Carton Forming Mandrel and Panel Rotation Mechanism

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Solution Overview

Problem

Current carton forming systems face challenges such as unstable stacking, increased shipping costs due to asymmetric shapes, limited depth, and complexity in forming cartons of different sizes, especially when using corrugated fibreboard materials.

Innovation Solution

A system comprising a mandrel and a panel rotation apparatus that orients carton blanks from a flat configuration to a orthogonal configuration, allowing for efficient top-loading and forming of cartons with increased structural stability and leak resistance, capable of accommodating various sizes and depths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pre-folded and pre-glued blanks are used to enable easy erection, then carton formation speed is improved, but shipping stability deteriorates due to asymmetric shape and unstable stacking

Engineering Contradiction:
Improvecarton formation speedVSAvoidshipping stability
Core Design Contradiction:
ProductivityVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-scoring the blank along predetermined fold lines before shipping. This allows the blank to be easily erected at the destination without requiring pre-folding or pre-gluing. The scoring creates weak points that facilitate clean folding, enabling rapid carton formation while maintaining a flat, stable configuration for efficient shipping and stacking.

Inventive Principle:
Principle #10Preliminary action

2Loss of energy

If completely flat unglued blanks are used for bulk shipping, then shipping cost is reduced, but device complexity increases to fold and configure the blank

Engineering Contradiction:
Improveshipping costVSAvoidfolding mechanism complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the blank into multiple panels separated by predetermined fold lines that are pre-scored. This segmentation allows each panel to be independently positioned and folded along its designated line. The scoring creates controlled weak points that guide the folding process, reducing the complexity of the forming mechanism while enabling reliable carton construction from flat blanks.

Inventive Principle:
Principle #1Segmentation

3Adaptability or versatility

If complicated shoe devices and plungers are used to fold blanks, then carton formation capability is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:
Improvecarton formation capabilityVSAvoidshoe device complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies self-service by designing the blank with self-aligning features including predetermined fold lines and positioning elements. When the blank is placed in the forming device, these features automatically guide the blank into the correct position and orientation. The pre-scored fold lines create natural bending points that guide the folding process without requiring complex guidance mechanisms, allowing the blank to essentially form itself with minimal mechanical intervention.

Inventive Principle:
Principle #25Self-service

4Strength

If pre-formed interlocking panels are used to eliminate glue, then structural stability is improved, but manufacturing precision requirements increase for interlocking features

Engineering Contradiction:
Improvestructural stabilityVSAvoidinterlocking panel precision
Core Design Contradiction:
StrengthVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by modifying the physical properties of the blank through pre-scoring. The scoring process creates controlled weaknesses along predetermined lines, changing the mechanical properties of the material at those locations. This allows the panels to be easily folded and interconnected along the scored lines without requiring high-precision interlocking features or glue, as the scored lines provide natural alignment and connection points that maintain structural stability.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS8961380B2Method and system for forming a carton from a carton blank
Publication Date: 2015.02.24 LANGEN H J PAUL
  • US8961380B2 patent drawing
  • US8961380B2 patent drawing
  • US8961380B2 patent drawing

AI summary

Systems and methods are disclosed for forming a carton. The system may comprise a magazine for storing a plurality of carton blanks in a generally flat configuration. The system also has a mandrel and a panel rotation apparatus. The mandrel has a first surface oriented at a first orientation and a second surface oriented at a second orientation that may be generally orthogonal to the first orientation. The panel rotation apparatus is operable to engage a second panel of the carton blank and rotate the second panel to proximate to, and generally in the same orientation as, the second surface of the mandrel such that the second panel is oriented in a second orientation generally orthogonal to the first panel.