Cup Forming with Non-Circular Mandrel for Circular Cross-Section
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Solution Overview
Problem
Existing methods for producing cups from paper and similar materials face challenges in shaping thick and stiff materials, particularly in forming airtight connections and maintaining circular cross-sections, which complicates the production of top curls and bottom skirts.
Innovation Solution
A method involving winding flat segments onto a mandrel with a non-circular cross-section, applying differential pressing forces, and using a pressing die to form a conical sleeve, which simplifies the formation of airtight connections and maintains a circular cross-section, even with stiff materials, by doubling the material thickness at the overlap region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flat segment is wound onto a circular mandrel to form a conical sleeve, then the cup structure is formed, but the cross-section deviates from circular shape when using thick and stiff materials
Solution Approach 1:
The patent applies asymmetry by using a mandrel with a non-circular cross-section (specifically oval or flattened in the overlap region) rather than a circular one. This asymmetric mandrel shape compensates for the doubled material thickness at the overlap region, ensuring that the final cup achieves a circular cross-section despite the asymmetric material distribution during winding.
Solution Approach 2:
The patent applies local quality by differentiating the mandrel shape in specific regions: the mandrel is flattened or oval in the region where the material overlap occurs, while other regions maintain different characteristics. This localized shape adjustment ensures proper circular cross-section formation only where needed at the overlap region.
2Strength
If pressing force is applied uniformly across the overlap region, then the material is compressed, but the top curl and bottom skirt formation becomes difficult for thick materials
Solution Approach 1:
The patent applies local quality by exerting differential pressing forces on different regions of the overlap. Specifically, greater pressing force is applied to the regions directly adjoining the top edge and bottom edge of the sleeve, while less force is applied to the center region. This localized differential pressing simplifies the subsequent formation of top curls and bottom skirts by pre-compressing the material where it will be folded.
Solution Approach 2:
The patent applies preliminary action by pre-compressing the overlap regions before the actual cup forming operations. The differential pressing force is applied in advance to prepare the material structure, making the subsequent folding and forming of top curls and bottom skirts easier and more efficient.
3Reliability
If the overlap region is not compressed, then the material remains thick, but airtight connection and proper shaping becomes problematic
Solution Approach 1:
The patent applies local quality by selectively compressing only the overlap regions of the conical sleeve while leaving other regions uncompressed. This localized compression achieves airtight connections at the overlap areas through increased material density and bonding pressure, while maintaining uniform material thickness in the non-overlap regions for proper shaping.
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 method allows for the efficient production of cups with airtight connections and circular cross-sections, enabling the processing of thick and stiff paper or plastic materials without requiring significant apparatus reinforcement, and simplifies the formation of top curls and bottom skirts.
Implementation Method 1
a pressing force is exerted in the region of the overlap when the sections which adjoin the side edges are connected, wherein the pressing force is greater in those regions which directly adjoin the bottom edge of the sleeve and the top edge of the sleeve than in the other regions of the overlap
Implementation Method 2
winding the flat segment onto a winding mandrel, so that there is an overlap in the region of the side edges of the segment... with winding mandrel a cross section of the winding mandrel differs from a circular shape
Data Source
AI summary
A method for producing a cup from a flat segment and a pot-like base, including the steps of winding the flat segment onto a winding mandrel, so that there is an overlap in the region of the side edges of the segment, connecting the sections, which adjoin the side edges, in the region of the overlap, so that a conical sleeve is produced, inserting the pot-like base into the conical sleeve, and connecting a circumferential wall of the pot-like base in a substantially liquid-tight manner to an inner face of the sleeve.