Rotary Cutting Die Inserts for Corrugated Board Ejection
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Solution Overview
Problem
Rotary cutting dies for corrugated board struggle to control pressure exerted by product ejectors, leading to either damage of the die cut product or inadequate separation, as existing solutions like softer elastomer ejectors or water jet cutters have limited success and are costly.
Innovation Solution
The rotary cutting die incorporates inserts that support product ejectors, allowing them to extend below the die board's outer surface, reducing compressed pressure and enabling controlled ejection without damaging the corrugated board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If product ejectors exert high pressure to separate die cut product from cutting die, then separation effectiveness is improved, but flute crushing and product damage occur
Solution Approach 1:
The patent introduces an intermediary structure (the insert with recessed area) between the die board and the product ejector. This intermediary allows the ejector to be positioned closer to the product while distributing the ejection force over a larger area, reducing pressure concentration that causes flute crushing while maintaining effective separation.
Solution Approach 2:
The patent changes the geometric parameters of the ejector support structure by creating a recessed area in the insert. This modifies the pressure distribution parameters of the ejector, allowing it to exert sufficient force for separation while reducing peak pressure that would crush the flutes. The recessed area effectively increases the contact area and redistributes the force.
2Object-affected harmful factors
If softer elastomer ejectors are used to reduce pressure, then flute crushing is reduced, but cost increases and separation effectiveness decreases
Solution Approach 1:
Instead of changing the material properties (softness) of the ejector, the patent changes the geometric parameters by introducing a recessed support structure. This allows the use of standard, cost-effective ejector materials while achieving pressure control through geometric design rather than material selection.
Solution Approach 2:
The recessed insert acts as an intermediary that mediates between the ejector and the product. It provides a structured support that distributes the ejection force, achieving the pressure control effect without requiring softer, more expensive elastomer materials.
3Stress or pressure
If product ejectors are made longer to reduce compressed pressure, then pressure control is improved, but device complexity increases
Solution Approach 1:
The patent embeds the ejector support insert within the die board structure, creating a nested configuration. The insert with its recessed area is integrated into the existing die board, allowing longer ejectors to be supported without adding external complexity or requiring separate support structures.
Solution Approach 2:
The insert structure serves multiple functions: it supports the ejector, provides the recessed area for pressure distribution, and integrates with the die board. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity despite the longer ejector length.
Data Source
AI summary
A rotary cutting die apparatus for die cutting corrugated board. The apparatus comprises a die board having one or more opening formed therein. Inserts are seated and secured in the openings. Product ejectors for ejecting die cut product are adhered or otherwise secured to the inserts that are in turn secured within the openings in the die board.