position and cutting path can be quickly adjusted through digital programming, allowing rapid switching between different packaging designs without the time-consuming process of manufacturing new die cutters

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses digital patterns and computer-controlled positioning to replicate cutting and creasing designs, replacing the need to physically manufacture custom die cutters for each packaging type while maintaining high cutting accuracy

Inventive Principle:

Principle #26Copying

4Ease of manufacture

If manual creasing processes are used, then equipment costs are reduced, but productivity and precision deteriorate

Engineering Contradiction:

Improveequipment simplicityVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines cutting and creasing operations into a single integrated plotter system that performs both functions in one automated process, eliminating the need for separate manual creasing operations while improving both productivity and precision

Inventive Principle:

Principle #5Merging (Combining)

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 solution enables high-quality, precise creasing and cutting of packaging materials, increasing automation and reducing production costs, making it suitable for short runs and customized packaging without the need for custom dies.

Implementation Method 1

an extruder, configured to extrude at least one profile onto the work surface according to the pre-set creasing pattern

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS20230173783A1Plotter, related unit, and method for creasing and cutting sheets of packaging material

Publication Date: 2023.06.08 LOGICSISTEMI SRL

AI summary

The present disclosure relates to a plotter for creasing and cutting a sheet of packaging material, the plotter comprising a work surface and a tool-holder head movable on the work surface according to a pre-set creasing pattern and a pre-set cutting pattern. The plotter comprises a creasing unit, configured to be mounted on the tool-holder head, which includes an extruder, configured to extrude at least one profile onto the work surface according to the pre-set creasing pattern, and a creasing tool provided with a groove adapted to couple, in use, with the at least one profile extruded by the extruder thereby obtaining a corresponding folding line on the sheet of packaging material. The invention also relates to a creasing unit and to a creasing method.