Corrugated carton design method and equipment and storage medium

Abstract

The invention relates to the technical field of packaging cartons, in particular to a corrugated carton design method which comprises the following steps: S1, calculating and determining the angle value of each folding point by using a specific mathematical model according to the stability requirement of multi-layer stacking; s2, regulating and controlling the thickness and position of an internal partition material based on the angle determined in the previous step according to the protection performance requirements of fragile articles in transportation; s3, according to the softening and deformation problems in the high-humidity environment, selecting a proper coating material type and accurately distributing the coating material at the key part; and S4, determining an outer layer treatment scheme, a printing ink formula and drying time based on the optimization results of the previous steps, and adjusting a sealing mode to match the speed and strength requirements of an automatic packaging line. The damping and buffering capacity of the whole container on the vibration or shaking effect caused by external disturbance factors is improved by accurately adjusting the internal supporting assembly and the gap arrangement, and meanwhile reasonable distribution of the internal space is guaranteed, so that the fragile products are effectively protected.

Description

Technical Field

[0001] The present invention relates to the technical field of packaging cartons, and specifically to a design method, equipment and storage medium for corrugated cartons. Background Art

[0002] Corrugated cartons are made by die-cutting, creasing, nailing or gluing corrugated cardboard. Corrugated cartons are the most widely used packaging products, and their usage has always been the first among various packaging products. For more than half a century, corrugated cartons have gradually replaced transportation packaging containers such as wooden boxes with their superior performance and good processing performance, becoming the main force in transportation packaging. In addition to protecting goods, facilitating storage and transportation, they also play a role in beautifying and promoting goods.

[0003] The corrugated carton design method refers to optimizing and adjusting the carton structure, materials and processing technology to improve its performance in actual use. However, how to accurately control the folding angles of corrugated cartons is a major challenge. Especially when stacked in multiple layers, it is necessary to ensure the accuracy of each folding angle to enhance the overall stability of the carton and prevent collapse or tilt caused by uneven stress. Secondly, in protecting fragile items, reasonable control of the thickness and position of the internal partition materials is crucial to adapt to different shapes and weights of items, so as to provide sufficient protection during transportation and reduce damage. Summary of the Invention

[0004] Aiming at the deficiencies of the prior art, the present invention provides a design method, equipment and storage medium for corrugated cartons, which solves the problems that corrugated cartons are prone to collapse or tilt due to uneven stress and the internal partition materials cannot provide sufficient protection for items.

[0005] To achieve the above objectives, the present invention is realized through the following technical solutions: A design method for corrugated cartons includes the following steps:

[0006] S1. According to the stability requirements of multi-layer stacking, use a specific mathematical model to calculate and determine the angle values of each folding point;

[0007] S2. According to the protection performance requirements of fragile items during transportation, based on the angles determined in the previous step, adjust the thickness and position of the internal partition materials;

[0008] S3. According to the problem of softening and deformation in high humidity environments, select a suitable coating material type and accurately distribute it at key positions;

[0009] S4. Based on the optimized results of the previous steps, determine the outer layer treatment plan, ink formula and drying time, and adjust the sealing method to match the speed and strength requirements of the automated packaging line.

[0010] Preferably, the specific steps of step S1 are as follows:

[0011] Determine the maximum stacking height H of corrugated cartons at different numbers of layers;

[0012] Calculate the ratio of the uniformly distributed load P borne by each layer of cartons to the stacking layer height D, and select an appropriate mathematical model to estimate the optimal folding angle A;

[0013] Adjust the inclination angle θ between adjacent layers based on the results output by the model and physical properties to enhance the overall stable structure;

[0014] If the currently calculated maximum stable inclination angle θ exceeds the safety range limit θmax, use reinforcing ribs or other supporting elements to ensure that θmax is not exceeded. Where θ represents the actual inclination angle of the folding point, and θmax represents the safety inclination upper limit set according to experience.

