NL2004517C2 - METHOD FOR MANUFACTURING A THREE-DIMENSIONAL OBJECT AND THE METHOD OBTAINED. - Google Patents

Description

Method for manufacturing a three-dimensional article, as well as article obtained with the method

The invention relates to a method for manufacturing a three-dimensional object with an external main shape and at least one recess. An example of such an object is an interior element for a substantially rigid package, for example a cardboard box, which interior element has a certain elastic compressibility and comprises a body which has at least one recess, in which an angle, an edge or a projection part of an object to be packaged, such that the object can be suitably and shock-absorbing or anchored in the package by a number of suitably modeled interior elements.

Such a method and an interior element obtained therewith for accommodating an article with support, spacing and possibly shock-absorbing in a package are known. For example, it is generally customary to manufacture an interior element from an expanded foam material, for example expanded polystyrene foam (EPS), with an, for example, cube-like main shape, from which a corner zone, for example also with a general cube shape, is cut out. Such an element is placed on the bottom, for example in the four bottom corners of the package, for example a wooden box, a cardboard box, an aluminum box or the like, such that an article, for example a consumer article, such as a refrigerator, a television set, a loudspeaker, an industrial article, such as a gearbox for a car, an electric motor, can be worn thereby. After placing the article in the package in this way, such elements can optionally also be placed on the top side, whereafter the package is closed with a lid.

The dimensions of the package and the interior elements are chosen such that an article to be packaged is included in the package substantially without play and through the intervention of the interior elements.

As a result of the elastic properties of the foam material, not only a rattle-free package 10 is ensured, but the object is also protected against shock loads within certain limits, for example in case the package with content of some height falls to the ground.

The known method for manufacturing an interior element on the basis of forming interior elements of expanded plastic foam by expanding in a mold is very suitable for large series.

For smaller series, the mold costs are relatively high and, under certain circumstances, prohibitive, so that it is desirable to look for alternatives.

In connection with this, the invention provides a method which is particularly suitable for rapid adaptation at relatively low costs.

This method according to the invention, for manufacturing a three-dimensional object with an external main shape and at least one recess, is characterized by the following steps to be carried out in suitable order: (a) providing a blank of at least 30 one-way flexible material; (b) providing a rotary drivable winding mandrel whose outer shape is at least more or less similar to the main outer shape of an article to be manufactured; (c) taking into account the possible unidirectional flexibility of the material, winding up a number of layers of the material on the winding mandrel; (d) joining at least the end edge of the last-wound layer with the underlying layer; and (e) forming the at least one recess.

It is noted that under a more or less uniform outer shape of winding mandrel on the main outer shape of an object to be manufactured, it is meant that the outer shape of the winding mandrel for example in an interior element to be manufactured according to the method with triangular cross-section, also substantially triangular in cross-section is.

It is further noted that it will be most practical in most circumstances if the mandrel 20 is prismatic. "Prismatic" is understood to mean a shape which has the same cross-sectional shape at every axial position, that is to say, every position with respect to the winding or rotation axis. A cylinder, for example, therefore also qualifies under this definition.

Under certain circumstances it can be practical to connect all superimposed layers. Use can be made for this purpose of an adhesion between all layers. A cheaper and nevertheless effective method is to connect the end edge of the last wound-up layer with the underlying layer. This joining can take place by means of glue or other adhesive means, for example one or more staples.

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Preferably, the method comprises the step (f1) of selecting a fiber material.

More preferably, the fiber material is anisotropic, and the method further comprises the step (g1) of orienting the fibers of the fiber material relative to the winding axis of the mandrel such that in the final loading direction of the three-dimensional object, the fibers be oriented that a desired damping behavior is obtained. With the final loading direction, reference is made to the main direction in which the product to be packaged will load the three-dimensional object.

Attention is drawn to the fact that many materials transverse to the main surface have a large degree of elastic compressibility and that after winding up the elastic compressibility in the direction of the planes of the layers will be very limited. The design of objects according to the invention is preferably taken into account.

According to a further preferred embodiment, the method comprises the step (f1) of choosing corrugated cardboard as material. Corrugated cardboard has the advantage that it is cheap and recyclable.

