Box Corner Reinforcement via Side Wall Positioning
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Solution Overview
Problem
Current methods for manufacturing packaging boxes are complex and require precise positioning of angular elements, leading to inefficient gluing and stability issues due to incorrect alignment, which affects the stackability and stability of the boxes.
Innovation Solution
A method and machine that involves folding and gluing angular elements directly onto the inner faces of side walls using hot gluing, cold gluing, or metallic staples, eliminating the need for accurate positioning on the bottom wall, and utilizing a machine with cutting, feeding, and gripping devices to simplify the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If angular elements are positioned on the bottom wall before gluing, then positioning accuracy is improved, but system complexity increases due to extreme accuracy requirements
Solution Approach 1:
The patent inverts the conventional sequence by positioning angular elements on the side walls instead of the bottom wall. This reversal eliminates the need for complex positioning mechanisms on the bottom wall, as the angular elements are now positioned during the side wall folding operation itself, which is a simpler and more integrated process step.
Solution Approach 2:
The angular elements are positioned on the side walls before the folding operation, allowing them to be automatically positioned during the folding process itself. This preliminary positioning eliminates the need for separate, complex positioning mechanisms, as the folding action naturally places the angular elements in their correct positions.
2Productivity
If angular elements are incorrectly positioned, then gluing efficiency is improved, but box stability deteriorates
Solution Approach 1:
By inverting the positioning location from bottom wall to side wall, the patent ensures that angular elements are positioned during the side wall folding operation. This guarantees correct positioning and effective gluing, as the angular elements are now positioned relative to the side walls they will be attached to, eliminating the stability issues caused by incorrect bottom wall positioning.
3Manufacturing precision
If precise positioning mechanisms are implemented, then angular element placement accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the need for expensive precise positioning mechanisms by inverting the positioning approach. Instead of using complex mechanisms to position angular elements on the bottom wall, the system positions them on the side walls during the folding operation, which is a simpler, lower-cost process that achieves the same positioning accuracy.
Solution Approach 2:
The folding operation itself serves the dual function of forming the side walls and positioning the angular elements. This self-service approach eliminates the need for separate positioning mechanisms, as the folding action naturally positions the angular elements in their correct locations during the same operational step.
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
Ensures correct and effective fastening of side walls to angular elements, simplifying the production system and reducing costs by eliminating the complexity of precise positioning, thereby enhancing the stability and stackability of the boxes.
Implementation Method 1
Each gripping head 20 being defined by a body displaying a plurality of nozzles which hold the corresponding angular element 5 on such a body by means of a suction
Implementation Method 2
a step in which two first side panels opposing to each other are folded orthogonally to the central panel
Implementation Method 3
The angular elements 5 are each fixed to the inner face of the corresponding side walls 3 and 4 (specifically, according to the embodiment shown in figure 3, to the inner face of the corresponding side wall 4 and of the corresponding appendix) by hot gluing
Implementation Method 4
The forming plate 15 (figure 10), which is adapted to be vertically handled by means of actuating devices (intrinsically known and not shown) and to be coupled with a flat blank 16 and to push the flat blank 16 itself downwards and along a forming channel 17
Data Source
Figure 1~2
Figure 3~6
Figure 4~5
AI summary
A box (1) is made according to the method, including a box body (1a) defined by a bottom wall (2), several side wall (3, 4), and several angles (4a) delimited by adjacent side walls; and angular elements (5) arranged at an angle (4a). The method includes a step of folding a flat blank (16) displaying a central panel (2') which defines the bottom wall (2), at least one first side panel (4') which includes an appendix (6), and two second side panels (3'); in the step of folding, the side panels are folded to define the side walls; the appendix is folded to define a corner of a angle of the box body and to overlap a second panel; and a step of fastening in which the angular element is fixed to the box body. The main feature of the method consists in that it includes a step of affixing in which the angular element is arranged on the flat blank; the step of affixing being essentially prior to the step of folding.