[0015] Preferably, the specific steps of S2 are as follows:

[0016] Analyze the stress distribution S(x) of the internal goods on the side walls of the carton under different inclination angle conditions;

[0017] Conduct local reinforcement on specific areas, that is, select a partition material with an appropriate thickness and suitable elasticity and arrange it in the stress concentration area;

[0018] Test the shock absorption effect ΔE of the same goods sample under the same packaging method before and after placing this material, and evaluate the protection improvement ratio P = (ΔE before - ΔE after) / ΔE after;

[0019] If the improved protection coefficient P is greater than or equal to the critical protection efficiency index Pcrit, confirm the optimization plan.

[0020] Preferably, the specific steps of S3 are as follows:

[0021] Detect the change trends of relative humidity H and temperature T in the potential application environment and their changes with seasons;

[0022] Use these parameters to establish an environmental factor matrix M(H,T), and select the optimal coating material by comparing the weather resistance indices W of various materials;

[0023] Apply the selected material to the parts that may be most affected by moisture and have the highest risk of compression deformation, and record the application amount.

[0024] Preferably, the specific steps of S4 are as follows:

[0025] Define the different mechanical loads that may occur during the logistics links experienced by the target product;

[0026] Design external wear-resistant protection measures and their associated profiles for different scenarios, and ensure that the final product meets relevant national standards to determine the specific process flow;

[0027] Experiment and test the effects of different ink ratios on the clarity of specific printed patterns, and formulate the most suitable working system in combination with the actual printing speed;

[0028] Use a conditional judgment expression. If the image resolution is R, when the resolution R≥Rtarget (where Rtarget represents the acceptable minimum resolution), set an appropriate drying duration to ensure good printing quality.

[0029] An electronic device, the electronic device includes: a processor and a memory;

[0030] The processor is used to execute the steps of the corrugated cardboard box design method according to any one of claims 1 to 5 by calling the program or instructions stored in the memory.

[0031] A computer-readable storage medium stores a program or instructions, and the program or instructions cause a computer to execute the corrugated cardboard box design method according to any one of claims 1 to 5.

[0032] The present invention provides a corrugated cardboard box design method, device and storage medium. It has the following beneficial effects:

[0033] 1. By using mathematical theory combined with mechanical simulation, the present invention analyzes the overall force distribution of the cardboard box under different folding angle conditions, and thus provides a basis for the stability and bearing strength during stacking. By carefully considering the interaction between multiple layers of corrugated cardboard under actual working conditions, and flexibly setting the parameter value range according to different customer or product requirements for the structural stability of the cardboard box; and then combining multiple iterative experiments in the laboratory environment to finally obtain the optimal solution. Thus, it can be ensured that a good and stable state can be maintained whether in a static state or during loading, unloading and transportation.

[0034] 2. By precisely adjusting the internal support components and gap settings, the present invention improves the shock absorption and buffering ability of the entire container against vibrations or shaking effects caused by external disturbance factors, while ensuring the rational distribution of the internal space, preventing the displacement and collision of goods, and thus realizing the effective protection of fragile items. Detailed implementation manners

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0036] Embodiment:

[0037] An embodiment of the present invention provides a corrugated cardboard box design method, including the following steps:

[0038] S1. According to the stability requirements of multi-layer stacking, use a specific mathematical model to calculate and determine the angle value of each folding point;

[0039] S2. According to the protection performance requirements of fragile items during transportation, adjust the thickness and position of the internal partition material based on the angles determined in the previous step;

[0040] S3. According to the problem of softening and deformation in a high-humidity environment, select a suitable coating material type and accurately distribute it at key positions;

[0041] S4. Based on the results optimized in the previous steps, determine the outer layer treatment plan, ink formula, and drying time, and adjust the sealing method to match the speed and strength requirements of the automated packaging line.

[0042] Next, describe the specific steps of calculating and determining the angle value of each folding point based on the stability requirements of multi-layer stacking of the present invention:

[0043] The first step: Determine the maximum allowable stacking height H of the corrugated cardboard box under different number of layers through experiments and simulations. Specifically, on the premise of ensuring that the structure does not collapse, according to the design standards and actual transportation requirements, find the maximum height H corresponding to the most economical maximum stacking number. For example, through pressure tests, determine that the maximum safe height for 10-layer stacking is 2 meters. This value is usually determined by the mechanical properties of the material and the weight of the carried goods, and the environmental changes during storage or transportation need to be considered.

