Creased Blank for Forming Containers with Rounded Edges
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Solution Overview
Problem
Existing methods for forming containers with rounded or beveled edges require significant modifications to packing machinery and additional processing steps, leading to increased costs, complexity, and machine downtime, as they necessitate pre-bending and specialized equipment to maintain the desired shape and appearance.
Innovation Solution
A laminar blank with modified edge portions featuring a zone of creasing lines and a zone free of creasing lines allows for easier folding into containers with rounded or beveled edges, eliminating the need for pre-bending and major machinery modifications, using dust flaps to compensate for reduced panel widths and facilitate smooth folding on conventional machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the blank is modified to form containers with rounded or beveled edges, then the container appearance and shape are improved, but the overall width of the blank is reduced requiring significant packing machine modifications
Solution Approach 1:
The modified edge portion is segmented into a first zone with creasing lines and a second zone free of creasing lines. This segmentation allows the blank to be folded progressively through multiple creasing lines rather than requiring a single sharp bend, enabling rounded or beveled edges to form on conventional packing machines without major modifications
Solution Approach 2:
The blank has different local properties: the first zone contains creasing lines that guide folding, while the second zone is free of creasing lines to allow the blank panels to be at least partly superimposed and affixed to each other. This local differentiation enables the formation of rounded or beveled edges while maintaining compatibility with conventional packing machines
2Shape
If creasing lines are included to define bevelled or rounded edge portions, then the desired container shape is achieved, but an additional pre-bending step is required increasing process complexity
Solution Approach 1:
The creasing lines are pre-formed in the blank at specific locations and orientations before the folding process. These pre-formed creasing lines guide the folding operation to automatically produce the desired rounded or beveled edges without requiring additional pre-bending steps or specialist equipment
Solution Approach 2:
The invention extracts the pre-bending operation from the assembly process by incorporating all necessary creasing lines directly into the blank design. This eliminates the need for separate pre-bending equipment and steps, simplifying the overall manufacturing process while maintaining the ability to form rounded or beveled edges
3Shape
If the blank width is reduced to accommodate bevelled or rounded edges, then the container shape is improved, but machine downtime increases due to significant packing machine modifications
Solution Approach 1:
The modified edge portion design with its two-zone structure serves multiple functions: it guides folding through creasing lines, allows panel superimposition in the second zone, and maintains compatibility with conventional packing machines. This multi-functionality enables the use of existing machinery without major modifications, avoiding increased machine downtime
4Shape
If the blank is designed with reduced panel widths for rounded edges, then the container appearance is improved, but additional manufacturing costs are incurred
Solution Approach 1:
The blank design incorporates all necessary features for forming rounded or beveled edges directly into the structure itself through the modified edge portion with its two-zone creasing pattern. This self-service approach eliminates the need for additional specialized equipment, pre-bending steps, or complex machine modifications, thereby reducing additional manufacturing costs while achieving the desired container appearance
Data Source
AI summary
A blank (300) for forming a container for consumer articles comprises panels (308, 309, 312, 314) for forming corresponding walls of the container. First side panels (311) extend from the rear wall panel (312) and second side panels (310) extend from the front wall panel (308). When assembling the container, the first and the second side panels overlap to form at least part of left and right side walls. The first side panels or the second side panels or both are connected to the respective one of the rear wall panel and the front wall panel by modified edge portions (3100, 3110, 3120, 3130). The blank comprises a pair of flaps extending from the first side panels or the second side panels or both.