According to a still further preferred embodiment, the step (g1) comprises orienting the longitudinal direction of the corrugated cardboard waves relative to the winding axis of the mandrel, such that in the final loading direction of the three-dimensional object the corrugated cardboard waves such be oriented that a desired damping behavior is obtained. Attention is drawn to the fact that corrugated cardboard is a material which has a large degree of elastic compressibility transversely to the main surface of the cardboard and that after winding up the elastic compressibility in the direction of the planes of the layers will be very limited. The design of objects according to the invention is preferably taken into account. It is therefore conceivable that the winding direction 5 of the mandrel makes an angle with the direction of the corrugated cardboard waves.

According to a further preferred embodiment, the method comprises the step (f1) of choosing cellulose or softboard as material. These materials have the advantage that it exhibits a much more constant damping than, for example, corrugated cardboard, and therefore the desired protection of the product to be packaged is well predictable.

According to a further preferred embodiment, the method comprises the step (f2) of choosing plastic as material. Plastic too has a much more constant damping than, for example, corrugated cardboard, which means that the desired protection of the product to be packaged can also be predicted with plastic.

According to a very important aspect of the invention, the method comprises the step of: (h) arranging a number of perforations so modeled in the blank before step (c) that, after winding up the blank on the mandrel, the perforations mutually registered relationship in 25 successive layers and together form the at least one recess.

Such perforations can easily be calculated with a computer, taking into account the shape of the winding mandrel, the thickness of the blank material and the desired shape of the recess or recesses. The perforations can be provided in any suitable manner, for example by laser cutting, which makes it possible in a very simple manner for a rapid changeover from one production series to another, or also by a simple and simple punching operation.

According to yet another aspect of the invention, the method comprises the steps of: (i) performing step (f) such that the material is a corrugated cardboard of the type with at least two skin foils; (j) performing step (b) such that the winding mandrel has at least two corner zones; and (k) forming elongated weakening zones over the entire width of the blank prior to step (c), which weakening zones are positioned such that they correspond to the corner zones of the winding mandrel.

The step (k) facilitates the winding of the blank.

According to a further preferred embodiment of the invention, the method comprises the step (1) of mutually gluing one or more layers lying on top of each other depending on the desired stiffness of the three-dimensional object to be manufactured. An object according to the invention, the layers of which are superimposed on each other, will have a greater rigidity than the same object of which only the outer end edge is connected to the bottom layer. Depending on the desired mechanical stiffness relative to the desired elastic compressibility, a desired local amount of glue can be used.

Finally, the invention also relates to a three-dimensional object, which has been obtained by carrying out one of the methods specified above.

The invention will now be explained with reference to the accompanying drawings. Show in the drawings: 7

Figure 1: a perspective view of a package with a spaced-apart interior with interior elements according to the invention;

Figure 2: the detail II of figure 1 on a larger scale;

Figure 3: a perspective view of a device for performing the method according to the invention;

Figure 4: a schematic perspective view 10 of a perforated blank ready to be wound on a rotary drivable winding mandrel;

Figure 5: a perspective view of a finished interior element in the phase in which it can be removed from the winding mandrel; Figure 6A: a front and side view of a finished interior element obtained by winding in the form of a blank;

Figure 6B: the interior element according to Figure 6A, after it has been folded along the folding zones by twice 90 °;

Figure 6C: a top view of a perforated blank wound up in accordance with the fold lines indicated in the drawing to obtain the pre-interior element according to Figure 6A; Figure 7A: a top view of an expanded mandrel on which a pre-interior element is wound;

Figure 7B: the side view of Figure 7A;

Figure 8A: a view corresponding with figure 7A of the situation in which the mandrel is contracted and the pre-interior element can be slid off the mandrel;

Figure 8B: a view corresponding with Figure 7B of the situation according to Figure 8A; 8

Figure 9 shows diagrammatically a cross section through a winding mandrel with a number of openings, which serve to retain the front edge zone of a blank to be wound up by means of underpressure; Figure 10 shows a cross-section corresponding with Figure 9 of a mandrel with retractable barbs for holding the front edge zone of a blank to be wound up;

Figure 11 shows a complete final package manufactured according to the method of the invention;

Figure 12 shows a support assembly of interior elements manufactured according to the method of the invention, used in a transport crate; and

Figure 13 shows a pallet-like carrier manufactured according to the method of the invention.

