Tubular Punch Insert Placement in Foil Cavities
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Solution Overview
Problem
Current methods for inserting electronic modules or transparent inserts into smart cards or similar fine documents face challenges due to the thin thickness of the card and insert materials, resulting in a minimum gap of 0.05 to 0.10 mm between the insert and the cavity, which is difficult to eliminate and requires complex, high-precision machinery, increasing manufacturing costs.
Innovation Solution
A method using a tubular cutting punch to create a cavity and cut an insert from film, where the punch is lowered orthogonally to cut a slug, then lifted to clear space for the film, and the insert is cut and pushed into the cavity without moving the foil, eliminating the need for high-precision positioning systems and ensuring a precise fit without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-precision robotised multiple-axis machines with assisted vision control systems are used to place inserts in cavities, then positioning precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The process is segmented into two sequential punching operations: first creating the cavity in the foil, then cutting the insert from the film. Each operation uses a simple tubular punch without requiring complex positioning systems, achieving high precision through process segmentation rather than sophisticated equipment
Solution Approach 2:
The same tubular punch that creates the cavity serves dual purpose by also cutting the insert to the exact same dimensions and shape. The punch essentially 'measures' and 'cuts' the insert based on its own geometry, eliminating the need for separate positioning and measurement systems
2Manufacturing precision
If high-precision robotised multiple-axis machines with assisted vision control systems are used to place inserts in cavities, then positioning precision is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive, complex high-precision machines with simple, inexpensive tubular punches. The punches are basic tooling elements that can be easily manufactured and replaced, eliminating the need for costly robotised systems with vision control while achieving the same positioning precision
Solution Approach 2:
The invention extracts and eliminates the unnecessary complexity of high-precision positioning systems, assisted vision control, and multiple-axis robots from the manufacturing process. Only the essential punching function remains, performed by simple tubular tools that achieve precision through the process design rather than equipment sophistication
3Ease of operation
If the foil is displaced transversally during the cutting and insertion process, then flexibility in operation is improved, but positioning precision deteriorates
Solution Approach 1:
The cavity is punched in the foil first, establishing a fixed reference position. The foil is then positioned relative to this pre-created cavity before the insert is cut and inserted. This preliminary action of creating the cavity first serves as a positioning reference that eliminates the need for complex real-time alignment during subsequent operations
Data Source
AI summary
To place an insert cut out of film with no gaps in a cavity formed in a foil, after placing the foil on a supporting substrate, the cavity is punched into the foil by means of a tubular cutting punch comprising an inner pusher with a cutting edge in the required shaped of the cavity and the insert, so that the edge goes through the thickness of the foil and cuts a slug out of it; the punch is lifted with the slug held inside the punch, without moving the foil, the film is brought between the foil and the edge of the punch, the punch is lowered once again so as to cut the insert out of the film and then push the insert cut in that way in the cavity with a pusher, and the punch and the pusher are removed, with the insert held in place in the cavity.