Container Manufacturing Machine with Micro-Shaping Relief
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Solution Overview
Problem
Existing machines for manufacturing containers from composite materials are limited in shape modification and cannot produce defined, marked decorations, leading to standardized and unvaried container designs.
Innovation Solution
A machine that impresses a shape in relief on a sheet of deformable material, forms a tubular blank, and closes the bottom end, allowing for micro-shaping to create complex designs and decorations, while also enabling macro-shaping through blow moulding, with the use of ultrasound welding for joining and heat-weldability to simplify the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If blow moulding is used for macroshaping, then the overall external shape can be modified, but defined and marked decorations cannot be realized
Solution Approach 1:
The shaping process is divided into two distinct stages: macroshaping through blow moulding to create the overall external shape, and microshaping through impression moulding to add defined decorations. This segmentation allows each process to specialize in one aspect without compromising the other.
Solution Approach 2:
The microshaping impression is applied to the container blank before the final blow moulding process. This preliminary action ensures that the decorative relief pattern is already present on the material, allowing the subsequent blow moulding to preserve rather than destroy the decorative details.
2Adaptability or versatility
If the container shape is significantly modified, then variety is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The impression mould is designed to serve multiple functions: it creates the decorative relief pattern, defines the container's cross-sectional shape, and establishes the structural framework. This multi-functionality allows various container shapes to be produced using the same basic process sequence, reducing overall system complexity.
Solution Approach 2:
The invention allows modification of container shapes by changing parameters such as the relief pattern design, material properties, and processing conditions, rather than requiring fundamentally different manufacturing equipment for each shape variation.
3Manufacturing precision
If microshaping is applied to create complex designs, then decoration quality improves, but material stretching requirements increase
Solution Approach 1:
The material's physical parameters are modified by heating it to increased temperatures before the microshaping impression process. This temporary parameter change increases the material's ductility and stretching capacity, allowing complex decorative patterns to be impressed without exceeding the material's strength limits.
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
Enables the production of containers with defined and marked relief shapes, increased productivity, and varied designs, while maintaining a simple and cost-effective manufacturing process.
Implementation Method 1
The method can comprise a step of heating the sheet, before carrying out the step of impressing the shape in relief. This step has the effect of increasing the malleability of the material and making the following impression step more effective.
Implementation Method 2
Following the enveloping step, the lateral flaps of the sheet can be reciprocally joined by ultrasound welding.
Implementation Method 3
deformation by blow moulding of the container, also known as macroshaping, is obtained by closing the container internally of a profiled cavity, created by closing two half-dies and forcing the lateral walls of the container against the walls of the profiled cavity, by means of insufflating pressurized gas therein.
Data Source
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AI summary
An embodiment of the present invention discloses a machine (100) for realising containers, comprising: a first apparatus (110) for impressing a shape in relief on a sheet (905) of deformable material, a second apparatus (115) able to envelop the sheet on itself and reciprocally join lateral flaps thereof in order to form a tubular blank (915), and a third apparatus (120) able to close a bottom end of the tubular blank (915), wherein the second apparatus (115) comprises: a plurality of support cores (335), each of which is provided with enveloping means (340, 345) for winding a sheet about itself, and movement means (355) of the support cores (335) through a plurality of work stations, which comprise at least a receiving station (365) of the sheet from the first apparatus, a fixing station (370) provided with means (470) able to reciprocally join the lateral flaps of the sheet enveloped on the support core (335), and a transfer station (380) of the sheet to the third apparatus (120), wherein the movement means (355) of the second apparatus (115) comprise a rotor (385) able to rotate about a horizontal axis, about which the support cores (335) are arranged radially and angularly equidistant, wherein the third apparatus (120) comprises: a plurality of support cores (600), movement means (635) of the support cores through a plurality of work stations, which comprise at least a receiving station (640) of the tubular blank from the second apparatus (115), a sealing station (645) comprising means (675) for flattening a bottom end of the tubular blank (915) bringing two portions into reciprocal contact and joining the two portions to one another, forming a rib, and a release station (650) of the tubular blank from the support core, and folding means (720) arranged between the sealing station and the release station, which are able to cooperate with the movement of the support core (600) between the stations, for folding the opposite ends of the rib below and towards an inside of the tubular blank (915), wherein the movement means (635) of the third apparatus (120) comprise a rotor (660) able to rotate about a horizontal axis, about which the support cores (600) are arranged radially and angularly equidistant.