Patterning for constructable utensil
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Solution Overview
Problem
The manufacturing of patterned constructible utensils faces challenges in reducing costs and improving constructability, particularly due to the complexity and cost of creating score patterns that require intersecting score lines, which can lead to uneven folding and increased production costs, especially in high-volume disposable utensil production.
Innovation Solution
A system and method utilizing a bowl-forming score pattern with non-intersecting score elements that converge and produce discontinuities, allowing for more economical die production and enabling predictable uniform bending/folding, suitable for high-speed rotary printing processes, and adaptable to various substrates and utensil designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If intersecting score lines are used to create bowl-forming patterns, then the utensil can achieve complex shaping, but the manufacturing cost increases and folding uniformity decreases
Solution Approach 1:
The score pattern is divided into multiple non-intersecting score lines that segment the bowl-forming function across separate elements. Each score line independently contributes to the bowl shape without requiring intersection, simplifying die design and reducing manufacturing complexity while maintaining the overall bowl-forming capability
Solution Approach 2:
The score lines extend into the longitudinal dimension of the utensil, using length to achieve bowl-forming rather than relying on intersecting patterns in a single plane. This dimensional approach allows complex shaping through non-intersecting linear elements distributed along the utensil's length
2Shape
If intersecting score lines are used to create bowl-forming patterns, then the utensil can achieve complex shaping, but the folding uniformity and predictability decrease
Solution Approach 1:
By segmenting the bowl-forming function into multiple non-intersecting score lines, each score line can be precisely controlled and folded uniformly without the complications of intersections. This segmentation eliminates variability introduced by intersecting score patterns, improving folding predictability and uniformity
Solution Approach 2:
The score lines are pre-configured in specific patterns and positions on the blank before folding occurs. This preliminary arrangement of non-intersecting scores ensures that folding forces are distributed uniformly, creating predictable and consistent bowl formation without the need for complex intersecting patterns
3Adaptability or versatility
If complex score patterns are used, then the utensil shaping capability is improved, but the die production cost increases
Solution Approach 1:
The die is designed with multiple independent scoring elements that segment the shaping function. Each element can be independently manufactured and positioned, reducing die production complexity while maintaining versatile shaping capability through the combined action of multiple simple score lines
Solution Approach 2:
The die utilizes the longitudinal dimension of the blank to create shaping patterns, extending score lines along the length rather than relying on complex two-dimensional intersecting patterns. This approach simplifies die design while achieving versatile bowl-forming capability through the spatial distribution of non-intersecting scores
Data Source
AI summary
A system and method for reducing manufacturing costs of patterned constructible utensils and improving their constructability. One constructible utensil includes a set of scores (e.g., a quad of scores including an outer pair and an inner pair, a single such pair, or other number of scores) that are shaped to converge when moving from a bowl-region towards the handle portion. The scores do not intersect but stop and produce various alterations in the converging score pattern. These alterations in the converging pattern help with propagation of a bowl-forming fold responsive to a constructing manipulation of the handle portion (e.g., folding, bending, and other operation on the handle portion and one or more scores on the handle portion).