Glued Top Flange Forming for Secure Corner Containers
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Solution Overview
Problem
Conventional containers with flanges are prone to disengagement and require complex, time-consuming, and expensive sealing processes due to the flange not being formed or glued in place during initial container formation, leading to weak and ineffective seals.
Innovation Solution
A container forming apparatus and method that includes a blank transfer station with adhesive applicators and a compression station with a vertically movable mandrel and forming tool to rotate and glue flange panels into a fully formed top flange, ensuring secure engagement and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flange is merely folded into place during initial container formation without gluing, then the container formation process is simple and fast, but the flange is weak and prone to disengagement
Solution Approach 1:
The adhesive is applied to the flange panels during the initial container formation process, before the panels are folded into place. This preliminary application of adhesive ensures that when the flange panels are folded and compressed, they are already bonded, creating a strong and reliable flange structure that resists disengagement while maintaining efficient production speed.
2Ease of manufacture
If the flange is not formed during initial container formation but folded out later, then containers can be stacked and transported efficiently, but the sealing process becomes complex and time-consuming
Solution Approach 1:
The flange panels are formed and bonded with adhesive during the initial container formation process, creating a fully formed and secure flange structure before the containers are stacked and transported. This preliminary formation eliminates the need for complex post-formation flange folding and sealing operations, significantly reducing sealing process time while maintaining ease of stacking and transport.
3Device complexity
If the flange is not glued in place during initial formation, then the manufacturing process is simpler and less expensive, but the container requires a more robust and expensive seal
Solution Approach 1:
The adhesive is applied to the flange panels during initial container formation, and the panels are folded and compressed to create a permanently bonded flange structure. This preliminary bonding eliminates the need for complex and expensive post-formation sealing mechanisms, as the flange itself provides the necessary structural integrity and sealing surface, thereby reducing both manufacturing process complexity and sealing costs.
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 structural integrity and sealing ability of containers by forming a fully glued flange during initial formation, improving de-nesting characteristics and enabling easier, faster, and more cost-effective sealing.
Implementation Method 1
at least one of the adhesive applicators applies hot-melt adhesive to an exterior surface of the flange panels extending from the top edge of the corner panels
Data Source
AI summary
A container forming apparatus for forming a container from a blank includes a blank transfer station including an adhesive assembly having a plurality of adhesive applicators, and a compression station downstream of the blank transfer station, the compression station including a vertically movable mandrel and a forming tool below the mandrel. The forming tool defines a cavity therein and has an inner profile complementary in shape to an outer profile of the mandrel. Hot-melt adhesive is applied to a surface of the blank as the blank is transferred through the adhesive assembly. The blank is positioned beneath the mandrel, and the mandrel drives the blank downward into the cavity of forming tool. Compression plates fold panels of the blank, and the formed container includes a fully formed top flange.