Figure 1 shows a package 1 and an interior 3 to be placed therein according to an arrow 2. The interior 3 is entirely made of corrugated cardboard. It comprises eight corner interior elements, all of which are indicated by 4. The interior elements 4 are connected to each other by means of rods 5 and thus together form the interior 3.

Figure 2 shows on a larger scale an interior element 4, to which a rod 5 is connected. It will be clear from this figure that the interior element is made up of a number of layers of corrugated cardboard and has a corner recess 6 into which a corner zone of an object to be packaged fits. The rod 5 is connected to the interior element 4. This connection can be established by adhesion, such as by glue, but the rod can also be placed thereon after placing the object on the bottom interior elements 4. After placing the 4 bars shown in Figure 1, the upper four interior elements 4 can then be placed, whereafter 9 the contents of the package are ready and the package 1 can be closed by means of a cover (not shown).

The bars are formed by winding corrugated cardboard and attaching at least the end edge zone to the bottom layer.

Figure 3 shows a device 7 for manufacturing an interior element 8 according to Figure 6B.

The device 7 comprises a frame 9 which carries a supply roll 10 of corrugated cardboard, which can be supplied according to arrow 11 to a punching and creasing station 12. For the sake of clarity, the drawing of means of transport with which corrugated cardboard according to 13 arrow 11 is being transported. A stamp 14 is movable up and down in the direction of an arrow 15 and has a profiling which ensures the punching of predetermined perforations (see figure 6C for this example) and the formation of ridges or folding lines, which are also shown in figure 6C. The thus obtained blank 16 with 20 perforations 17, 18 is coupled with its front edge to a mandrel 20 that is rotatable by a motor 19 and has suction openings for fixing the front edge zone of the blank 16 with force against the mandrel 20. length of the blank 16, as well as the shape and location of the perforation 17 and the folding lines 22 (see figure 6C) is determined by the profiling of the punch 14 or a separate cutting device (not shown).

The up and down movement 15 of the punch 14 is driven by a hydraulic cylinder 23. The entire device 7, and in particular the synchronization of the various components, takes place from a central control unit (not shown).

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Figure 4 shows a supplied blank 24 with a series of perforations, all of which are different from each other but for the sake of convenience all are indicated by 25, as well as a number of folding lines 22. The mandrel 20 engages the leading edge zone 26 of the blank 24; the mandrel 20 is then rotated by the drive motor 19 in the direction of the arrow 27 and thus coils the blank 24, whereby an interior element 4 is ultimately obtained. The end-edge zone is adhered to the underlying corrugated cardboard layer by glue from a glue nozzle 28. The interior element 4 is thus ready and can be pushed off the mandrel 20 according to Figure 5 according to an arrow 29.

Figure 6A shows a pre-interior element 30 in front and side view.

Figure 6B shows that the front interior element 30 can be modeled in front and side view by hinging the side zones 32 downwards according to arrows 31 into the interior element 8.

Figure 6C shows the blank 16 obtained by punching and creasing through the station 12 according to Figure 3. The end edge 33 shown on the top in Figure 6C corresponds to the inside of the interior element, while the end edge drawn on the bottom 34 corresponds to the outside of the interior element. Figure 7A shows an expandable and contractible mandrel 35. In Figures 7A and 7B, the mandrel is shown in its expanded position. By rotating a gear-rack and pinion drive 36 between the two parts of the mandrel 35, the mandrel can be moved between its expanded state shown in Figs. 7A and 7B and its state contracted in Figs. 8A and 8B. In the expanded state, corrugated cardboard is wound into an interior element. After winding up, the finished interior element 37 is pushed off the contracted mandrel according to Fig. 8A and Fig. 8B according to an arrow 38.

Figure 9 shows a hollow mandrel 39 which can be connected to a source for underpressure and has suction openings 21 for retaining the front edge zone of a blank to be wound up by means of underpressure.

For the sake of completeness, it is noted that instead of, or if desired in addition to, the suction openings 21 shown for generating a vacuum therewith, the skilled person may also be provided with alternative (not shown) retaining means, such as hooks, grippers or a receiving list. .

Figure 10 shows a mandrel 40 which, as an alternative to the suction openings 21, has a number of barbs 41 which are expandable and retractable and can engage the leading edge zone of a blank in the expanded state and can be retracted after winding up a blank such that the finished interior element can be slid off the mandrel.