[0044] Step 2: Precisely measure the ratio of the uniformly distributed force P borne by each layer of cartons to the stacking height D. This ratio can characterize the pressure intensity that each unit height of a layer has to bear, that is, the force-bearing degree per unit area of each layer of cartons, which is an important factor in measuring the stability of multi-layer stacking. On this basis, an appropriate model is selected to estimate the optimal folding angle A. This process involves the formula R = P / D, where the parameter R represents the above-mentioned proportional relationship; D represents the stacking layer height (the range can be from the minimum layer height until the maximum allowable stacking height H obtained previously minus the thickness of the upper layer), and in order to obtain good stability effects, R should preferably approach the optimal value within a certain reasonable numerical range, which will affect the size of the crease angle calculated later and the slope of the trend graph of its change amplitude.

[0045] Step 3: Adjust the inclination angle θ between adjacent layers according to the results given by the model and the actual physical characteristics to optimize the stability of the overall system architecture, aiming to make the internal structure of the corrugated cardboard more firmly combined together. To ensure that the shape remains stable and does not fall apart during the application of external forces, and can effectively disperse the stress transmitted from the outside to other positions that are not directly compressed. If the calculated maximum inclination angle at this time exceeds the pre-given empirical safety threshold θmax, then the method of adding reinforcement components will be adopted to control the final formed angle within a suitable range, such as using reinforcing ribs or adding additional supports to prevent the carton from collapsing and damaging the internal items, where θ refers to the measured value of a specific corner position, and θmax is the limit safety reference number summarized from a large number of practices. For example, in an instance, it is assumed that after multiple tests, about 35° is a generally recognized safety limit. In some application scenarios, once it is calculated that the maximum rotation deviation of a single unit reaches 37°, an auxiliary strengthening device needs to be immediately introduced for correction until it returns to the acceptable range again to ensure that the safety of the overall structure is not threatened by anything.

[0046] Next, the specific steps of adjusting the thickness and position of the internal partition material based on the angle determined in the previous step of the present invention are described. Through four key processes, the design optimization of the corrugated carton is achieved.

[0047] First, systematically analyze the stress distribution S(x) of the internal goods on the side walls of the carton under different inclination angle conditions. The stress distribution is determined through mechanical experiments or simulation, aiming to understand which parts of the packaging are subjected to greater pressure or tension. The stress function S(x) reflects the stress magnitude caused by the change of the goods position x under a specific angle.

[0048] Then, after identifying the high strain concentration areas, materials with appropriate properties will be selected and arranged in appropriate thicknesses at the locations where additional support is required. During the selection process, emphasis is placed on two properties: elasticity and thickness. The material not only needs to be thick enough to provide support but also must have sufficient resilience to avoid deformation. The specific parameter ranges of the material depend on the tested goods and specific environmental requirements; the appropriate elasticity and thickness can be obtained through repeated testing.

[0049] Immediately after selecting the reinforcement material, its performance will be tested: by comparing the impact shock absorption data ΔE (i.e., the change before and after placement), the protection improvement ratio P = (ΔEbefore - ΔEafter) / ΔEafter is used to evaluate the improvement brought about by this change. This formula is used to measure the effectiveness ratio of the improvement measures, and the measurement criterion is the improvement level after optimization compared to before. Generally, the higher the P value, the more the protection effectiveness is enhanced.

[0050] To ensure the effectiveness of this process, a critical protection efficiency index Pcrit is set as a threshold to determine whether the desired effect is achieved. Specifically, if the ratio P obtained after improvement is greater than or equal to the critical value, it can be confirmed as the best adjustment method; otherwise, continue to adjust until the most suitable materials and layouts are found.

