Stackable Cardboard Box Corner Reinforcement Folding
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Solution Overview
Problem
Single-station folder-gluer machines used for forming stackable cardboard boxes have limitations, including mediocre corner reinforcement quality, which affects the mechanical properties and resistance to compression, and require expensive two-station machines for better performance.
Innovation Solution
A method and machine design that uses a shaping cavity with multiple levels to fold corner reinforcement flaps with dihedral pressers, allowing a single pressing element to perform both folding steps, resulting in improved corner reinforcement geometry and mechanical properties without the need for indentations or openings, enabling the production of closed containers with enhanced compressive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional single-station machines use two separate forming means for corner reinforcement folding, then the corner reinforcements can be formed, but the structure becomes complex and the quality is poor with overlapping and irregular edges
Solution Approach 1:
The patent merges two separate forming means into a single integrated forming means that performs both folding operations. This single forming means includes a pressing member that can fold the corner reinforcement flap against the side wall and then fold it against the adjacent side wall, eliminating the need for two separate forming stations and reducing machine complexity while improving corner reinforcement quality by preventing overlapping and irregular edges
Solution Approach 2:
The patent introduces a new dimensional approach by using a pressing member that moves through three levels (first level, second level, and third level) of the forming cavity. The pressing member descends to the second level to perform the first fold, then the blank is raised to the third level to perform the second fold. This vertical dimensional change allows a single forming means to accomplish what traditionally required two separate forming means
2Ease of manufacture
If openings or notches are made in flaps to allow passage of forming means, then corner reinforcement folding can be achieved, but the mechanical properties and compressive strength are impaired
Solution Approach 1:
The patent applies preliminary action by providing folding guides that pre-position the side flaps in the correct orientation before the forming means arrives. The folding guides ensure that the side flaps are properly aligned and supported, allowing the pressing member to fold the corner reinforcement flap without needing to pass through openings or notches in the flaps, thereby maintaining the integrity and strength of the box structure
3Manufacturing precision
If two-station machines are used for better corner reinforcement quality, then manufacturing precision improves, but the machine cost and complexity increase
Solution Approach 1:
The patent merges the functions of two separate stations into a single station by integrating multiple forming operations into one cohesive forming cavity. The single forming means with its pressing member and folding guides performs all corner reinforcement folding operations in one station, eliminating the need for a second station while maintaining high manufacturing precision and corner reinforcement quality
Solution Approach 2:
The forming cavity and forming means are designed with multi-functionality to perform multiple operations within a single station. The pressing member can fold corner reinforcement flaps against different side walls, and the folding guides can accommodate various flap configurations, making the single station as effective as two separate stations
Data Source
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AI summary
The present invention relates in particular to a method of forming a blank so as to form a stackable cardboard box, and a machine implementing such a method, notable for corner reinforcements each formed by a single forming means carrying out a first fold of a corner reinforcement flap, at a level of the forming cavity, and a second fold of the flap, at another level of the forming cavity higher than that of the first fold.