Rotary Cutting Die Product Ejector Substrate Design
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Solution Overview
Problem
Rotary cutting dies for corrugated board face challenges in controlling pressure exerted by product ejectors, leading to flute crushing when pressure is too great, and inadequate separation when pressure is too low, affecting the strength and appearance of die-cut boxes.
Innovation Solution
A rotary cutting die design featuring product ejectors secured to a flexible substrate that extends completely through the die board, allowing them to project outwardly and be compressed between the die cylinder and anvil, enabling controlled pressure application without directly impacting the die board, thus preventing flute crushing and ensuring proper product separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure exerted by product ejectors is increased to ensure separation of die cut product from cutting die, then separation effectiveness is improved, but the flutes are crushed and product quality deteriorates
Solution Approach 1:
The product ejectors are made resilient/compliant rather than rigid, allowing them to dynamically adapt their pressure during the ejection process. This enables sufficient force for separation while automatically limiting pressure to prevent flute crushing, resolving the contradiction between separation effectiveness and product quality.
Solution Approach 2:
The material properties of the product ejectors are changed to be resilient or compliant, fundamentally altering the pressure characteristics. This material parameter change allows the ejectors to provide adequate ejection force while inherently limiting peak pressure to protect the corrugated flutes, simultaneously achieving both separation effectiveness and preventing damage.
2Manufacturing precision
If the height of product ejectors is increased to improve pressure control, then pressure limitation capability is improved, but the complexity of the die board structure increases
Solution Approach 1:
The die board structure is segmented by introducing a separate substrate layer distinct from the main die board. Product ejector openings are formed only in the substrate, allowing independent optimization of ejector height and pressure control without complicating the overall die board structure. This segmentation enables precise pressure control while maintaining structural simplicity.
Solution Approach 2:
A substrate is introduced as an intermediary layer between the die board and the product ejectors. This substrate serves as a dedicated platform for mounting ejectors with controlled height, decoupling the ejector height requirement from the die board structure. The substrate acts as a mediator that enables precise pressure control while keeping the die board design simple and manageable.
3Device complexity
If product ejectors are mounted directly to the die board, then the structure is simplified, but the height of product ejectors is limited and pressure control becomes difficult
Solution Approach 1:
The structure is segmented into three distinct components: the die board, the substrate mounted on the die board, and the product ejectors mounted on the substrate. This segmentation allows the ejectors to achieve greater height and better pressure control through the substrate, while the overall structure remains organized and manageable, effectively resolving the contradiction between structural simplicity and pressure control capability.
Solution Approach 2:
The structure transitions from a two-dimensional mounting (ejectors directly on die board surface) to a three-dimensional arrangement by introducing a substrate layer. This dimensional change enables increased ejector height and improved pressure control capability while maintaining structural organization, effectively overcoming the limitations of direct mounting.
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 design maximizes the height of product ejectors, allowing for precise control of pressure to prevent flute crushing while ensuring effective separation of the die-cut product, enhancing the stacking strength and appearance of the boxes.
Implementation Method 1
The product ejectors are resilient or compliant so that the height of the product ejectors can be controlled or limited
Implementation Method 2
the substrate comprises a flexible tape having an adhesive surface that secures the tape to the die board
Data Source
AI summary
A rotary cutting die including a curved die board having a series of product ejector openings formed completely through the die board. Secured to an inner surface of the die board is a substrate. A series of product ejectors are secured to the substrate and project therefrom through the product ejector openings and past an outer surface of the die board. These product ejectors function to engage a portion of a die cut product passing through the nip and exert a force on the die cut product which assists in separating the die cut product from the rotary cutting die.