Upper Punch Segmentation for Ridge-Free Compact Pressing

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Solution Overview

Problem

Existing compact production methods result in compacts with webs, leading to instability, discomfort during consumption, and aesthetic issues due to web-related discoloration and irregular shapes.

Innovation Solution

A tool system comprising an upper punch with a larger diameter and a lower punch, where the upper punch molding element and lower punch molding element interact to form the compact shape, reducing or eliminating the web by determining the compact's geometric shape independently of the die, thereby allowing for the production of rimless or minimally webbed compacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional punch and die system is used for compact production, then the compact can be produced efficiently, but the compact develops a ridge (web) that reduces stability and creates aesthetic issues

Engineering Contradiction:

Improvecompact shape uniformityVSAvoidcompact stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The upper punch is segmented into two functional parts: an upper punch forming element (with smaller diameter) that defines the compact geometry, and an upper punch rim element (with larger diameter) that contacts the die disk. This segmentation allows the forming elements to create ridge-free compacts while the rim element provides structural support and positioning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the upper punch have different diameters and functions. The central forming element has a smaller diameter matched to the die opening to prevent ridge formation, while the peripheral rim element has a larger diameter for mechanical support. This local differentiation resolves the contradiction between forming precision and structural stability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If traditional punch design with matching diameters is used, then the punching operation is simple, but ridge formation occurs affecting consumption comfort and appearance

Engineering Contradiction:

Improvepunching operation simplicityVSAvoidridge-related discomfort and discoloration

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Instead of making the punch diameter match the die opening (traditional approach), the invention inverts the relationship by making the forming element diameter smaller than the die opening. This inversion prevents the material from contacting the die wall during forming, eliminating ridge formation while maintaining manufacturing simplicity.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If upper punch diameter is increased to prevent ridge formation, then ridge-free compacts are achieved, but the punch requires larger support structure

Engineering Contradiction:

Improveridge eliminationVSAvoidpunch structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The upper punch is divided into the forming element and rim element, allowing the forming element to maintain a diameter matched to the compact size (for precision) while the rim element provides the larger diameter needed for mechanical support. This segmentation avoids the need for a completely larger punch structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The punch structure has localized variations in diameter: the central forming region has smaller diameter for precision forming, while the peripheral rim region has larger diameter for structural support. This local quality differentiation achieves ridge elimination without overall structural complexity.

Inventive Principle:

Principle #3Local quality

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 achieves compacts with enhanced stability, improved swallowing experience, and a uniform aesthetic appearance by eliminating or significantly reducing the web, resulting in a more consistent and visually appealing product.

Implementation Method 1

the two punches are moved towards each other by control cams and enter the area of a pressure roller station. In the pressure roller station, the punches are pressed against each other, compacting the material in the die opening or die into a tablet

Methodology Applied

Scientific EffectMechanical pressure: Mechanical Force

Data Source

PatentEP4253027A1Device for producing borderless pressed articles

Publication Date: 2023.10.04 KORSCH AG DE

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Figure 2

AI summary

In a first aspect, the invention relates to a tooling system for producing a compact during a pressing operation of a press machine, comprising an upper punch (3) and a lower punch (5). The upper punch (3) comprises an upper punch forming element (7) and the lower punch (5) a lower punch forming element (9), which together form the geometric shape of the compact. Furthermore, the upper punch (3) has an upper punch rim element (11), which gives the upper punch (3) a larger diameter compared to the diameters of the upper punch forming element and the lower punch forming element, so that the upper punch can be placed on a die disk or a die (13) during the pressing of the material. In a further aspect, the invention relates to a press machine comprising the tooling system according to the invention.Additionally, the invention relates to a pressing method for producing a pressed piece in a pressing process using the tool system according to the invention.