Vacuum Forming Tools for Automated Folding Box Inserts
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Solution Overview
Problem
Existing devices for producing inserts for folding boxes from flat blanks lack automation, requiring manual intervention and inefficiency in forming the necessary structures to subdivide the inner volume.
Innovation Solution
A device with movable forming tools perpendicular to the blank plane, equipped with vacuum suction for fixing and shaping the blank into a grid-like structure, allowing for automated production of inserts and parallel processing with folding boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual methods are used to produce inserts from flat blanks, then flexibility in handling complex shapes is maintained, but automation level and production efficiency are reduced
Solution Approach 1:
The forming tool is divided into multiple independent forming elements (2a-2e) that can be individually positioned and controlled. Each forming element can be independently adjusted to create different shapes and configurations, enabling automated production of various insert designs without requiring complete tool redesign
Solution Approach 2:
The forming elements are designed to be movable and adjustable during the forming process. The elements can be positioned at different locations and adjusted to different heights or angles, allowing the same automated tool to produce multiple insert configurations dynamically without manual intervention
2Manufacturing precision
If forming tools are used to erect floor areas and wall areas from the blank, then the insert structure is created, but the forming tools must be precisely positioned and coordinated
Solution Approach 1:
The insert is formed by multiple separate forming elements (2a-2e) that each create specific portions of the final structure. This segmentation allows each element to be independently controlled and positioned, ensuring precise formation of individual walls and floors while simplifying the overall coordination requirement
Solution Approach 2:
The forming elements are designed to work simultaneously at the same operational level, with standardized movement paths and positioning mechanisms. This equipotential design ensures that all elements can be coordinated through a single control system without complex inter-element timing or positioning requirements
3Manufacturing precision
If vacuum suction devices are used to fix the blank, then holding force and positioning accuracy are improved, but the device complexity increases
Solution Approach 1:
The vacuum suction devices are integrated into the existing forming tool structure, serving dual functions: they provide holding force to secure the blank during forming and also assist in positioning the blank initially. This multi-functionality reduces the need for separate positioning mechanisms, thereby limiting the increase in device complexity
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
Enables fully automated manufacturing of inserts from flat blanks, facilitating efficient subdivision of the folding box volume and enabling simultaneous production of folding boxes and inserts, improving production efficiency and accuracy.
Implementation Method 1
the means for fixing the blank for use on the molds are designed by negative pressure or vacuum suction devices
Data Source
Figure 1
Figure 2
Figure 3a~4
AI summary
The device (1) has device forming tools (2a to 2e), which are displaced perpendicularly to a plane of a section (8) on one hand and relatively to each other on another hand. The forming tools are equipped with a unit for fixing pieces of the section. The unit is formed from pieces of the section by lower pressure or vacuum suction. An independent claim is also included for a machine for manufacturing an insert for a folding box of a flat lying section.