Integrated Tooling for Container Flange Forming
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Solution Overview
Problem
Existing tools for forming flanged containers from blanks are inefficient and require multiple steps, leading to higher tooling costs and waste, as they lack a unified mechanism to form both the container body and flange effectively.
Innovation Solution
A tool comprising a first and second tool assembly, where at least one assembly is movable between open and closed positions, featuring flange forming collars that allow for the folding and clamping of a rolled flange, enabling the formation of a container with a single step process, integrating the formation of the bottom wall, side wall, and flange into a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple tool assemblies are used to form the container body and flange separately, then the forming process can be divided into distinct steps, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple tool assemblies into a single integrated tool assembly that performs both container body forming and flange forming operations. The tool assembly includes a first forming surface for the container body and a second forming surface for the flange, both integrated into one device that moves simultaneously to complete both forming operations in a single step, thereby reducing device complexity while maintaining manufacturing simplicity
Solution Approach 2:
The integrated tool assembly serves multiple functions: it forms both the container body and the flange structure, and it can process different types of blanks (paperboard, plastic, metal) within a single device. This multi-functionality eliminates the need for separate specialized tool assemblies for each forming operation
2Manufacturing precision
If multiple tool assemblies are used for separate forming operations, then each operation can be optimized independently, but the manufacturing time and productivity decrease
Solution Approach 1:
The integrated tool assembly performs container body forming and flange forming simultaneously in a continuous motion, eliminating the idle time between separate operations. The tool moves from the open position through the forming operation to the closed position in one continuous action, maximizing productivity while maintaining precision through the integrated design
Solution Approach 2:
The tool assembly is pre-configured with both forming surfaces positioned and oriented correctly before the forming operation begins. The first forming surface for the container body and the second forming surface for the flange are both prepared in advance within the same tool assembly, allowing immediate simultaneous forming when the tool is activated
3Device complexity
If separate tool assemblies are used for container body and flange forming, then each tool can be simpler in design, but material waste increases due to multiple handling steps
Solution Approach 1:
By merging the container body forming and flange forming operations into a single integrated tool assembly, the patent eliminates multiple handling steps that would otherwise be required. The blank remains in position throughout the process, being formed in one location by the integrated tool, which prevents material waste from handling, repositioning, and transfer between separate tools
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 integrated tooling process reduces manufacturing complexity, lowers costs, and enhances efficiency by allowing a single tool to form a complete container with a rolled flange, eliminating the need for multiple tool assemblies and minimizing waste.
Implementation Method 1
pressing the blank between the first tool assembly and the second tool assembly to form the blank into the container having an interior and actuating the flange forming features for forming the flange of the container by at least partially folding a first portion of the flange with respect to a second portion of the flange
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
A tool and a method for forming a container from a blank, the container including a flange. The tool comprises a first tool assembly (41) and a second tool assembly (43). At least one of the first tool assembly and the second tool assembly is moveable between an open position, wherein the blank is received between the first tool assembly and the second tool assembly, and a closed position wherein the blank is formed into the container. The first tool assembly and the second tool assembly comprise flange forming collars (59, 75, 77) for forming the flange of the container whereby a first portion of the flange is folded with respect to a second portion of the flange.