Polygonal Container Erecting Mechanism for Octagonal Forming
Solution Overview
Problem
Existing methods for forming polygonal containers from knocked-down flats are inefficient and costly, particularly for non-rectangular shapes like octagons, which require more complex machinery and lack space efficiency and stacking strength.
Innovation Solution
A machine with two erecting mechanisms is used to transform a knocked-down flat container into a partially erected rectangular configuration, and then further into a polygonal shape by applying force to exterior surfaces, utilizing suction cups and miter bars to form corners and seal the bottom flaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular shaped container is used, then the manufacturing process is simple and efficient, but the space efficiency and stacking strength are insufficient for non-rectangular products
Solution Approach 1:
The container is divided into multiple panels (rectangular panels and corner panels) that can be separately formed and assembled. The corner panels are distinct segments that provide structural strength while the rectangular panels maintain manufacturing simplicity. This segmentation allows the container to achieve both ease of manufacture and enhanced stacking strength through its polygonal configuration.
Solution Approach 2:
The container employs asymmetric corner panels with angled configurations rather than symmetric rectangular corners. These asymmetric corner elements provide the necessary structural strength for stacking while maintaining overall manufacturing efficiency through standardized panel formation processes. The asymmetry in corner design directly addresses the stacking strength requirement.
2Ease of manufacture
If a rectangular shaped container is used, then the manufacturing process is simple and efficient, but the space efficiency is insufficient for non-rectangular products
Solution Approach 1:
The container employs asymmetric corner panels with angled configurations rather than symmetric rectangular corners. These asymmetric corner elements provide the necessary structural strength for stacking while maintaining overall manufacturing efficiency through standardized panel formation processes. The asymmetry in corner design directly addresses the stacking strength requirement.
Solution Approach 2:
The container is divided into multiple panels (rectangular panels and corner panels) that can be separately formed and assembled. The corner panels are distinct segments that provide structural strength while the rectangular panels maintain manufacturing simplicity. This segmentation allows the container to achieve both ease of manufacture and enhanced stacking strength through its polygonal configuration.
3Strength
If known methods and systems are used to form octagonal containers from knocked-down flats, then the desired space efficiency and stacking strength are achieved, but the machinery becomes more complicated and expensive
Solution Approach 1:
The knocked-down flat container is pre-formed with corner panels and panel configurations that are prepared in advance for easy erection into polygonal shapes. The flat container includes pre-scored lines, pre-formed flaps, and pre-configured corner panels that facilitate simple erection without requiring complex machinery. This preliminary preparation enables standard case erector machines to form polygonal containers with enhanced stacking strength.
Solution Approach 2:
The invention adapts existing case erector machines to perform multiple functions - they can now erect both traditional rectangular containers and polygonal containers with enhanced stacking strength. The system uses universal components like suction cups, erector arms, and control systems that can handle different container types, reducing the need for specialized expensive machinery while achieving the desired stacking strength.
4Strength
If known methods and systems are used to form octagonal containers from knocked-down flats, then the desired space efficiency and stacking strength are achieved, but the operation becomes more complicated
Solution Approach 1:
The knocked-down flat container is pre-formed with corner panels and panel configurations that are prepared in advance for easy erection into polygonal shapes. The flat container includes pre-scored lines, pre-formed flaps, and pre-configured corner panels that facilitate simple erection without requiring complex machinery. This preliminary preparation enables standard case erector machines to form polygonal containers with enhanced stacking strength.
Solution Approach 2:
The container structure is designed to self-erect into its final polygonal configuration through the inherent geometry of the knocked-down flat. The corner panels and panel connections are designed to automatically form the correct angles and positions during the erection process, reducing the need for complex operational controls and manual intervention while maintaining the desired stacking strength.
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 method allows for efficient and cost-effective formation of polygonal containers, such as octagons, from knocked-down flats, improving space efficiency and stacking strength while reducing manufacturing and packaging costs.
Implementation Method 1
The second erecting mechanism is configured to receive the partially erected container in the substantially rectangular configuration and erect the partially erected container from the rectangular configuration into the polygonal container by applying a force to an exterior surface of the partially erected container
Data Source
AI summary
A machine for erecting a polygonal container from a knocked-down flat (KDF) container formed from a blank of sheet material is provided. The container includes four main side panels, at least one corner panel extending between two of the main side panels, and at least one bottom flap extending from one of the main side panels. The machine includes a body, a first erecting mechanism coupled to the body, and a second erecting mechanism coupled to the body. The first erecting mechanism receives the KDF container and erects the KDF container into a partially erected container having a substantially rectangular configuration, and the second erecting mechanism receives the partially erected container and erects the partially erected container from the substantially rectangular configuration into the polygonal container by applying a force to an exterior surface of the partially erected container to erect the polygonal container that has more than four sides.