Heated Mandrels for Round Insulated Cup Forming
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Solution Overview
Problem
Existing cup-forming machines struggle to produce insulated cups with a round cross-section and minimize visible imperfections, often resulting in out-of-round cups and creases due to stress in the material during the forming process.
Innovation Solution
A cup-forming machine uses heated male and female mandrels and receivers to form insulated cups from cellular non-aromatic polymeric material blanks, applying heat to reduce stress and ensure a round cross-section and even brim formation, with the heat-control system maintaining temperatures between 150°F to 250°F for mandrels and 100°F to 250°F for receivers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heat is applied to the body blank during wrapping, then stress in the body blank is reduced and round cross-section is achieved, but device complexity increases due to heat-control system
Solution Approach 1:
The patent applies heat to the body blank during the wrapping operation, changing the temperature parameter of the material to reduce stress and enable proper forming. The heat-control system maintains temperatures between 150°F to 250°F for mandrels and 100°F to 250°F for receivers, which softens the cellular polymeric material and allows it to conform to the mandrel shape without stress-induced deformation, achieving a round cross-section.
2Manufacturing precision
If heat is applied to reduce stress, then visible imperfections are minimized, but energy consumption increases
Solution Approach 1:
The patent utilizes thermal energy to change the physical state of the cellular polymeric material by heating it to specific temperature ranges (150°F to 250°F for mandrels, 100°F to 250°F for receivers). This temperature control softens the material, allowing stress relief during forming without creating visible imperfections such as creases or deformities, while the heat-control system manages energy usage efficiently.
3Manufacturing precision
If heated male and female mandrels are used, then brim formation quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs heated male and female mandrels during the brim-forming operation, maintaining temperatures between 150°F to 250°F. This thermal parameter change keeps the cellular polymeric material pliable during brim curling, ensuring even and high-quality brim formation without visible imperfections. The heated mandrels prevent stress-induced defects while the heat-control system manages the thermal process efficiently.
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 process effectively minimizes the formation of out-of-round cups and visible imperfections, producing cups with a substantially round cross-section and even rolled brims, enhancing the quality and usability of the insulated cups.
Implementation Method 1
a heating operation in which heat is transferred to the body blank to reduce stress in the body blank during wrapping of the body blank around a heated male mandrel
Implementation Method 2
a warming operation in which heat is transferred to the body after the body-forming operation is complete and during curling of the top edge of the body during the brim-forming operation
Data Source
AI summary
A cup-forming machine includes having a male mandrel and a female receiver. The male mandrel uses a cup body blank and a floor blank to form a body of a cup. The female receive receives the body and forms a rolled brim on the body to establish a cup.