Shaping Tool for Foldable Packages with Adjustable Lugs
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Solution Overview
Problem
Existing packaging technologies are limited in shaping packages of varying sizes and complex designs, requiring multiple molds and being inefficient and costly, while lacking a single tool capable of forming a wide range of sizes, shapes, and material types without specific components.
Innovation Solution
A shaping tool with an overhead conveyor, clamping means, erecting mechanisms, and independently movable shaping lugs that can form packages of predetermined shapes from foldable blanks, allowing for continuous conversion of blanks into shaped packages without the need for pack-specific components, using a combination of conveyors and control systems for precise shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple molds are used to shape packages of varying sizes and designs, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The shaping tool employs a universal base mold that can accommodate multiple package shapes and sizes through adjustable components. The movable walls and adjustable positioning mechanisms allow a single base mold to serve multiple functions for different package configurations, eliminating the need for multiple specialized molds while maintaining manufacturing precision.
Solution Approach 2:
The shaping tool incorporates dynamic elements including movable walls that can be repositioned, adjustable positioning mechanisms, and flexible components that adapt to different package shapes. These dynamic features enable the same physical tool to be reconfigured for various package types, reducing device complexity while preserving the ability to achieve precise shape control.
2Manufacturing precision
If pack-specific components are used for each package design, then manufacturing precision is improved, but productivity decreases due to setup time
Solution Approach 1:
The shaping tool uses universal base mold and adjustable components that can be reconfigured without removing entire components. The movable walls and adjustable positioning mechanisms allow rapid reconfiguration for different package designs while maintaining precision, enabling continuous production without lengthy setup times associated with exchanging pack-specific components.
Solution Approach 2:
The dynamic reconfiguration capabilities of the shaping tool, including movable walls and adjustable mechanisms, allow operators to quickly adapt the tool for different package types during production. This dynamic adjustability eliminates the need to stop production for component exchanges, maintaining both precision and continuous productivity.
3Device complexity
If a single tool is designed to handle various package sizes and shapes, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The shaping tool is divided into modular components including a base mold, movable walls, adjustable positioning mechanisms, and support structures. Each segment can be independently positioned and adjusted, allowing a single tool to achieve precise control over various package shapes and sizes through coordinated movement of individual segments rather than requiring multiple specialized tools.
Solution Approach 2:
The movable and adjustable components within the single shaping tool provide dynamic control over package geometry. The movable walls and adjustable positioning mechanisms enable real-time adjustment during operation, allowing the tool to maintain manufacturing precision across different package types while using a reduced number of components compared to multiple fixed molds.
4Ease of manufacture
If traditional scoring and folding line techniques are used, then ease of manufacture is improved, but adaptability deteriorates for complex package designs
Solution Approach 1:
The shaping tool replaces traditional manual scoring and folding line techniques with a mechanical pressing and shaping system. The tool uses controlled mechanical pressure through movable walls and positioning mechanisms to form complex package shapes directly, eliminating the need for pre-scoring and manual folding operations while providing flexibility for various package designs.
Solution Approach 2:
The shaping tool enables parameter changes in package geometry through adjustable positioning mechanisms and movable walls that can be reconfigured for different shapes and sizes. This allows the same tool to adapt to various package designs by adjusting parameters such as wall angles, corner radii, and overall dimensions, providing both ease of manufacture and design flexibility.
Data Source
AI summary
The present invention provides a shaping tool for shaping a package formed of a foldable blank, the tool comprising: —an overhead conveyor comprising a plurality of downwardly protruding spaced apart counter-means; —a first conveyor extending between a receiving end towards an output end, and adapted to receive the foldable blank from an incoming conveying line at the receiving end and to position the foldable blank below one of the downwardly protruding counter-means; —a shaping station extending away from the receiving end, the shaping station comprising: a pair of parallel shaping tracks, each positioned on one side of the first conveyor, the pair of generally parallel shaping tracks comprising a plurality of pairs of independently movable shaping lugs, each pair of shaping lugs having a predetermined shape and adapted to receive one of the foldable blanks there-between; the pair of lugs movable towards each other to form a package having a desired shape.