Tray Forming Apparatus Double Glued Corner Construction
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Solution Overview
Problem
Existing container fabrication systems face challenges in strengthening paperboard trays for stacking and delivery, as current reinforced corner constructions are time-consuming to fabricate and increase production costs.
Innovation Solution
A tray forming apparatus and method that uses a platen and forming rail to fold and secure a blank into a tray with a double-glued corner construction, employing folding arms and a compression plate to ensure corner adhesion, with adhesive application for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforced corner construction is used to strengthen the tray, then the tray strength is improved, but the fabrication time increases
Solution Approach 1:
The corner support members are pre-formed and integrated into the blank structure before the forming process begins. The blanks are pre-scored and pre-perforated with all necessary fold lines and adhesive application points, allowing the reinforced corner construction to be created automatically during the standard forming operation without additional manual steps.
Solution Approach 2:
The forming apparatus automatically applies adhesive to the corner support members and automatically folds and secures them during the tray forming process. The mechanism uses the tray's own structure and the forming process itself to create the reinforced corners, eliminating the need for separate reinforcement operations.
2Strength
If a reinforced corner construction is used to strengthen the tray, then the tray strength is improved, but the manufacturing cost increases
Solution Approach 1:
The corner support members and all folding features are pre-configured in the blank during manufacturing, allowing the reinforced structure to be created using the existing automated forming equipment without requiring additional specialized machinery or manual labor, thereby avoiding increased manufacturing costs.
Solution Approach 2:
The invention changes the structural parameters of the blank by incorporating integrated corner support members with specific geometric configurations that allow them to be formed from standard paperboard materials using existing equipment, achieving reinforcement without requiring expensive materials or processes.
3Strength
If multiple flaps or folds are added to reinforce corners, then the tray strength is improved, but the device complexity increases
Solution Approach 1:
The forming apparatus uses existing multi-functional components (forming rails, folding arms, compression plates) that already perform multiple functions in the tray forming process. These same components automatically create the reinforced corner construction without requiring additional specialized devices, maintaining device simplicity while achieving structural reinforcement.
Data Source
AI summary
A tray forming apparatus forms a blank into a tray having a double glued side wall construction for providing a desirable strength to the tray. A platen drives the blank through a forming rails which fold the blank into a partially formed tray having bottom, end and side walls, and inside corner supports formed about the platen. The platen is retracted prior to folding arms further extended portions of the partially formed tray. A compression plate and the folding arms are biased against adhesive portions of the tray for forming a fully formed tray having a double glued side wall construction.