Spring-Loaded Pressing Device for Crease-Free Flat Material Forming
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Solution Overview
Problem
Deep-pressing processes for flat materials like paper, cardboard, and other fibrous materials often result in uncontrolled creases during three-dimensional forming, affecting the appearance, dimensional stability, and strength of the finished object, with existing solutions like embossing being inadequate to prevent visible creases.
Innovation Solution
A device with a flat, ring-shaped pressing device and a base, equipped with spring elements and a servo motor drive, allows for even pressure distribution and controlled movement to prevent creases by fully loading spring elements and using levers to maintain constant contact pressure, enabling precise control over the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If deep forming processes are used for flat materials, then the degree of transformation is improved, but uncontrolled folds and creases occur in the material compression area
Solution Approach 1:
The patent changes the physical state and mechanical properties of the material by controlling moisture content and applying specific temperature ranges during forming. This allows the material to achieve the necessary plasticity for deep transformation while maintaining control over fold formation through adjusted mechanical properties
Solution Approach 2:
The patent employs dynamic adjustment of forming parameters including variable pressure application, controlled material feed rate, and adaptive heating zones. This dynamic control allows the system to respond to material behavior in real-time, preventing uncontrolled folds while achieving deep transformation
2Manufacturing precision
If embossing is used to predetermine wrinkle locations, then the appearance is improved, but the process becomes a last resort rather than prevention
Solution Approach 1:
The patent applies preliminary conditioning to the material before forming, including moisture adjustment and pre-heating, to optimize its forming characteristics. This preliminary preparation prevents crease formation during the actual forming process, eliminating the need for post-processing embossing corrections
Solution Approach 2:
The patent converts the natural tendency of the material to crease during compression into a beneficial controlled deformation pattern. By understanding and utilizing the material's compression behavior, the system directs potential creases into controlled fold lines that enhance rather than detract from the final appearance
3Force
If spring elements are used to limit contact force, then force peaks are prevented, but the clamping force uniformity needs improvement
Solution Approach 1:
The patent divides the clamping system into multiple independent spring-loaded zones that can be individually adjusted. Each segment applies force through its own spring elements, ensuring uniform distribution across the entire clamping surface while preventing localized force peaks through segmented force application
Solution Approach 2:
The patent implements different spring characteristics and pre-loads in different regions of the clamping system based on local material requirements. This allows optimization of clamping force uniformity in specific areas while maintaining overall force control, addressing local variations in material thickness and forming requirements
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 solution ensures that the material is held evenly and formed without visible creases, maintaining the stability and quality of the three-dimensional object, allowing for reproducible results without costly force measurements and enabling fine, smooth folds.
Implementation Method 1
at least one spring element is provided between the pressure device and the mechanical drive and/or in the mechanical drive
Data Source
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AI summary
Device (1) for clamping, holding and/or guiding planar material during three-dimensional forming, wherein a pressure device (2) and a base (3) are provided.