Dimensionally Variable Lid Manufacturing Using Pre-Formed Scorelines
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Solution Overview
Problem
Existing methods struggle to stably manufacture lids of different sizes to fit variously sized boxes, as forming scorelines and perforated lines on cut lid sheets is difficult and inconsistent.
Innovation Solution
A dimensionally variable lid manufacturing method using rectangular lid sheets with pre-formed scorelines and perforated lines, where the sheets are cut in strip shapes along adjustment sides using specific cutters and a scoreline roller, allowing for adjustable cut-off widths to match box sizes, while maintaining a reference area for printing and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lid sheets are cut to different sizes according to box sizes, then lids can fit various box sizes, but it becomes difficult to stably form scorelines and perforated lines at correct positions
Solution Approach 1:
Scorelines and perforated lines are formed on rectangular lid sheets before cutting the sheets to different sizes. This preliminary formation ensures that the scorelines and perforated lines are created at precise, predetermined positions on the full-size sheets, avoiding positioning errors that would occur if these features were formed after cutting to various sizes.
Solution Approach 2:
The lid sheet is divided into a reference area (where scorelines and perforated lines are formed) and adjustment sides (which are cut to different widths). By segmenting the sheet this way, the reference area maintains consistent dimensions and feature positions across all lid sizes, while the adjustment sides provide the necessary size variation.
2Adaptability or versatility
If rectangular lid sheets are cut to match various box sizes, then lids can cover different top end openings, but material waste increases
Solution Approach 1:
The lid manufacturing system dynamically adjusts the cut-off widths of the adjustment sides based on the specific box size requirements, while maintaining a consistent reference area. This dynamic adjustment allows optimal material utilization for each lid size while preserving the essential scoreline and perforated line positions.
Solution Approach 2:
A single rectangular lid sheet design with a universal reference area serves multiple box sizes by varying only the adjustment side widths. This universal reference area contains all necessary scorelines and perforated lines that work across different lid sizes, reducing the need for multiple dedicated sheet designs and minimizing overall material waste.
3Adaptability or versatility
If scorelines and perforated lines are formed after cutting lid sheets to different sizes, then customization is possible, but manufacturing stability decreases
Solution Approach 1:
Scorelines and perforated lines are formed on full-size rectangular lid sheets before cutting to various dimensions. This preliminary formation on standardized, full-size sheets ensures consistent and stable creation of these features, as the sheets maintain uniform dimensions and properties during the scoring and perforating processes.
Solution Approach 2:
The lid sheet is segmented into a reference area (containing scorelines and perforated lines) and adjustment sides (cut to different widths). This segmentation allows the reference area to maintain consistent dimensions and feature formation stability across all lid sizes, while the adjustment sides provide the necessary customization.
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 the stable production of lids of different sizes that correspond to various box sizes, maintaining printed objects and reducing material costs through efficient cutting and scoring processes.
Implementation Method 1
a first dimension adjustment step of cutting off a portion of each of the lid sheets along the first adjustment side in a strip shape with a first cutter
Implementation Method 2
a second dimension adjustment step of cutting off a portion of the lid sheet along the second adjustment side in a strip shape using a second cutter
Implementation Method 3
forming, in the lid sheet, a second scoreline extending parallel to the first scoreline using a scoreline roller disposed at a predetermined interval from the first cutter such that the second scoreline allows the lid to be bent downwardly
Data Source
AI summary
A first scoreline, and a perforated line along which a lid can be severed are formed beforehand in a lid sheet. The portion of the lid sheet along its first adjustment side is cut off in a strip shape by a first cutter. The portion of the lid sheet along its second adjustment side is cut off in a strip shape by a second cutter.