[0051] Next, the specific steps of the present invention for selecting a suitable coating material type and precisely distributing it at key positions based on the softening and deformation problems in a high humidity environment will be described:

[0052] First, it is necessary to detect the changing trends of the relative humidity H and temperature T in the potential application environment and how these factors change with the seasons. The purpose of this step is to understand the humidity and temperature challenges that the target corrugated box may encounter in the future, thus laying a data foundation for subsequent selection of the most suitable environmental protection coating material. For example, if the target market is in a tropical region with a long rainy season and hot and humid air throughout the year, the humidity temperature difference between different months in this region is particularly important for product design.

[0053] Subsequently, the collected parameters are used to establish a unique factor matrix M(H,T) that can reflect the local environmental conditions. With the help of this model, the materials marked by different types of weather resistance indexes are compared and analyzed, and then the coating materials with the best comprehensive performance are selected. The optimal performance here not only means the ability to maintain a stable state under extreme conditions, but also takes into account economic cost factors to ensure that the selected materials can withstand harsh climates and have a high cost-effectiveness advantage during the validity period. In one embodiment, it was found through experimental comparison that polyolefin modified resin has a stronger waterproof and moisture-proof effect than traditional polyethylene film, and is therefore identified as a more suitable candidate substance to resist the adverse factors in high-humidity environments. In addition, in order to better cope with various uncertainties that arise under actual working conditions, long-term aging tests are usually conducted in a laboratory environment to simulate extreme temperature and humidity values ​​to verify the accuracy of the selection of the final shortlisted materials and determine the ideal index value range for their weather resistance. Generally speaking, the test scenario between 25℃ and 30℃ and humidity level above 80%RH is the most representative and meets the requirements. For those outer packaging that have been used in the southern coastal areas for a long time, samples that can adapt to more stringent extreme conditions such as 40℃ and 100%RH should be selected for assessment to ensure that the expected effect can be achieved even in harsh use environments. At this time, the corresponding weather resistance index should be maintained within a very high level range (such as above 9), which serves as an important basis for judging the quality of the material.

[0054] Next, consider applying the determined optimal coating material to the parts that are most susceptible to moisture erosion and structural deformation, such as edge seams or bottom support planes, because they are often more susceptible to damage and deformation when subjected to external stress in a wet state, which directly affects the overall mechanical performance of the carton. During the coating process, it is also necessary to accurately control the mass of the surface carrier per square centimeter in order to obtain an ideal coating coverage that is uniform, firm, and does not waste excess resources. In a specific embodiment, spraying or painting can be used to strengthen the gaps between the multi-layer structures inside the cardboard, and the amount can be economically reasonable while ensuring good closed isolation. This quantitative management measure helps to ensure that each product leaving the factory is always in a good packaging protection state, and no matter which area it is transported through, it will not easily be damaged or leaked due to natural wind and rain.

[0055] Next, the specific steps of the present invention for determining the outer layer treatment scheme, ink formula and drying time based on the optimization results of the previous steps, and adjusting the sealing method to match the speed and strength requirements of the automated packaging line are described:

[0056] By definition, different types of mechanical loads that the target product may encounter throughout the logistics chain are first defined. For example, during the entire process from warehousing handling to long-distance distribution, forces of different magnitudes and directions will be experienced. These loads cover vertical drops, stacking weights, and other physical extrusion conditions.

[0057] Subsequently, anti-wear protection countermeasures and their corresponding configuration files suitable for various situations are designed to ensure that the corrugated cardboard boxes remain intact and meet national standards requirements regardless of how complex the situation is. For example, for the case of high stacking pressure, a thicker and tougher outer wall material is set to resist damage; the configuration file records various response settings for mechanical loads and the corresponding parameter values, such as the greater the mechanical load value, the more durable the design details are required.

[0058] Next, the actual impact of various ink formulation schemes on the final graphic clarity I is experimentally evaluated. In this process, multiple factors will be considered, including characteristics such as chromatic saturation and color reproduction effect, and the actual printing speed will also be combined. If a formulation can improve the pattern fineness level without slowing down the production progress, then this option will become the preferred solution. Suppose a certain ink can quickly adhere and exhibit good imaging characteristics, and it is preferentially selected without reducing the efficiency of the assembly line operation, which ensures the aesthetics and consistency of the finished product.

