Single-Piece Mesh Container Folding to Reduce Manufacturing Waste
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Solution Overview
Problem
Existing methods for producing mesh containers with outwardly extending rims are inefficient, leading to higher manufacturing costs and material waste.
Innovation Solution
A method involving the expansion of perforated sheet metal to create a mesh material, where a precursor for the mesh container is cut from the web, allowing for the formation of side panels, a bottom panel, and a rim as a single piece, reducing the need for separate rim attachment and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate mesh pieces are used to form side walls and bottom, then the container can be assembled from multiple components, but the manufacturing complexity and time increase due to multiple assembly steps
Solution Approach 1:
The patent combines multiple separate mesh pieces (side walls and bottom) into a single integrated mesh container by expanding a perforated sheet metal web into a three-dimensional structure. The web is transformed from a two-dimensional flat state into a 3D container where the side panels and bottom panel form a unified structure, eliminating the need for separate assembly of multiple components.
Solution Approach 2:
The invention applies dimensionality change by expanding the perforated web from a 2D flat sheet into a 3D container structure. The expansion process creates vertical side panels and a bottom panel from the flat web, adding the third dimension and transforming the geometric configuration without requiring separate components.
2Ease of manufacture
If a non-mesh rail is fitted to the upper edges to form a rim, then the rim structure is provided, but the manufacturing steps and material usage increase
Solution Approach 1:
The patent merges the rim function into the mesh container structure itself. The upper edges of the expanded mesh side panels naturally form the rim structure, eliminating the need for separate non-mesh rail components. The mesh material serves dual purposes as both the container body and the rim-forming element.
Solution Approach 2:
The mesh material performs multiple functions: it forms the side panels, the bottom panel, and simultaneously creates the rim structure at the upper edges. This multi-functionality reduces the need for additional specialized components and simplifies the overall manufacturing process.
3Productivity
If multiple separate mesh pieces are assembled with seams, then the container can be constructed, but the production time and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the entire container structure from a single expanded web before final assembly. The perforated sheet metal is expanded into the complete three-dimensional container shape with all side panels and bottom panel already integrated, eliminating subsequent assembly steps that would be required for multiple separate pieces.
Solution Approach 2:
The expansion process creates a continuous mesh structure without interruptions or seams. The single web expansion maintains continuous material flow and structural integrity throughout the container formation, eliminating the discontinuous assembly process required when joining multiple separate mesh pieces.
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 enables the efficient construction of mesh containers with reduced manufacturing costs and less material waste, while also enhancing the structural integrity of the containers by integrating the rim as part of the single-piece construction.
Implementation Method 1
expanding a perforated portion of a web of sheet metal by stretching it along an expansion direction to create a stretched or expanded portion of mesh
Data Source
AI summary
A mesh container two sets of opposing sides, a bottom, and a rim extending outwardly from the top of the sides is folded from one or more precursors cut from a web comprising a mesh portion formed by perforating and stretching part of a sheet and an unstretched portion. Each precursor is single piece that is folded into at least two side panels made at least partly of mesh and a portion of the outwardly extending rim made of the unstretched portion of the web. One or more portions for a bottom panel may be included with the two side panels, the bottom of the container being formed by folding the bottom panel portions away for the side panels to form an overlapping joint with each other.