Fanfolding Thrust Tools for Corrugated Web Crease Control

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Solution Overview

Problem

Existing systems for forming and fanfolding sheet materials like corrugated cardboard suffer from the formation of press creases due to unilateral support and varying feeding speeds, which limit folding and stacking speed and efficiency.

Innovation Solution

A system with dual-sided creasing and thrust tools that form creases on both sides of the continuous web, ensuring coordinated folding and fanfolding without free zones, using interconnected tools to maintain web flatness and prevent press creases.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If support elements always support the strip from the bottom with unilateral support, then the structure is simple, but press creases form in the strip due to continuous changes of feeding speed

Engineering Contradiction:

Improvesupport structureVSAvoidcrease formation

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies bilateral support where thrust tools support the web from both top and bottom sides, reversing the conventional unilateral bottom-only support approach. This inversion allows the web to be supported during folding from both directions, preventing press creases while maintaining structural simplicity

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent implements localized thrust tools that apply support forces at specific locations on both sides of the web during folding. This local quality approach ensures precise control of the folding process at critical points without requiring complex global support structures

Inventive Principle:

Principle #3Local quality

2Device complexity

If support elements project in cantilever fashion and retract laterally to slide out of fold lines, then the mechanism is simple, but feeding speed decreases strongly affecting working speed

Engineering Contradiction:

Improvesupport mechanismVSAvoidfolding speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent employs thrust tools that move continuously with the web during the folding process rather than retracting and repositioning. This continuous action eliminates speed interruptions, maintaining constant feeding speed and maximizing productivity while keeping the mechanism relatively simple

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If latch members operate on the cardboard web on one side only at one every two fold lines, then the mechanism is simple, but press creases form in the vicinity of the first latch member and feeding speed is limited

Engineering Contradiction:

Improvefolding mechanismVSAvoidpress crease formation

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent transitions from unilateral latch member operation to bilateral thrust tool operation, applying support from both top and bottom sides of the web. This inversion eliminates press creases by distributing support forces evenly while allowing higher feeding speeds

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The thrust tools are positioned and activated in advance to support the web before folding occurs, ensuring proper web control and preventing press crease formation from the outset rather than reacting to creases after they form

Inventive Principle:

Principle #10Preliminary action

4Device complexity

If fold lines are formed on one side only of the strip, then the creasing process is simple, but press creases form due to unbalanced support

Engineering Contradiction:

Improvecreasing processVSAvoidweb flatness

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent forms creases on both top and bottom sides of the web alternately, inverting the conventional single-sided creasing approach. This bilateral creasing creates balanced folding characteristics that work synergistically with bilateral thrust tool support to maintain web flatness and prevent press creases

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP4341188B1A system and method for forming and fanfolding a sheet material

Publication Date: 2025.07.02 PANOTEC SRL

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AI summary

A system (1) for forming and fanfolding a sheet material, such as corrugated cardboard, from a continuous web (M) of indefinite length having a bottom side (S1), a top side (S2) and longitudinal side edges (B), which system (1) comprises a frame (3', 3'') defining a vertical center plane (π), a feeding device having means for guiding the web (M) in a longitudinal direction (L), a creasing device (2) located downstream of the feeding device to form transverse creases (C1, C2) on the web (M) spaced apart at a constant longitudinal pitch (K) and defining adjacent partitions (P), and a folding device (14) located downstream of the creasing device (2) for progressively and alternately folding the adjacent partitions (P) along the creases (C1, C2) into a fanfold arrangement. The folding device (14) comprises at least one first group (15) of thrust tools (17) acting on the creases (C1) formed on the bottom side (S1) of the web (M) and at least one second group (16) of thrust tools (18) acting on the creases (C2) formed on the top side (S2) of the web (M). The thrust tools of each group (15, 16) are mechanically connected to and operatively dependent on each other so that all the tools of the same group (15, 16) will be forced to follow the same trajectory (T1, T2).