Fiber Packaging Forming Fixing Element Segmentation
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Solution Overview
Problem
Existing fiber-based packaging materials have limited formability during deep drawing, restricting design freedom and increasing the risk of cracks, which hampers the creation of complex packaging structures like blister or clamshell packs.
Innovation Solution
A device comprising a die with a mold cavity, a stamp, and a hold-down device, along with a fixing element that reduces material flow during shaping, allows for greater deformation and formation of complex packaging elements from fiber-based materials like paper or cardboard, enabling the creation of multi-cavity packs and clamshell designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fiber-based packaging material is used to facilitate recycling, then environmental compatibility is improved, but formability during deep drawing deteriorates
Solution Approach 1:
The hold-down device is divided into multiple sections with fixing elements (pins) that segment the packaging material at specific locations. This segmentation allows different regions of the material to have different degrees of freedom during forming, enabling complex shapes to be achieved without exceeding the yield point of the fiber-based material.
Solution Approach 2:
The fixing elements are positioned in advance at predetermined locations on the hold-down device before the forming process begins. This preliminary positioning controls the material flow and deformation pattern during deep drawing, preventing cracks while achieving the desired complex packaging shapes.
2Adaptability or versatility
If the packaging material is stretched beyond the permissible yield point to achieve complex shapes, then design freedom is improved, but cracks occur
Solution Approach 1:
The hold-down device implements local quality control through strategically positioned fixing elements that provide differential constraints across the packaging material surface. Areas with fixing elements maintain stricter control to prevent cracking, while areas without fixing elements allow greater deformation freedom to achieve complex shapes.
Solution Approach 2:
The invention changes the physical parameters of the forming process by introducing fixed reference points through the fixing elements. This alters the stress distribution and deformation pattern during deep drawing, enabling the material to undergo larger overall deformations without local stress concentrations that would cause cracking.
3Manufacturing precision
If hold-down pressure is increased to prevent material flow, then positioning accuracy is improved, but deformation capability deteriorates
Solution Approach 1:
Instead of applying uniform hold-down pressure across the entire material surface, the invention segments the constraint function into discrete fixing elements. This segmentation provides precise positioning at critical locations while leaving other areas free to deform, thereby maintaining both positioning accuracy and deformation capability.
Solution Approach 2:
The fixing elements provide dynamic constraints that adapt to the forming process. They maintain fixed positions to ensure positioning accuracy while allowing the material to deform around them, effectively decoupling the positioning function from the deformation limitation that would result from uniform pressure application.
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
The solution enhances the formability of fiber-based packaging materials, allowing for the production of packaging elements with greater deformation and complexity, while preventing cracks and enabling efficient recycling, thus offering environmental compatibility and design flexibility.
Implementation Method 1
at least one punch with which the packaging element can be drawn into the at least one mold cavity to form at least one shape
Implementation Method 2
at least one fixing element with which, in at least one region of the gap, a subsequent flow of the packaging element during the formation of the at least one shape can be at least reduced
Data Source
Figure 1
Figure 2~3
AI summary
Device (1) for forming a packaging element (2, 13) which consists at least partially of a fiber-based packaging material, comprising at least: - a die (3) with at least one forming cavity (4); - at least one punch (5) with which the packaging element (2, 13) can be drawn into the at least one forming cavity (4) to form at least one shape (6.1, ..., 6.6); - at least one hold-down device (7, 8) for holding the packaging element (2, 13) in a gap (9); and - at least one fixing element (10) with which a flow of the packaging element (2, 13) in at least one region of the gap (9) during the formation of the at least one shape (6.1, ..., 6.6) can be at least reduced, wherein the at least one fixing element (10) extends at least partially through the gap (9).Furthermore, a method for forming a packaging element (2, 13) which consists at least partially of a fiber-based packaging material, using such a device (1) is proposed.