Forming Tool for Packaging Troughs Using Vacuum Draw
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Solution Overview
Problem
Existing packaging production methods require individual blanks to be fed into a forming station, leading to inefficiencies and space constraints, especially when processing non-thermoplastically deformable materials like cardboard, which cannot be further processed directly due to space limitations and formation of small folds during shaping.
Innovation Solution
A method involving a pre-punched material sheet where a sub-area is incompletely punched out with retaining lugs, allowing it to be connected to the residual sheet, positioned on a female die part, and suctioned into a forming cavity using a vertically movable insert, eliminating the need for a male die part and enabling easier access for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual blanks are fully separated and fed to the forming station, then the material can be processed one by one, but the productivity decreases and the device complexity increases due to individual transfer requirements
Solution Approach 1:
The material sheet is divided into multiple sub-areas with retaining lugs that allow incomplete separation. Each sub-area remains connected to the residual area through retaining lugs during transport, enabling batch processing while maintaining individual formability. This segmentation allows multiple packages to be produced simultaneously from one material sheet without requiring individual handling of each blank.
Solution Approach 2:
Multiple sub-areas are kept connected to the residual area through retaining lugs, allowing them to be transported and positioned together as a group. This merging approach enables batch feeding to the forming station, improving productivity by processing multiple packages in sequence without requiring separate handling for each individual blank.
2Ease of manufacture
If a male die part is positioned above the female die part for forming, then the forming process can be completed, but the space availability for further processing decreases
Solution Approach 1:
Instead of using a male die part positioned above the female die part, the invention inverts the forming approach by using only a female die part with a forming cavity. The material is drawn into the cavity from above, and forming is completed without requiring a male die part to press from the opposite side. This inversion eliminates the need for overhead space and allows direct access to the formed package for further processing.
3Manufacturing precision
If a fold retainer is used to clamp the material, then the material position can be controlled, but small folds still form during forming
Solution Approach 1:
A vacuum unit is used to suction the sub-area onto the vertically movable insert, providing uniform and controlled holding force across the entire material surface. This pneumatic approach replaces mechanical clamping with a fold retainer, distributing the holding force evenly to prevent localized stress concentrations that cause folding, while maintaining precise material position control throughout the forming process.
4Loss of substance
If the sub-area is incompletely punched out with retaining lugs, then the material sheet can be efficiently utilized, but additional positioning mechanisms are required
Solution Approach 1:
The retaining lugs on the incompletely punched sub-area serve a dual function: they maintain connection to the residual area for efficient material utilization, and they automatically provide positioning references for the forming process. The sub-area's own structure (the retaining lugs and their arrangement) enables positioning without requiring external positioning mechanisms, as the relative positions are inherently defined by the punching pattern.
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 allows for efficient production of packaging from non-thermoplastically deformable materials, facilitating automated positioning, reducing material waste, and enabling direct further processing of formed packaging without the need for additional handling steps.
Implementation Method 1
a vacuum unit which can have applied thereto a vacuum and which is configured for sucking the sub-area of the material sheet onto the vertically movable insert by means of a vacuum
Data Source
AI summary
A pre-punched material sheet for constructing a packaging trough, the material sheet includes a sub-area that has been punched out incompletely so that the sub-area is connected to a residual area of the material sheet through a plurality of retaining lugs. The material sheet is positioned on top of a female die part of a forming tool and the sub-area at least partially covers an opening of a forming cavity of the female die part. The residual area of the material sheet may be clamped in position against the female die part. The sub-area of the material sheet is sucked onto an insert in the forming cavity using a vacuum. The insert is vertically movable in the forming cavity from a first position to a second position to draw the sheet into the forming cavity and thereby form the packaging trough.