Bail Handle Applicator Mandrel System for Lightweight Containers
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Solution Overview
Problem
Existing methods for installing a bail handle on lightweight containers with little to no top load strength often result in the container top crushing due to the required downward force.
Innovation Solution
An apparatus and method using a pickup mandrel, stationary mandrel, and applicator mandrel with vacuum assistance and collars to apply a bail handle to a container without applying force on the top, utilizing frustoconical shapes and inclined tabs to secure the handle without damaging the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bail handle is applied to a lightweight container using conventional methods, then the handle can be installed, but the container top will crush due to the downward force required
Solution Approach 1:
The installation process is divided into multiple stages using different mandrels: a pickup mandrel for initial handling, a stationary mandrel for stable positioning during handle attachment, and an applicator mandrel for final installation. This segmentation allows the handle to be installed without applying crushing force to the container top.
Solution Approach 2:
The stationary mandrel acts as an intermediary support structure that receives the bail handle from the pickup mandrel and provides a stable base for attachment. This intermediary allows the handle to be secured without directly loading the container top.
2Reliability
If downward force is applied to install the bail handle, then the handle can be secured to the container, but lightweight containers with little top load strength will be damaged
Solution Approach 1:
The bail handle is preliminarily attached to the stationary mandrel before being transferred to the container. This preliminary action secures the handle in the correct position and orientation, ensuring reliable attachment without requiring forceful downward pressure on the container top during the final installation.
Solution Approach 2:
Instead of applying downward force directly to the container top to install the handle, the method inverts the approach by first securing the handle to a stationary mandrel and then transferring it to the container. This reversal eliminates the harmful downward force on the container while achieving secure handle attachment.
3Ease of operation
If a pickup mandrel with vacuum openings is used to pick up the bail handle, then the handle can be grasped and positioned, but the mandrel structure becomes more complex
Solution Approach 1:
The pickup mandrel incorporates vacuum openings that use pneumatic principles to grasp and hold the bail handle. This pneumatic mechanism provides easy and reliable pickup and positioning of the handle without requiring complex mechanical clamping structures, thereby improving ease of operation while minimizing added complexity.
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
Enables the installation of a bail handle on lightweight containers without applying significant downward force, preventing top crushing and ensuring the container's integrity.
Implementation Method 1
a pickup mandrel that further comprises openings for applying a vacuum to the bail handle
Data Source
AI summary
Provided is a method and apparatus for applying a bail handle to a container. The applicator includes a pickup mandrel for picking up the bail handle to be applied to a container; a stationary mandrel for receiving the bail handle from the pickup mandrel, the stationary mandrel having an engaging surface which has a diameter larger than an inner diameter of the bail handle when picked up by the pickup mandrel; and an applicator mandrel for receiving the bail handle from the pickup mandrel, the applicator mandrel having an engaging surface which has a diameter equal to or smaller than the stationary mandrel.