Mesh Container Folded from Single Perforated Sheet Metal Precursor
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Solution Overview
Problem
Existing methods for producing mesh containers with outwardly extending rims are inefficient, requiring separate steps for forming panels and attaching a rim, leading to higher manufacturing costs and material waste.
Innovation Solution
A method involving the expansion and cutting of a perforated sheet metal web to create precursors that can be folded into mesh containers with integrated side panels and rims, eliminating the need for a separate rim attachment step and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate mesh pieces are used to form side panels and a separate rail is fitted to form the rim, then the container can be assembled from multiple components, but the manufacturing process becomes more complex and time-consuming with separate attachment steps
Solution Approach 1:
The patent combines the side panels and rim into a single integrated mesh container body formed from one continuous mesh material. The mesh material is configured to form side panels, a bottom panel, and a rim as integral parts without requiring separate components or attachment steps, thereby simplifying the manufacturing process while maintaining structural integrity
Solution Approach 2:
The single mesh material serves multiple functions simultaneously: it forms the side panels for containment, the bottom panel for support, and the rim for structural reinforcement and stacking. This multi-functional design eliminates the need for separate specialized components for each function
2Productivity
If separate mesh pieces are used to form side panels and a separate rail is fitted to form the rim, then the container can be assembled from multiple components, but the production time increases due to separate attachment steps
Solution Approach 1:
The patent combines the side panels and rim into a single integrated mesh container body formed from one continuous mesh material. The mesh material is configured to form side panels, a bottom panel, and a rim as integral parts without requiring separate attachment steps, thereby simplifying the manufacturing process while maintaining structural integrity
Solution Approach 2:
The rim is pre-formed as an integral part of the mesh container body during the initial forming process, rather than being attached as a separate component later. This preliminary formation of the rim structure eliminates subsequent attachment operations and reduces overall production time
3Loss of substance
If separate mesh pieces are used to form side panels and a separate rail is fitted to form the rim, then the container can be assembled from multiple components, but material waste increases due to separate cutting and attachment
Solution Approach 1:
The patent combines the side panels and rim into a single integrated mesh container body formed from one continuous mesh material. The mesh material is configured to form side panels, a bottom panel, and a rim as integral parts without requiring separate attachment steps, thereby simplifying the manufacturing process while maintaining structural integrity
Solution Approach 2:
The mesh material is strategically cut and formed into segments that will become the side panels, bottom panel, and rim, but these segments remain connected through the mesh structure itself. This segmentation allows for optimized material usage while maintaining the integrated structure, reducing waste compared to completely separate components
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
This approach enables more efficient production of mesh containers with reduced manufacturing costs and improved structural strength by using a single piece of sheet metal to form sides and rims, while minimizing waste and simplifying the production process.
Implementation Method 1
a perforated intermediate portion of a web of sheet metal is expanded along an expansion direction to create a web with an intermediate stretched portion of mesh between a leading unstretched portion and a trailing unstretched portion
Data Source
AI summary
A mesh container two sets of opposing sides, a bottom, and a rim extending outwardly from the top of the sides is folded from one or more precursors cut from a web comprising a mesh portion formed by perforating and stretching part of a sheet and an unstretched portion. Each precursor is single piece that is folded into at least two side panels made at least partly of mesh and a portion of the outwardly extending rim made of the unstretched portion of the web. One or more portions for a bottom panel may be included with the two side panels, the bottom of the container being formed by folding the bottom panel portions away for the side panels to form an overlapping joint with each other.