Sequential Creasing and Laser Cutting for Custom Cardboard Sheets
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Solution Overview
Problem
Current technologies for producing cardboard and corrugated cardboard packaging and displays face limitations in flexibility and customization due to the use of mechanical dies, leading to high setup times, logistic complications, and low productivity, especially with the introduction of digital printers.
Innovation Solution
An 'all-in-one' apparatus for sequential creasing and cutting using an optical station, creasing module, and laser cutting module, controlled by a programmable logic controller (PLC) and processing unit, which synchronizes conveyor belts for precise and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical dies are used for cutting and creasing, then high production speeds are achieved, but flexibility and customization are limited due to die replacement requirements
Solution Approach 1:
The patent replaces traditional mechanical die systems with a laser-based processing system. The laser apparatus can perform both cutting and creasing operations without requiring physical die replacement, thereby maintaining high production speeds while enabling flexible customization for different packaging designs and materials.
Solution Approach 2:
The laser apparatus is designed to perform multiple functions (cutting, creasing, and marking) using a single device. This multi-functional capability eliminates the need for separate die tools for each operation, providing both high productivity and adaptability for various production requirements.
2Reliability
If separate dedicated machines are used for creasing and laser cutting, then each process can be optimized, but continuous processing is not possible and productivity decreases
Solution Approach 1:
The patent combines creasing and laser cutting operations into a single integrated apparatus. The laser system can sequentially perform creasing followed by cutting on the same material sheet without requiring transfer between machines, enabling continuous processing and improving overall productivity while maintaining process optimization.
3Adaptability or versatility
If traditional plotter systems with mechanical tools are used, then customization possibilities are enabled, but productivity remains limited
Solution Approach 1:
The patent replaces mechanical plotter tools with a laser-based system that maintains the customization capabilities of digital design while eliminating the speed limitations of mechanical cutting tools. The laser can rapidly process customized designs without the physical constraints of mechanical die replacement or tool movement.
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
Enables high-speed, flexible, and precise production of customized cardboard and corrugated cardboard products with reduced downtime, optimizing productivity and minimizing waste.
Implementation Method 1
a laser cutting module provided downstream of the creasing module for carrying out sequential laser cutting on the sheet
Implementation Method 2
an optical register designed to acquire parameters of the received sheet such as thickness of the sheet, creasing pattern, laser cutting pattern, X/Y offset positions, rotation angle, print deformations
Data Source
Figure 1~2
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AI summary
In an apparatus (1) and a method for creasing and cutting sheets of material for packaging or display, or corrugated carton structure material such as cardboard and corrugated cardboard, a sheet Sx to be processed is fed sequentially through an optical station (100), a creasing module (200) and a laser cutting module (300) for being sequentially creased and cut, and wherein the creasing and cutting status work profiles are input by a programming logic controller (PLC) by way of a Job Processor, and wherein the speeds of the conveyor belts that convey the sheets, are adjusted automatically by a processing unit based on parameters of the creasing and cutting operations.