Figure 11 shows a package 42 manufactured according to the winding method, wherein recesses are included both in the top 43 and in the bottom 44 for fixing a product to be packaged in the package 42.

The package 42 can be closed by gluing surfaces A, B, C and D onto surfaces A ', B', C 'and D', respectively. It is noted that package 42 is a complete final package in which the product to be packaged can be accommodated without the intervention of additional fixing means 30. Thus, a three-dimensional object according to the invention is the package 42 itself, and because of its shape and specifically modeled recess (s) it is particularly intended for storing and / or transporting 12 specific articles, such as consumer articles, and / or industrial articles. such as car or machine parts.

Figure 12 shows a transport crate 45 including a number of wound interior elements 46, 47 for supporting and fixing products, for example heavy machine parts. The interior elements 46 and 47 are provided with cooperating recesses such that they fit into each other and thus together form a stable support assembly of interior elements in the transport crate 45.

Figure 13 shows a pallet 48 assembled from a plurality of interior elements 49, 50 and 51 assembled according to the winding method of the invention, on which a product can be received. Because the interior elements 49, 50 are manufactured with slightly different shapes, the product 52 can hereby be accommodated perfectly fitting, providing a very stable support for product 52. Thus, a three-dimensional article 20 produced according to the winding method of the invention serves as a pallet-like carrier 48 with at least one recess for suitably accommodating an article 52 to be supported.

The invention is not limited to the embodiments described above. Advantageously, use can therefore be made of corrugated cardboard with more than one skin film, for example two, three or even four. Fabric-like materials, fiber materials, plastic corrugated sheets, or the like are also suitable choices. Corrugated cardboard has the advantage of being recyclable.

When a mandrel with suction openings is used, to remove a ready interior element from the mandrel in the axial direction, the suction openings 13 can temporarily serve to blow out air under some pressure, whereby removal can take place more easily.

The embodiments described above, although showing preferred embodiments of the invention, are only intended to illustrate the present invention and not to limit the description of the invention in any way. In particular, it is noted that a person skilled in the art can combine technical measures of the various embodiments. The scope of the invention is therefore solely determined by the following claims.

Claims (11)

A method for manufacturing a three-dimensional object with an external main shape and at least one recess, comprising the following steps to be carried out in suitable order: (a) providing a blank of material that is flexible in at least one direction; (b) providing a rotary drivable winding mandrel whose outer shape is at least more or less similar to the main outer shape of an article to be manufactured; (c) taking into account the possible unidirectional flexibility of the material, winding up a number of layers of the material on the winding mandrel; (d) joining at least the end edge of the last-wound layer with the underlying layer; and (e) forming the at least one recess. The method of claim 1, comprising the step of: (f1) selecting a fiber material. 25 3. Method as claimed in claim 2, wherein the fiber material is anisotropic, and the method further comprises the step of: (g1) orienting the fibers of the fiber material relative to the winding axis of the mandrel, such that in the final loading direction of the three-dimensional object the fibers are oriented such that a desired damping behavior is obtained. The method according to any of the preceding claims, wherein the step (f1) comprises selecting corrugated cardboard as material. 5 A method according to claim 4, wherein the step (g1) comprises orienting the longitudinal direction of the corrugated cardboard waves relative to the winding axis of the mandrel. 10 The method according to any of the preceding claims, wherein the step (f1) comprises selecting cellulose or softboard as material. The method of claim 1, comprising the step of: (f2) selecting plastic as material. 8. Method as claimed in any of the foregoing claims, comprising the step of: (h) arranging a number of perforations so modeled in the blank before step (c) that, after winding up the blank on the mandrel, the perforations are mutually mutually registered relationship in 25 successive layers and together form the at least one recess. 9. Method as claimed in any of the foregoing claims, comprising the steps of: (i) performing step (f1) such that the material is a corrugated cardboard of the type with at least two skin foils; (j) performing step (b) such that the winding mandrel has at least two corner zones; and (k) forming elongated weakening zones over the entire width of the blank prior to step (c), which weakening zones are arranged such that they correspond to the corner zones of the winding mandrel. 10. Method as claimed in any of the foregoing claims, further comprising the step of: (1) mutually gluing one or more superimposed layers, depending on the desired stiffness of the three-dimensional object to be manufactured. A three-dimensional object obtained by performing a method according to any one of the preceding claims.