Box Assembly Device with Jig-Based Bottom Flap Folding

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Solution Overview

Problem

Conventional box assembly devices require complex processes to join the flaps of folded corrugated cardboard, making the assembly of boxes cumbersome.

Innovation Solution

A box assembly device with a robot body, holding mechanism, folding mechanism, and robotic arm that folds the bottom flaps inside to form a cylindrical shape, using jigs to easily assemble the box by overlapping and engaging the bottom boards, and optionally employing a blow mechanism to spread flaps for interference-free folding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional box assembly devices are used to join the joint of folded flaps, then the box can be assembled, but the process becomes complicated and cumbersome

Engineering Contradiction:

Improveease of box assemblyVSAvoidcomplexity of assembly process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention divides the box material into distinct functional components: side boards, bottom boards, and bottom flaps. Each component is positioned and folded independently through automated mechanisms, simplifying the overall assembly process by breaking down the complex joining operation into manageable segments

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The box material is designed with self-foldable flaps and boards that automatically engage with each other through the automated folding mechanism. The structure itself facilitates the assembly process by incorporating pre-designed fold lines and engagement features that require minimal external intervention

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If the bottom flaps are folded inside to overlap with bottom boards, then the box structure is formed, but the process requires precise control

Engineering Contradiction:

Improveprecision of flap foldingVSAvoidease of folding operation

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

A blow mechanism is introduced as an intermediary device to assist in spreading and positioning the bottom flaps before folding. This intermediary mechanism facilitates the folding operation by preparing the flaps in advance, making the subsequent folding action more precise and easier to control

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bottom flaps are spread outside and positioned in advance using the blow mechanism before the actual folding operation occurs. This preliminary positioning ensures that when the folding mechanism activates, the flaps are already in the optimal position for precise and easy folding

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11529785B2Box assembly device and method of assembling box

Publication Date: 2022.12.20 KAWASAKI JUKOGYO KK

AI summary

In a box assembly device, a holding mechanism causes one of bottom boards to contact a first jig and folds the bottom board inside, while the holding mechanism holding the box material in a state where the box material is developed in a cylindrical shape from a folded state. The folding mechanism folds the bottom flap inside so as to overlap with one of the bottom boards. The holding mechanism causes the other bottom board to contact the second jig while holding the box material and folds the other bottom board inside and upwardly so as to overlap with the bottom flap to engage the bottom boards with each other.