Paper Funnel Component for Packaging Containers
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Solution Overview
Problem
Existing packaging containers face challenges in reducing resin usage, preventing scorching and crinkling during manufacturing, and maintaining design integrity under varying internal and external pressure conditions, especially when filled with powdery or granular contents.
Innovation Solution
A manufacturing method using a sheet member with paper as the main component, involving punching, rolling, and welding to form a funnel component with a tapered shape, and integrating it into a cup-shaped container body, which reduces resin usage and avoids scorching and crinkling, while ensuring the container's design remains intact under pressure changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a resin-molded funnel component is used, then manufacturing precision and durability are improved, but resin usage increases and environmental friendliness deteriorates
Solution Approach 1:
The invention changes the material parameter from resin to paper-based material, maintaining the funnel component's structural integrity while reducing resin usage. The paper funnel is formed through controlled deformation and joining processes that preserve manufacturing precision despite the material change.
Solution Approach 2:
The invention uses composite material construction by joining paper sheets through welding or adhesive bonding to create the funnel component. This composite approach maintains the necessary structural properties while eliminating resin usage, resolving the contradiction between precision and environmental friendliness.
2Productivity
If ultrasonic vibration is applied to form a flange portion, then manufacturing efficiency is improved, but scorching occurs
Solution Approach 1:
The invention replaces the ultrasonic vibration mechanism with a simple pressing operation. The flange portion is formed by mechanically pressing the paper material between molds, eliminating the ultrasonic energy that causes scorching while maintaining efficient production through the simplicity of the pressing process.
3Productivity
If packaging containers are filled in high temperature environments, then filling efficiency is improved, but design degradation occurs due to pressure changes
Solution Approach 1:
The invention provides beforehand cushioning by forming the paper funnel with predetermined structural characteristics that can withstand pressure changes. The funnel's geometry and material properties are designed in advance to resist deformation, cushioning against the harmful effects of pressure differential that would otherwise degrade the container design.
4Loss of substance
If paper material is used for funnel component, then resin usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention segments the manufacturing process into distinct steps: forming the paper sheet into a funnel shape, joining the edges through welding or adhesive bonding, and assembling into the container. This segmentation simplifies the overall complexity by breaking down the paper funnel manufacturing into manageable, standardized operations.
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 method enables mass production of packaging containers with reduced resin usage, prevents scorching and crinkling, and maintains the container's design integrity by using a paper-based funnel component that can withstand pressure changes without degrading the outer appearance.
Implementation Method 1
punching the sheet member by using a die
Implementation Method 2
rolling the blank material
Implementation Method 3
folding back the corrugated line portion
Implementation Method 4
welded
Implementation Method 5
folding the wide opening side portion back outward
Implementation Method 6
performing a pressing process on the third intermediate product by using a mold
Data Source
AI summary
A funnel component is manufactured by the following processes: forming a first intermediate product that is tapered, by rolling the blank material; forming a second intermediate product by folding back and welding a narrow opening side portion of the first intermediate product; forming a third intermediate product having the side wall portion by folding the wide opening side portion of the second intermediate product back outward; forming a cylindrical discharge portion forming the narrow opening side portion, a first tapered portion that connects to the discharge portion and has a tapered shape, and a second tapered portion that has a tapered shape having a taper angle less than the first tapered portion, by performing a drawing process on the third intermediate product.