Prismatic Box Forming Machine with Adjustable Molding Cavity
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Solution Overview
Problem
Existing machines are unable to efficiently form prismatic box bases or lids with six, eight, or more sides by bending and attaching die cut plates, as they require manual labor and result in high material consumption due to the need for extended die cut plates with retaining flaps of equal height.
Innovation Solution
A machine with a molding cavity and plunger system that bends and attaches die cut plates with a polygonal base wall and alternating simple and composite side walls, using pressure blades and actuators to form prismatic shapes, allowing for automatic formation of hexagonal or octagonal cross-sections with adjustable dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual bending and attaching of die cut plates is used to form prismatic box bases or lids with six, eight, or more sides, then the process can be completed, but it requires a lot of manual labor and is relatively tedious
Solution Approach 1:
The die cut plate is designed with self-bending geometric features including hinge lines, attachment flaps, and retaining flaps that automatically fold and interlock during the insertion stroke into the molding cavity, eliminating the need for manual bending operations. The plate serves itself by using its own structural features to achieve the desired three-dimensional form.
Solution Approach 2:
The die cut plate is pre-configured with all necessary flaps, hinges, and geometric features before insertion. The retaining flaps are pre-positioned to engage with the molding cavity walls during insertion, and attachment flaps are pre-formed to automatically attach to side walls, performing the bending and attaching actions as preliminary integrated features rather than sequential manual operations.
2Reliability
If retaining flaps with height equivalent to the height of the wall are provided, then the base or lid can be formed, but it involves a considerable extension of the die cut plate, resulting in a high consumption of sheet material
Solution Approach 1:
The retaining flaps are designed with varying heights and configurations tailored to specific locations on the die cut plate. Rather than uniformly extending all flaps to maximum height, each retaining flap is dimensioned locally to provide just enough structural support for its specific position, optimizing material usage while maintaining the necessary structural integrity of the formed base or lid.
3Adaptability or versatility
If existing machines with fixed molding cavities are used, then rectangular boxes can be formed, but they are not capable of forming bases or lids for prismatic boxes having six, eight, or more sides
Solution Approach 1:
The molding cavity incorporates movable side walls that can be adjusted to different positions and angles. This dynamic configuration allows the same molding cavity to adapt to various polygonal shapes (hexagonal, octagonal, etc.) by repositioning the side walls, providing versatility without requiring completely different cavity designs for each shape.
Solution Approach 2:
The molding cavity is designed as a universal fixture capable of forming multiple types of prismatic box bases or lids with different numbers of sides. Through adjustable side walls and reconfigurable elements, a single molding cavity performs the function of multiple specialized cavities, enabling production of hexagonal, octagonal, and other polygonal forms without increasing overall device complexity.
Data Source
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AI summary
The machine for forming prismatic box bases or lids by bending and attaching die cut plates comprises a molding cavity (11) with an inlet opening and a plunger (70) moved by a drive mechanism between an extracted position and an introduced position with respect to the molding cavity (11). The molding cavity (11) comprises an integer number greater than two of simple wall bending elements (12) and an equal integer number greater than two of composite wall bending elements (13, 13X, 13Y) arranged around the path of the plunger and intercalated with one another defining a polygon, and an equal integer number greater than two of pairs of pressure blades (14) arranged such that the pressure blades (14) of each pair flank one of the composite wall bending elements (13, 13X, 13Y). The pressure blades (14) are moved by blade actuators (15) between a retracted position and a pressure position.