Polymeric Rule Die Extrusion for Cardboard Creasing
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Solution Overview
Problem
The die-cutting and creasing industry faces challenges with the high environmental impact, resource consumption, and complexity of traditional steel-rule die systems, which require skilled craftsmen, extensive storage, and generate pollution.
Innovation Solution
A polymeric rule die system where elongate rules are bonded to the die body through extrusion and curing of a polymerizable material, eliminating the need for grooved slots and skilled craftsmen, and allowing for automated production and storage of die layouts on a computer medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional steel-rule die systems are used, then durability and withstanding harsh operating conditions is improved, but environmental impact, resource consumption, and production complexity increase
Solution Approach 1:
The patent changes the material parameter from traditional steel rules to polymeric rules made from polymerizable materials. This material substitution maintains the functional requirements for die-cutting and creasing while significantly reducing environmental impact and resource consumption. The polymeric material can be extruded and cured in place, eliminating the need for steel production and associated environmental harm.
Solution Approach 2:
The patent replaces the mechanical steel-rule system with a polymeric rule system that is extruded and cured directly onto the die body. This substitution eliminates the need for heavy steel materials and complex mechanical assembly, reducing both environmental impact and production complexity while maintaining operational reliability.
2Reliability
If traditional steel-rule die systems are used, then durability is improved, but resource consumption and storage requirements increase
Solution Approach 1:
The patent changes the material parameter from steel to polymeric materials, which consume fewer resources during production and require less storage space. The polymeric rules can be manufactured on-demand through extrusion, eliminating the need to store large quantities of steel rules and reducing overall resource consumption.
Solution Approach 2:
The patent employs polymeric rules that can be easily manufactured and replaced if needed, rather than investing in durable steel rules that require significant resources to produce and store. The polymeric material allows for cost-effective, on-demand production of rules, reducing both resource consumption and storage requirements.
3Reliability
If traditional steel-rule die systems are used, then durability is improved, but production complexity and skilled craftsmanship requirements increase
Solution Approach 1:
The patent replaces the complex mechanical process of fitting steel rules into grooved slots with a simplified extrusion and curing process. The polymeric rule material is extruded directly onto the die body and cured in place, eliminating the need for skilled craftsmen to manually fit and secure steel rules, thereby reducing production complexity while maintaining durability.
Solution Approach 2:
The polymeric rule material performs its own bonding function through the extrusion and curing process, eliminating the need for separate assembly steps and skilled craftsmanship. The material self-adheres to the die body as it cures, simplifying the production process while ensuring durable attachment.
4Reliability
If traditional steel-rule die systems are used, then durability is improved, but storage area requirements increase
Solution Approach 1:
The patent changes from storing pre-fabricated steel rules to on-demand extrusion of polymeric rule material. This eliminates the need for large storage areas to keep inventory of steel rules, as the polymeric material can be manufactured directly on the die body when needed, reducing storage area requirements while maintaining the durability of the rules.
Solution Approach 2:
The patent employs a system where polymeric rules are manufactured on-demand rather than stored for future use. This approach eliminates the need for extensive storage facilities, as rules are created only when needed for production, reducing the area of stationary storage objects while maintaining operational reliability.
5Reliability
If traditional steel-rule die systems are used, then durability is improved, but manufacturing time and lead time increase
Solution Approach 1:
The patent applies preliminary action by pre-positioning the polymeric rule material directly onto the die body through extrusion before the actual die-cutting or creasing operation. This eliminates the time-consuming steps of manually fitting and securing steel rules, reducing production lead time while ensuring the rules are properly positioned for durable operation.
Solution Approach 2:
The patent replaces the time-consuming mechanical assembly process of fitting steel rules with a rapid extrusion and curing process. The polymeric material is extruded and cured in place, significantly reducing the time required to prepare the die for operation while maintaining the durability and reliability of the rules during use.
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
The polymeric rule die system reduces environmental impact, minimizes resource consumption, and simplifies production, enabling the creation of high-quality creases and new package shapes with improved sustainability and aesthetic quality.
Implementation Method 1
extruding through the nozzle onto the broad surface of the die, as the nozzle and the die body are moved relative to one another, a flowable polymerisable material and polymerising the extruded material to form a rule that is bonded to the broad surface of the die body
Implementation Method 2
polymerising the extruded material to form a rule that is bonded to the broad surface of the die body
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
A surface-adhesive-rule technology (SART) for creating a surface-adhesive-rule (SAR) die and counter die for pre-treating cardboard. Wherein the pre-treating comprises: creasing, cutting, embossing the cardboard. The SART system may comprise: a rule-drawer having one or more: cartridges, nozzles, and pressure actuator. A leading mechanism that carries the rule-drawer; and a controller that controls the rule-drawer and the leading mechanism according to a layout of a SAR die. Each cartridge may comprise flexible materiel and may be associated with a nozzle having an orifice with a profile. Further the leading mechanism moves the rule-drawer and the rule-drawer draws a plurality of surface-adhesive rules from the flexible material having an attribute to reserve the shape of the orifice profile through which it is deposited on the surface of a die's body according to commands obtained from the controller.