Curvilinear Box Forming Machine Seamless Base Integration
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Solution Overview
Problem
Existing machines for forming and covering curvilinear paper or cardboard boxes face challenges in automatic production, as separate parts like the base and cylindrical wall are not seamlessly integrated, and the entire processing from assembly to covering is not efficiently automated, resulting in low productivity and quality issues.
Innovation Solution
A machine and method that stably joins a pre-glued disk to the base and cylindrical wall, using a gripper element and conveyor belt for precise alignment, followed by a carrousel unit with a covering station that rotates and synchronizes the box with a pre-glued covering sheet for complete coverage, ensuring high-quality and efficient production of curvilinear boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If prior art machines assemble separate parts (base and cylindrical wall) by gluing, then the box structure is formed, but the separate parts are visible and felt in the finished box, reducing product quality
Solution Approach 1:
The patent merges the base and cylindrical wall into a single integrated piece of cardboard through a die-cutting process. The cardboard blank includes both the base portion and cylindrical wall portion as one continuous structure, eliminating the need for separate assembly operations and ensuring seamless integration in the finished box.
Solution Approach 2:
The patent performs preliminary forming of the cylindrical shape and pre-assembly of the base and wall during the die-cutting and forming stages, before the final box assembly. The cardboard is pre-formed into a cylindrical shape with the base already attached, reducing subsequent assembly complexity.
2Productivity
If prior art machines perform assembly and covering as separate operations, then the box structure is completed, but productivity is reduced due to manual intervention requirements
Solution Approach 1:
The patent combines multiple operations (die-cutting, forming, assembly, and covering) into a single integrated machine system. The covering station is integrated into the forming machine, allowing the entire process from blank to finished covered box to be performed automatically in one continuous operation.
Solution Approach 2:
The patent implements a continuous automatic process where the box moves through die-cutting, forming, assembly, and covering operations without interruption or manual intervention. The machine maintains continuous operation, with the covering station automatically applying the covering material as the box is formed and assembled.
3Speed
If the box is formed from separate base and wall parts, then assembly is possible, but the joining process requires additional gluing operations that reduce production speed
Solution Approach 1:
The cardboard blank is segmented into functional zones (base portion, cylindrical wall portion, and covering portion) that are die-cut from a single sheet. This segmentation allows each zone to be formed and assembled in its optimal position without requiring separate handling or additional joining operations.
Data Source
AI summary
A machine for making covered paper or cardboard boxes which have a curvilinear outline includes elements for forming a curvilinear box (6) and a covering station (R) operating in conjunction with elements for the linear feed of a pre-glued covering sheet (12), in such a way that the sheet (12) is connected to the outer wall of the box (6).