Single Sheet Perforator Body Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manual perforators have a complex construction requiring numerous components and multiple production steps, leading to high production costs.
Innovation Solution
A manually actuated mechanical perforator with a body made from a single folded sheet of metal or plastic, providing mechanical strength, rigidity, and elasticity through specific folds and holes, which simplifies the assembly by interlocking punches and an adjustable abutment element, reducing the number of components and production steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional construction scheme with multiple components is used, then functional reliability is improved, but device complexity and production cost increase
Solution Approach 1:
The patent merges multiple conventional components (fixed part, movable part, elastic elements, guide structures, abutment elements) into a single integrated body made from one folded sheet. The body simultaneously provides structural support, elastic return force, punch guidance, and position adjustment functionality, reducing component count while maintaining operational reliability through the interconnected design of these functions within the single sheet structure.
Solution Approach 2:
The single sheet body performs multiple functions concurrently: it acts as the fixed part housing, provides elastic return through folded sections, guides punch movement through integrated guide holes, enables position adjustment via abutment elements, and collects punching scraps. This multi-functionality eliminates the need for separate components for each function, resolving the contradiction between reliability and complexity.
2Manufacturing precision
If conventional construction with multiple production steps is used, then manufacturing precision is improved, but productivity and cost increase
Solution Approach 1:
The body is created by folding a single sheet into distinct functional sections (fixed part, movable part, elastic sections, guide structures) that are interconnected but can be independently defined during the folding process. This segmentation allows each functional area to be optimized during the single production process while maintaining overall manufacturing efficiency and precision without requiring multiple assembly steps.
Solution Approach 2:
All structural features, guide holes, abutment elements, and elastic folded sections are pre-formed during the single sheet fabrication process before final assembly. The punches and other components are then simply inserted into the pre-formed body structure, eliminating the need for complex multi-step manufacturing and assembly operations, thereby improving productivity while maintaining precision.
3Ease of manufacture
If single sheet construction is used, then ease of manufacture and productivity are improved, but mechanical strength and rigidity may worsen
Solution Approach 1:
The single sheet is folded to create different local structural qualities in different sections: tightly folded sections with small radii provide rigidity and dimensional stability for the fixed part and guide structures, while sections with larger folding radii provide flexibility and elastic return force for the movable part. This local differentiation of structural properties within the single sheet resolves the contradiction between ease of manufacture and mechanical strength.
Solution Approach 2:
The patent utilizes the folded sheet structure itself as a composite system where the interconnected folded sections create a structure with both rigid and flexible properties. The combination of tightly folded rigid sections and loosely folded elastic sections within the single sheet provides the necessary mechanical strength and rigidity while maintaining the simplicity of single-sheet construction and ease of manufacture.
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 simplified design reduces production costs and allows for modular construction to produce holes in various formats, while maintaining functionality and safety features like minimized friction and secure punch locking.
Implementation Method 1
sections with large curvature are configured to provide the function of actual elastic elements
Implementation Method 2
The edges of the aforesaid guide holes are preferably rounded to minimize the friction due to the sliding of the punch itself
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
The present invention relates to a manual mechanical perforator of thin sheets, used to prepare such sheets for the use in ring binders, belonging to the stationery sector. The components of the perforators of the known solutions are subjected to numerous production steps and complex assembly steps. The technical issue underlying the present invention is that of reaching a functional synthesis, a streamlining of the number of components and production steps, and therefore the significant reduction of production costs. The main and modular body of the invention, therefore the functional elements defined therein, exclusively consists of a suitable arrangement of folds and holes produced on a single sheet of shaped material, characterized by specific mechanical and technological properties.