Sequential Sheet Forming for Uniform-Thickness Containers
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Solution Overview
Problem
The challenge of producing containers with complex shapes using sheet materials is that existing processes struggle to ensure uniform deformation, leading to structural homogeneity issues and excessive thinning, which affects the mechanical and physical characteristics of the container.
Innovation Solution
A process involving multiple distinct steps of sheet deformation using forming members with progressively smaller operating surfaces to distribute material thickness uniformly, allowing for the use of thinner sheets and achieving greater structural homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-step forming process is used to produce containers with complex shapes, then the container can be formed efficiently, but excessive thinning occurs in various portions leading to structural inhomogeneity
Solution Approach 1:
The forming process is divided into multiple sequential steps, each with a forming member having a specific operating surface designed for that step. The first forming member has a first operating surface that contacts a first portion of the sheet, and the second forming member has a second operating surface that contacts a second portion of the sheet. This segmentation allows different regions of the sheet to be formed at different times, preventing excessive thinning in any single region while maintaining production efficiency.
2Manufacturing precision
If thicker sheet material is used to prevent excessive thinning during forming, then structural homogeneity is improved, but material usage and production costs increase
Solution Approach 1:
By segmenting the forming process into multiple steps with progressively smaller operating surfaces, the patent enables the use of thinner sheet material while maintaining structural homogeneity. The controlled sequential deformation prevents excessive thinning that would normally require thicker material, thus reducing material usage and production costs while achieving the desired structural uniformity.
3Manufacturing precision
If progressively smaller operating surfaces are used in sequential forming steps, then material thickness is distributed uniformly, but the device complexity increases
Solution Approach 1:
The forming device is segmented into multiple forming members, each with a specific operating surface size appropriate for its forming step. This segmentation achieves uniform thickness distribution through controlled sequential deformation.
Solution Approach 2:
The forming members are arranged in a nested configuration where the second forming member can be positioned within or alongside the first forming member. This nesting approach allows the progressively smaller operating surfaces to be integrated in a compact manner, reducing overall device complexity while maintaining the sequential forming capability.
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 approach enables the production of containers with complex shapes using thinner materials, improving structural homogeneity, extending shelf life, reducing material usage, and lowering production costs while allowing for the use of new materials and shapes that were previously difficult to achieve.
Implementation Method 1
operating said means for inserting the sheet into the forming cavity to deform it until a container blank is obtained having a shape approximating the given shape of the container
Implementation Method 2
blowing a gas under pressure into the forming cavity to deform the container blank until the container of the given shape is obtained
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~2
AI summary
Described herein is a process for obtaining a container (100) of a given shape starting from sheet material, comprising the steps of: - providing a sheet (110); - providing a mould (20) having a forming cavity (20A), which defines a reference axis (R) and has a shape corresponding to said given shape of said container (100); - positioning said sheet (110) over said forming cavity (20A); - providing a forming device (40) having forming means (41, 42) arranged on the side of said sheet opposite to said forming cavity, and operating said means for inserting said sheet (110) into said forming cavity (20A) to deform it until a container blank is obtained (101) having a shape approximating said given shape; and - blowing a gas under pressure into said forming cavity (20A) to deform said container blank (101) until said container (100) with said given shape is obtained. The process described enables use of sheet material of reduced thickness as compared to conventional processes.