Laminar Blank with Ablated Lines for Complex Container Shapes
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Solution Overview
Problem
Existing manufacturing processes for complex-shaped containers for consumer goods require specialized machines and significant downtime, increasing costs and inefficiencies, especially when transitioning between different container shapes.
Innovation Solution
A container design that utilizes a laminar blank with strategically placed ablation areas and ablated lines, allowing for the formation of three-dimensional walls using existing high-speed manufacturing machines with minimal modification, where the folding forces during assembly deform the blank to create complex shapes automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If specialized manufacturing machines are used to produce complex-shaped containers, then the container shape complexity is improved, but the manufacturing cost and machine downtime increase
Solution Approach 1:
The patent applies preliminary action by pre-forming ablation areas and ablated lines on the blank before the main forming process. These pre-prepared features enable the blank to automatically deform into complex three-dimensional shapes during normal high-speed manufacturing, eliminating the need for specialized deformation devices while achieving complex container shapes.
Solution Approach 2:
The invention enables self-service by designing the blank with ablation areas and ablated lines that allow the material itself to deform into complex shapes under normal folding forces during assembly. The blank serves its own shaping function without requiring external specialized equipment, thus avoiding increased device complexity while achieving complex container geometries.
2Shape
If specialized deformation devices are used to modify container walls after assembly, then the container shape is improved, but the process complexity and time consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-forming ablation areas and ablated lines on the blank before assembly. This ensures that the complex wall shapes are achieved during the normal high-speed assembly process, eliminating the need for post-assembly deformation operations and maintaining high productivity.
Solution Approach 2:
Instead of deforming the container walls after assembly as in conventional methods, the invention inverts the sequence by pre-preparing the blank with ablation features that enable automatic deformation during assembly. This reversal of the process sequence eliminates post-assembly deformation steps and maintains manufacturing efficiency.
3Ease of manufacture
If existing high-speed machines are used with minimal modification, then the manufacturing cost is reduced, but the container shape complexity is limited
Solution Approach 1:
The patent applies preliminary action by pre-forming ablation areas and ablated lines on the blank using existing high-speed manufacturing equipment. This preliminary preparation enables the blank to automatically deform into complex three-dimensional shapes during normal assembly, allowing existing machines to produce complex container shapes without major modifications while maintaining cost-effectiveness.
4Shape
If ablated lines extend across the inner surface of walls, then the three-dimensional shape is achieved, but the structural integrity may be compromised
Solution Approach 1:
The patent applies local quality by strategically positioning ablation areas and ablated lines in specific locations on the blank where they will create the desired three-dimensional wall shapes upon deformation. The ablated lines are configured to extend across the inner surface in patterns that achieve complex geometries while maintaining adequate structural integrity in critical load-bearing areas.
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
Enables the production of containers with complex shapes on existing high-speed machines with minimal downtime and cost, maintaining a smooth outer surface and facilitating easy adaptation to different shapes without major machine modifications.
Implementation Method 1
At least one of the front wall and the rear wall comprises an ablation area, wherein any ablation area on the front wall comprises at least one ablated line extending across the inner surface of the front wall to define a portion of the front wall that is spaced outwardly from the first plane
Implementation Method 2
the folding forces during assembly deform the blank to create complex shapes automatically
Data Source
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AI summary
There is provided a container (10) for consumer goods, the container (10) being at least partially formed from a blank (100) having a thickness (T). The container (10) comprises a top wall (12), a bottom wall, a front wall (14), a rear wall (16), and first and second side walls (18, 20). A top wall front edge (22), a bottom wall front edge (30), a first side wall front edge (38), and a second side wall front edge (42) together extend along a first plane. A top wall rear edge (24), a bottom wall rear edge (32), a first side wall rear edge (40), and a second side wall rear edge (44) together extend along a second plane. At least one of the front wall (14) and the rear wall (16) comprises an ablation area, wherein any ablation area on the front wall (14) comprises at least one ablated line (46, 48, 50, 52, 54) extending across the inner surface of the front wall (14) to define a portion (56) of the front wall (14) that is spaced outwardly from the first plane, and wherein any ablation area on the rear wall (16) comprises at least one ablated line (58, 60, 62, 64, 66) extending across the inner surface of the rear wall (16) to define a portion of the rear wall (16) that is spaced outwardly from the second plane. Each ablated line has a residual thickness (RT1 ) that is less than the thickness (T) of the laminar blank (100).