Container Forming Machine with Segmented Folding and Pre-glued Blanks
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Solution Overview
Problem
Existing machines for forming containers from blanks lack precision and are slow, leading to non-optimal formation and potential damage, making them unsuitable for containing small-sized loose articles.
Innovation Solution
A machine with shaping hoppers that progressively fold tubular blanks using a conveyor and pushing elements, along with folding means to create a tapered cross-sectional shape, ensuring precise and high-speed formation without breaking components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional folding mechanisms are used to form containers from blanks, then the container formation process can be completed, but the precision is insufficient and the operation speed is slow
Solution Approach 1:
The container formation process is divided into multiple sequential folding operations performed by separate folding elements (first folding element, second folding element, third folding element, fourth folding element). Each element handles a specific folding action on the blank, allowing precise control of each step while maintaining high-speed continuous production through the conveyor system.
Solution Approach 2:
The blanks are pre-glued before entering the forming mechanism, creating initial bonds that maintain structural integrity during the high-speed folding operations. This preliminary action allows the subsequent folding elements to operate at high speed without compromising formation precision, as the pre-glued structure provides a stable base for the folding actions.
2Productivity
If conventional folding mechanisms operate at high speed, then productivity increases, but the container formation quality deteriorates and damage may occur
Solution Approach 1:
The high-speed forming process is segmented into multiple discrete folding actions, each performed by a dedicated folding element. This segmentation allows each element to execute its specific folding task quickly and accurately, maintaining formation quality even at high operating speeds through the coordinated sequence of specialized folding operations.
Solution Approach 2:
Pre-gluing the blanks before high-speed folding creates initial structural stability, enabling the subsequent rapid folding operations to maintain precision. The preliminary bonding ensures that the blank maintains its integrity during high-speed manipulation by the folding elements, preventing damage while achieving high productivity.
3Shape
If the blank is folded using conventional means, then the container shape is formed, but the risk of breaking components increases
Solution Approach 1:
The blanks are pre-glued to create initial structural bonds before entering the folding sequence. This preliminary action significantly reduces the risk of component breaking during folding, as the pre-established bonds maintain structural integrity throughout the forming process while still allowing the blank to achieve the desired container shape.
Solution Approach 2:
The folding process is divided into multiple gentle, sequential actions by different folding elements rather than a single aggressive fold. This segmentation allows the blank to gradually transform into the container shape while maintaining component integrity, as each folding element performs a controlled, localized folding action that minimizes stress and breaking risk.
Data Source
AI summary
Described are a machine and a method for forming containers from blanks, including a plurality of shaping hoppers, an endless conveyor which defines a feed path and on which the hoppers are mounted in succession and a plurality of pushing elements which are movable in such a way as to follow the respective shaping hoppers along at least a stretch of the feed path and which have a to-and-fro operating movement towards and away from the respective hopper along a direction transverse, preferably perpendicular, to the feed path. The machine also includes folding means disposed along the feed path downstream of the pushing elements and configured to produce, respectively, a top closure and/or a bottom closure of the tubular blank.