[0059] The last part emphasizes the crucial role of image resolution in printing quality. The conditional expression is as follows: If the image resolution is R, then it is required to reach or exceed the preset minimum acceptable level Rtarget (such as 300 dpi) to be considered in a satisfactory state; and to maintain this quality, an appropriate curing time needs to be set. For example, assuming that a 1200 dpi printing device is currently used, even if the basic standard is 300 dpi, the drying time period should be appropriately extended so that the color is fully fixed to avoid blurring or decolorization problems. The appropriate drying duration range generally varies between 10 seconds and 60 seconds. When the high-quality printing mode is selected, it often comes with a longer waiting time for the ink to dry in exchange for a more perfect result display.

[0060] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A corrugated box design method, characterized in that: The following steps are involved: S1. According to the stability requirements of multi-layer stacking, a specific mathematical model is used to calculate and determine the angle value of each folding point; S2. According to the requirements of protection performance of fragile items during transportation, adjust the thickness and position of the internal partition material based on the angle determined in the previous step; S3. According to the softening and deformation problem in high humidity environment, select the appropriate coating material type and accurately distribute it in key areas; S4. Based on the results of the previous optimization steps, determine the outer layer treatment solution, ink formula and drying time, and adjust the sealing method to match the speed and strength requirements of the automated packaging line.

2. A corrugated box design method according to claim 1, characterized in that: The S1 step is specifically as follows: Determine the maximum stacking height H of corrugated boxes at different layers; Calculate the ratio of the uniformly distributed load P on each layer of cartons to the stacking layer height D, and select a suitable mathematical model to estimate the optimal folding angle A; Based on the model output results and physical properties, the tilt angle θ between two adjacent layers is adjusted to enhance the overall stable structure; If the currently calculated maximum stable tilt angle θ exceeds the safety range limit θmax, reinforcing ribs or other supporting elements are used to ensure that θmax is not exceeded, where θ represents the actual tilt angle of the folding point and θmax represents the upper limit of the safety tilt set based on experience.

3. A corrugated box design method according to claim 1, characterized in that: The S2 step is specifically as follows: Analyze the stress distribution S(x) of the internal cargo on the side wall of the carton under different tilt angles; Carry out local reinforcement in specific areas, that is, select barrier materials with appropriate thickness and elasticity and arrange them in stress concentration areas; Test the shock absorption effect ΔE of the same cargo sample in the same packaging method before and after the material is placed, and evaluate the protection improvement ratio P = (ΔE before - ΔE after) / ΔE after; If the improved protection factor P is greater than or equal to the critical protection efficiency index Pcrit, the optimization scheme is confirmed.

4. A corrugated box design method according to claim 1, characterized in that: The S3 step is specifically as follows: Detect the changing trends of relative humidity H and temperature T in potential application environments and their seasonal changes; These parameters are used to establish the environmental factor matrix M(H,T), and the optimal coating material is selected by comparing the weathering index W of various materials; Apply the selected material to the areas that are likely to be most affected by moisture and at the highest risk of compression deformation, and record the amount applied.

5. A corrugated box design method according to claim 1, characterized in that: The S4 step is specifically as follows: Definition of the different mechanical loads that may occur during the logistics steps that the target product goes through; Design external wear protection measures and their associated profiles for different scenarios, while ensuring that the final product complies with relevant national standards to determine the specific process flow; Experimentally test the effect of different ink ratios on the clarity of specific printed patterns, and formulate the most suitable working system based on the actual printing speed; Use conditional judgment expressions. If the image resolution is R, then the resolution R≥Rtarget (where Rtarget represents the lowest acceptable resolution) must be met. Then set an appropriate drying time to ensure good printing quality.

6. An electronic device, characterized in that: The electronic device comprises: a processor and a memory; The processor is used to execute the steps of the corrugated box design method according to any one of claims 1 to 5 by calling the program or instruction stored in the memory.

7. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a program or instruction, and the program or instruction enables a computer to execute the corrugated box design method according to any one of claims 1 to 5.