Blank Containment Device for Pressware Die Centering
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Solution Overview
Problem
The existing methods for forming disposable pressware containers, such as paperboard plates, face challenges in maintaining consistent positioning of circular blanks within die sets, leading to off-center products and increased waste due to cumbersome and hazardous adjustment processes of conventional blank stops, and inefficient energy absorption with rotating pin stops.
Innovation Solution
The implementation of improved stop mechanisms, including a lower die with defined recesses and adjustable stops that can be easily positioned using screws, combined with a draw ring featuring a recess to center and contain blanks effectively, allowing for better control over blank placement and energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional blank stops with shims are used, then positioning adjustment is possible, but adjustment is cumbersome and limited to discrete intervals
Solution Approach 1:
The patent replaces the mechanical shim-based adjustment system with a threaded rod mechanism that allows continuous positioning adjustment. The threaded rod engages with a nut or threaded hole in the blank stop, enabling smooth movement along the threaded path rather than discrete shim insertions.
Solution Approach 2:
The blank stop is made adjustable and dynamic through the threaded rod mechanism, allowing it to move to different positions along the draw ring. This replaces the static, fixed-position conventional blank stops that require disassembly and shim insertion for adjustment.
2Manufacturing precision
If conventional blank stops are adjusted, then positioning can be modified, but operator safety is compromised due to burn risk from hot forming apparatus
Solution Approach 1:
The forming apparatus adjusts itself through the threaded rod mechanism that can be operated from a safe position. The adjustment system allows the operator to control the blank stop position without physically placing hands near the hot forming surfaces, making the system self-adjusting from a safe distance.
3Loss of energy
If rotating pin stops are used, then some energy absorption occurs, but energy absorption efficiency is insufficient leading to blank bounce and off-center positioning
Solution Approach 1:
The patent extracts the energy absorption function from the positioning system by introducing a separate damping element that specifically addresses kinetic energy dissipation. This dedicated energy absorption component works in conjunction with the threaded rod positioning system to first stop the blank and then dissipate its energy.
Solution Approach 2:
The damping element is positioned to engage with the blank before it can bounce off the blank stop. This beforehand cushioning absorbs the impact energy and prevents the blank from rebounding, ensuring it remains centered in the die cavity.
4Ease of manufacture
If gravity-fed blank delivery is used, then feeding is simple, but blank bounce and off-center positioning occur due to significant impact energy
Solution Approach 1:
The patent introduces an intermediary damping element between the gravity-fed blank delivery system and the die cavity. This intermediary component absorbs the impact energy from the gravity-fed blanks, mediating the transition from high-speed delivery to precise positioning without requiring a completely different feeding mechanism.
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 solution enhances production speed by up to 15% and significantly reduces waste by ensuring accurate centering and forming of pressware containers, enabling the creation of plates with specific characteristics that were previously unattainable on conventional tooling.
Implementation Method 1
blanks that are gravity fed to the die forming apparatus contact the fixed angular blank stops with significant speed and energy. As a result, blanks will often 'bounce back' at least once before settling in between the two dies
Implementation Method 2
inefficient energy absorption with rotating pin stops
Data Source
AI summary
Embodiments of the invention provide improvements to dies used in the formation of pressware from blanks. In some embodiments, the die includes at least one stop that helps contain the blank as it is fed to the die and that allows for improved adjustability of the stop with respect to the die. In some embodiments, the die includes a defined recess that contains and centers the blank on the die as the blank is fed to the die.