Thermoforming Die Staggered Perforating Edges
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Solution Overview
Problem
Existing methods for producing thermoformed articles with non-planar mechanical weakening, such as food packaging, require additional processes like laser beam or water jet cutting, which are costly and inefficient, and cannot produce articles with complex geometries without re-adjusting focusing.
Innovation Solution
A thermoforming die with staggered and angled perforating or stamping cutting edges allows for the introduction of mechanical weakening during the thermoforming process, eliminating the need for additional cutting processes and enabling the production of complex geometries in a single station using standard thermoforming machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional processes like laser beam or water jet cutting are used to produce non-planar mechanical weakening, then the weakening pattern can be complex and arbitrary, but the production cost increases and manufacturing sequence becomes complex
Solution Approach 1:
The patent combines the mechanical weakening process with the thermoforming process into a single integrated operation. The perforating or stamping element is incorporated directly into the thermoforming die, allowing both the shaping and weakening of the plastic sheet to occur simultaneously during one closing movement of the upper and lower dies, eliminating the need for separate cutting processes
Solution Approach 2:
The thermoforming die is designed to perform multiple functions: it not only forms the spatial structure of the thermoformed article but also introduces the mechanical weakening through integrated perforating or stamping elements. This multi-functional die eliminates the need for separate specialized cutting equipment
2Adaptability or versatility
If laser beam or water jet is used for non-planar weakening, then arbitrary weakening patterns can be achieved, but additional processing steps and focusing re-adjustment are required
Solution Approach 1:
The mechanical weakening is introduced during the thermoforming process itself, before the article is removed from the die. The perforating or stamping elements are positioned and configured in advance within the die structure, so that when the die closes, both the forming and weakening actions occur simultaneously without requiring subsequent re-positioning or re-adjustment operations
Solution Approach 2:
The patent merges two separate processes (thermoforming and mechanical weakening) into a single integrated process. The upper and lower dies not only form the article but also simultaneously introduce the weakening through their integrated elements, eliminating the need for separate post-processing steps
3Shape
If mechanical weakening is introduced after thermoforming, then the article structure is first formed, but additional process steps and costs are incurred
Solution Approach 1:
The mechanical weakening is introduced during the thermoforming process itself, before the article is removed from the die. The perforating or stamping elements are positioned and configured in advance within the die structure, so that when the die closes, both the forming and weakening actions occur simultaneously without requiring subsequent re-positioning or re-adjustment operations
Solution Approach 2:
The patent merges two separate processes (thermoforming and mechanical weakening) into a single integrated process. The upper and lower dies not only form the article but also simultaneously introduce the weakening through their integrated elements, eliminating the need for separate post-processing steps
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 method enables the cost-effective production of thermoformed articles with arbitrary weakening patterns without additional processing steps, reducing production costs and simplifying manufacturing sequences, while maintaining high stability and allowing for the creation of customized lid elements.
Implementation Method 1
thermoforming the fed plastic sheet by closing the upper die and the lower die in the direction of movement of the die
Implementation Method 2
the mechanical weakening being introduced during the period of time during which the material to be formed is located in the thermoforming die
Data Source
AI summary
The invention relates to a process for producing thermoformed articles such as food packagings or parts thereof with a mechanical weakening between adjoining functional areas, which, for utilization by a user, can be at least partly separated at the mechanical weakening, in a thermoforming die having an upper die and a lower die, the mechanical weakening being introduced with a three-dimensional extension during the period of time during which the material to be formed is located in the thermoforming die, and a thermoforming die for implementing the process.