Reinforced Container Forming Machine with Rotating Folding Plows
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Solution Overview
Problem
Existing container forming machines struggle to produce stackable containers with sufficient strength for transportation and storage, often resulting in instability and collapse when not properly aligned or if the stacking strength requirements are not met.
Innovation Solution
A machine comprising a hopper assembly, transport mechanism, and folding plows that rotate and position stacking tabs relative to inner side panels, along with an adhesive application system to form reinforced corner structures and side walls, enabling the creation of a reinforced eight-sided tray from sheet material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional container forming machines are used, then the container can be formed from sheet material, but the stacking strength and stability are insufficient causing collapse during transport and storage
Solution Approach 1:
The container is divided into multiple panels (front, rear, first side, second side, bottom) that are separately formed and then joined together. Each panel can be independently strengthened through the folding process, allowing for optimized structural integrity at each segment while contributing to overall stacking strength and stability.
Solution Approach 2:
The folding mechanism creates curved or rounded corner structures where panels meet, rather than sharp angular joints. This curvature distributes stress more evenly across the container structure during stacking, preventing concentration of forces at vulnerable points and reducing collapse risk.
2Productivity
If the container structure is simplified for easier manufacturing, then production efficiency increases, but the stacking strength requirements cannot be met
Solution Approach 1:
The folding plows automatically form the panels and corner structures through a self-contained mechanical process. The blank is fed into the hopper and the folding plows automatically fold the panels into the final container shape with reinforced corners, eliminating the need for manual intervention while maintaining high structural integrity.
Solution Approach 2:
The corner structures are pre-formed during the folding process itself, before the container is fully assembled and stacked. The folding plows create the reinforced corner geometry as part of the initial forming operation, ensuring strength requirements are met before the container enters service.
3Reliability
If proper alignment features are added to ensure stable stacking, then stacking reliability improves, but the device complexity increases
Solution Approach 1:
The alignment features are integrated into the corner structures themselves rather than being separate components. The reinforced corners serve dual purposes: providing structural strength for stacking and creating natural alignment surfaces that guide proper positioning of stacked containers, eliminating the need for additional alignment devices.
Solution Approach 2:
The corner structures are locally reinforced with specific geometric features that provide both strength and alignment functionality. This localized enhancement at critical points (the corners) delivers the necessary alignment capability without requiring complex modifications throughout the entire container structure or the forming machine.
Data Source
AI summary
An apparatus for forming a container comprises a hopper assembly configured to store a plurality of blanks. Each blank includes a bottom panel, a pair of opposing end panels, at least one stacking tab, at least one inner side panel, and at least one outer side panel. A transport mechanism is positioned below the hopper assembly and is configured to transport a blank of the plurality of blanks from a first position to a second position. A pair of opposing folding plows is positioned below the hopper assembly. The folding plows are configured to rotate the inner side panels and the stacking tabs of the blank as the blank is transported from the first position to the second position. At least one stacking tab bullet is coupled to each folding plow. Each stacking tab bullet is configured to move a respective stacking tab relative to a corresponding inner side panel.