Corrugated Board Cutting and Speed Control for Precision Folding
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Solution Overview
Problem
Existing methods for producing corrugated board boxes face challenges in precision folding and cutting, leading to misaligned flaps and reduced efficiency, especially when cutting larger sheets into smaller boxes, and generate paper powder that can contaminate the product.
Innovation Solution
A method and device that preprocess a corrugated board sheet by creasing, slitting, and then cutting it into individual boxes before gluing and folding, using a speed increasing unit with endless belts to transfer and space the cut pieces precisely, enhancing cutting precision and reducing paper powder issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a corrugated board sheet of smaller size is produced to make small boxes, then the box size requirement is met, but the production efficiency is reduced and installation cost increases
Solution Approach 1:
The patent divides a large corrugated board sheet into multiple smaller sheets during the production process. By cutting the large sheet into smaller portions before box formation, the system can produce small boxes using standard equipment while maintaining high production efficiency. This segmentation allows one large sheet to serve multiple box production cycles without requiring specialized small-box machinery.
2Manufacturing precision
If folding precision is insufficient in the folding unit, then the panels are not folded at right angles causing misaligned flaps, but increasing folding precision requirements increases device complexity
Solution Approach 1:
The patent performs cutting operations before the folding and gluing steps. By dividing the large corrugated sheet into smaller sheets beforehand, the folding unit deals with smaller, more manageable pieces that are easier to fold precisely at right angles. This preliminary segmentation reduces the complexity requirements of the folding unit while ensuring proper flap alignment.
3Reliability
If cutting is performed after gluing and folding, then the box structure is complete, but cutting precision is reduced and paper powder contaminates the product
Solution Approach 1:
The patent performs cutting operations before gluing and folding steps. By cutting the corrugated board sheet into smaller portions while it remains flat and accessible, the system achieves higher cutting precision. The cut pieces are then processed through gluing and folding to create the final box structure, ensuring both precision and structural integrity without paper powder contamination from post-assembly cutting.
4Productivity
If a stack of board boxes is cut all at once, then processing speed is increased, but cutting precision is reduced and size accuracy is compromised
Solution Approach 1:
The patent segments the cutting process by dividing the large corrugated sheet into smaller sheets individually before box formation. Instead of cutting a complete stack of formed boxes simultaneously, the system cuts the flat sheet material in controlled portions. This approach maintains cutting size accuracy while still achieving high productivity through continuous processing of multiple smaller pieces in sequence.
Data Source
AI summary
Disclosed is a method for producing a board box by performing a box-making process of a corrugated board sheet which is formed to have dimensions of a plurality of board boxes wherein the yield of the board sheet and the production efficiency are enhanced and a countermeasure can be taken against paper powder. A method for making a box of a corrugated board sheet by performing a box-making process of a board sheet (S) which is formed to have dimensions of a plurality of board boxes and the cutting the board sheet (S) into dimensions of one board box comprises a step (I) for cutting the board sheet (S) into dimensions of one board box by a cut line (k) in the direction intersecting the conveyance direction (a) along a box making line (PL) after a ruling and grooving step (C) and before a pasting and folding step (E), and a speed increase step (J) for spacing the board sheets (S1) and (S2) thus cut by a set dimension following to the cutting step (I) by increasing the speed of the board sheets (S1) and (S2) while conveying toward a subsequent step.