Variable-Height Box Cutting and Void-Filling Bag Insertion
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Solution Overview
Problem
Existing methods for adapting cardboard boxes to the height and volume of diverse products result in inefficiencies, such as waste generation, complex and costly processes, and inadequate void-filling to prevent product movement and damage during shipping.
Innovation Solution
A method involving cutting the box along its vertical edges, forming fold lines, and inserting inflatable void-filling bags around the products to minimize empty spaces, with automated detection systems determining the necessary cuts and bag volume for secure packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the box height is reduced to adapt to product height, then the box is better adapted to the products, but waste cardboard is generated that must be removed
Solution Approach 1:
The patent applies preliminary action by pre-forming multiple fold lines at different heights around the box before filling. This allows the operator to select and form only the necessary fold lines after filling, based on the actual product height, thereby avoiding waste cardboard while maintaining adaptability. The fold lines are prepared in advance but activated only when needed.
2Adaptability or versatility
If multiple parallel fold lines are pre-formed around the box, then height adaptation is enabled, but the process becomes complex and expensive
Solution Approach 1:
The patent pre-forms multiple parallel fold lines at different heights around the box using a folding device. These fold lines are prepared in advance but only the necessary ones are activated after filling, based on product height. This preliminary preparation enables flexible height adaptation without requiring complex real-time calculations or multiple separate operations.
Solution Approach 2:
The patent segments the vertical surface of the box into multiple horizontal zones by creating parallel fold lines at different heights. This segmentation allows the operator to select and form only the fold lines corresponding to the actual product height, simplifying the overall process while maintaining adaptability. Instead of forming all possible fold lines, only the necessary segments are activated.
3Ease of manufacture
If fold lines are formed at discrete pitch intervals, then the process is simplified, but height adaptation becomes approximate and discontinuous
Solution Approach 1:
The patent pre-forms multiple parallel fold lines at different heights around the box before filling. This preliminary action provides a set of discrete height options that can be selected based on the actual product height. While the fold lines are formed at discrete intervals, this approach simplifies the manufacturing process while still providing sufficient height adaptation precision for most packaging applications.
4Reliability
If void-filling bags are inserted to prevent product movement, then product security is improved, but the process becomes more complex and costly
Solution Approach 1:
The patent applies preliminary action by inserting void-filling bags into the box before filling the products. This allows the bags to be positioned in advance in the empty spaces, and then the products are filled around them. This sequence simplifies the overall process by avoiding the need to insert bags after product filling, which would require more complex manipulation and increase costs.
Solution Approach 2:
The patent segments the void-filling process by using multiple separate void-filling bags placed in different regions of the box (around and above products). Each bag independently fills a specific void region, allowing for simple insertion and positioning. This segmentation avoids the need for complex single-piece void-filling structures or multi-step inflation processes.
5Reliability
If highly inflated void-filling bags are used, then void-filling effectiveness is improved, but cost increases and box closing becomes problematic
Solution Approach 1:
The patent applies preliminary action by inserting void-filling bags into the box before filling the products. This allows the bags to be positioned in advance in the empty spaces, and then the products are filled around them. This preliminary positioning simplifies the overall process and avoids the need for highly inflated bags that would be difficult to manage during closing.
Solution Approach 2:
The patent uses multiple separate void-filling bags placed in specific local regions where voids are detected (around and above products). Each bag is inflated to an appropriate local volume rather than uniformly throughout the entire box. This local quality approach provides effective void-filling while avoiding the problems associated with highly inflated bags, as each bag is sized appropriately for its specific location and function.
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
This approach effectively reduces box height and fills residual spaces with minimized void-filling bags, securely holding products in place and reducing movement and damage during handling and shipping.
Implementation Method 1
at least one inflated or inflatable void-filling bag is inserted into the box, around and/or above the packed products
Data Source
AI summary
The invention relates to the making of boxes of a variable volume adapted in each case to the height of the packed products, including cutting the box along its vertical edges and forming fold lines at a suitable height around the sides of the box to define top flaps; and then folding these flaps onto the contents of the prefilled box. At least one inflated or inflatable void-filling bag is inserted into the box, around and/or above the packed products, after the fold lines have been formed, and before the flaps are folded onto the contents of the box. The invention also provides a combined machine that cuts, marks, prepares and inserts void-filling bags, and closes boxes.Applicable to order filling.