Punch Tool Scoring Edge for SIM Card Substrate
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Solution Overview
Problem
Existing punch tools for creating data cards, such as SIM cards, face issues with securely holding the card within the carrier card while allowing easy detachment and often result in cracks due to high punching pressures, and struggle with robust connections that make separation difficult.
Innovation Solution
A punch tool with a rectilinear shape and rounded corners, featuring cut-outs and adjustable blades with a chamfered cutting edge, which punches and scores the substrate to create a plug card that can be easily detached from the carrier card, using a single tool to increase accuracy and reduce cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high punching pressures are used to securely hold the card within the carrier card, then the connection strength is improved, but cracks occur on the punched edge
Solution Approach 1:
The punching process is segmented into two distinct stages: first a punching stage that creates the card outline, then a scoring stage that creates a separation line. This segmentation allows each stage to use optimized pressure levels - high pressure for punching to ensure secure retention, and lower pressure for scoring to avoid cracking while still enabling easy separation.
Solution Approach 2:
The scoring action is performed preliminarily during the punching process itself, creating a pre-weakened separation line before the card is fully punched out. This preliminary scoring creates a line of weakness that facilitates easy later separation without requiring additional high-pressure operations that would cause cracking.
2Strength
If robust connections are created between the card and carrier card, then the card is securely retained, but the card becomes difficult to separate
Solution Approach 1:
The connection between card and carrier is segmented into two functional zones: a robust peripheral connection for secure retention, and a weakened scoring line for easy separation. This segmentation allows the card to be securely held during use while enabling simple detachment when needed.
Solution Approach 2:
Different mechanical properties are applied to different locations: the peripheral connection areas maintain full strength for secure retention, while the scoring line areas are locally weakened to facilitate easy separation. This local quality differentiation resolves the contradiction between strong retention and easy separation.
3Ease of manufacture
If a single punch tool is used for both punching and scoring, then manufacturing complexity is reduced, but the tool design becomes more complex
Solution Approach 1:
The punching and scoring functions are merged into a single integrated punch tool. The tool body incorporates both a punching edge for creating the card outline and scoring blades for creating the separation line, eliminating the need for separate tools and operations while streamlining the manufacturing process.
Solution Approach 2:
The punch tool is designed as a multi-functional device that performs both punching and scoring operations in a single tool. This universality allows one tool to accomplish what previously required multiple specialized tools, reducing manufacturing complexity despite the increased design requirements.
Data Source
Figure 1~3
AI summary
A punch tool (1) for punching a plug in smart card from a substrate where the punch tool has an edge (20) to delineate at least part of a periphery of the plug in card and there is also cutting edge (24) for cutting the areas not punched by the tool. The cutting edge passes partway through the depth of the substrate when the periphery is punched out by the edge (20) so connections between the plug in card and the main body are formed in a single action using a single tool.