Covering Blank Segments for Multi-Sided Box Folding
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Solution Overview
Problem
Existing methods for covering boxes with more than four sides using petalled covering blanks are complex, especially during the fold-over process, and require additional machinery, which increases complexity and costs, and are not suitable for modified blanks with oversize segments.
Innovation Solution
An apparatus and process utilizing a modified covering blank with at least one oversize segment to cover multiple faces, combined with a system of movable brushes that follow a predetermined path with changes in direction to facilitate efficient and flexible covering of boxes with any number of sides, allowing for rapid changeover to different shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If petalled covering blanks are used for boxes with more than four sides, then complete coverage of lateral walls is achieved, but the number of lips to be folded over increases considerably, increasing process complexity
Solution Approach 1:
The covering blank is divided into multiple segments (petals) connected to a central base, each segment corresponding to a lateral wall face. This segmentation allows each segment to be independently folded and positioned, enabling complete coverage of complex multi-sided boxes while maintaining manageable folding operations through the modular structure
Solution Approach 2:
The covering blank is pre-cut and pre-shaped with all necessary segments, connections, and folding lines before application. The base is pre-formed to match the bottom wall geometry, and segments are pre-positioned to ensure proper alignment during folding, eliminating the need for complex real-time adjustments during the covering process
2Area of stationary object
If the number of sides of the box increases, then more comprehensive coverage is needed, but the number of lips to be folded over increases considerably, requiring additional machinery
Solution Approach 1:
The covering blank design with a central base and multiple radiating segments provides a universal solution that can accommodate boxes with any number of sides. By adjusting the number and angular arrangement of segments, the same basic structure covers triangular, quadrangular, pentagonal, hexagonal, and other polygonal boxes without requiring fundamentally different machinery or approaches
Solution Approach 2:
The covering process employs dynamic folding sequences where segments are folded in a specific order and manner depending on the box geometry. The folding operations are adapted to the specific number of sides through programmable control, allowing the machine to handle variable complexity without physical reconfiguration
3Manufacturing precision
If odd-numbered sided boxes are covered, then complete coverage is achieved, but two additional steps are necessary to fold over all vertical edges, requiring three different folding steps
Solution Approach 1:
The covering blank for odd-sided boxes incorporates asymmetric segment arrangements where segments are not uniformly distributed around the base. This asymmetric design allows certain segments to span multiple faces or have extended lips that naturally cover additional edges, reducing the number of separate folding steps required compared to symmetric designs
4Device complexity
If modified covering blanks with oversize segments are used, then the number of lips for folding over is reduced, but existing prior art covering systems cannot be used
Solution Approach 1:
The covering blank design parameters are modified to include oversize segments that extend beyond the standard dimensions. These oversize segments reduce the number of lips requiring fold-over operations by allowing single segments to cover multiple faces or edges. The parameter changes in segment size and shape are compensated for by programmable control systems that adapt the folding sequences and brush positions accordingly
Data Source
AI summary
An apparatus (1) and a process for covering a box (2) with more than four sides, using a covering blank (6) having at least segment (8A) made in such a way that it completely covers at least two faces (5) of the lateral wall (4) of the box (2) and partly covers at least another face (5), comprise at least two folder elements (11) movable relative to the box (2) positioned in a fold over station to laterally fold the at least one segment (8A) and bring it completely into contact with the lateral wall (4) of the box (2); the apparatus and the process contemplate moving at least one of the folder elements (11) along a predetermined path comprising at least one change of direction.