Plastic Corrugated Box Scoring with Pre-Sealing
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Solution Overview
Problem
Producing plastic corrugated boxes with straight, consistent body scores and square corners is challenging due to the inherent memory of plastic and differences in profile compared to paper corrugated material, affecting their performance in automated packaging lines.
Innovation Solution
A process involving pre-sealing and ultrasonic scoring to form straight body scores in plastic corrugated boxes, using a scoring rule with varying segment widths to ensure accurate folding and alignment of flaps, and forming smooth, sealed edges to enhance box stability and reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional scoring methods are used on plastic corrugated material, then the process is simple, but the body scores are not straight and consistent
Solution Approach 1:
The patent applies preliminary action by pre-sealing the plastic corrugated material before scoring. This pre-sealing step prepares the material surface to receive accurate scores by removing the inherent memory and variability, enabling subsequent scoring to produce straight, consistent body scores that allow proper folding at corners and edges.
Solution Approach 2:
The patent changes the physical state and surface properties of the plastic material through pre-sealing treatment. This parameter change modifies the material's response to scoring, transforming it from a state with high variability and memory to a state that accepts precise, consistent scores, thereby improving manufacturing precision without significantly increasing device complexity.
2Reliability
If plastic corrugated boxes are made reusable, then sustainability improves, but the corners and body scores become inconsistent
Solution Approach 1:
The pre-sealing step performed before scoring creates a controlled surface that maintains consistency through repeated use. This preliminary preparation ensures that when boxes are folded and reused, the body scores remain straight and corners remain square, enabling reliable reusability while preserving manufacturing precision.
Solution Approach 2:
The pre-sealing process applies a counter-action to the inherent plastic memory and variability that would otherwise cause inconsistency. By sealing the material first, the process prevents the material from returning to its original shape or exhibiting variability during subsequent folding and reuse, thereby maintaining precision and enabling reusability.
3Manufacturing precision
If the scoring process is simplified, then manufacturing cost decreases, but the fold lines are not accurate
Solution Approach 1:
The pre-sealing step is a preliminary action that prepares the material for accurate scoring. Although it adds a step, it enables the subsequent scoring to be more accurate and consistent. The prepared surface allows the scoring tool to create precise fold lines without requiring complex or expensive scoring equipment, thereby improving accuracy while keeping the overall process relatively simple.
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 enables plastic corrugated boxes to perform similarly to paper corrugated boxes in automated packaging lines, ensuring consistent folding, reduced thickness of manufacturer's joints, and improved safety with smooth edges, allowing for easy cleaning and reuse.
Implementation Method 1
imparting straight, consistent, body scores in plastic corrugated material so that when the die cut blank is formed and glued into a box, the four corners of the box will fold in the intended location
Implementation Method 2
The box can include a third side wall panel positioned next to the second side wall panel, a first welded portion proximate the first edge of the second side wall panel and a first edge of the third side wall panel
Data Source
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AI summary
The box comprises a sheet of plastic corrugated material having a first outer layer, a second outer layer and a plurality of flutes extending between the first outer layer and the second outer layer. The sheet has a plurality of panels defining side walls of the box and a plurality of fold lines between adjacent panels of the plurality of panels. The sheet also includes a first plurality of welded portions proximate a top edge of the plurality of panels and a second plurality of welded portions proximate a bottom edge of the plurality of panels. Each of the plurality of fold lines includes a first portion in one of the first plurality of welded portions and a second portion in one of the second plurality of welded portions. Each of the plurality of fold lines can also include a third portion extending between the first portion and the second portion.