Cardboard Box Wrapping Without Die Blocks for Fast Format Change
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Solution Overview
Problem
Existing automated lines for making wrapped cardboard boxes face challenges in flexibility, speed, machine downtime during format changeover, and production of high-quality boxes with minimal creasing or imperfections, particularly when changing box formats.
Innovation Solution
An apparatus and method that utilizes a support structure with movable folding heads and columns, along with actuators and a control unit, to independently adjust to different box sizes and formats, allowing for precise folding operations without a die block, reducing creasing, and increasing production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a die block is used for wrapping boxes, then the folding operation can be performed, but the machine downtime increases during format changeover and stock management becomes complex
Solution Approach 1:
The patent removes the die block from the wrapping system entirely. Instead of using a die block that must be changed for each box format, the invention uses a die block-less wrapping machine where the wrapping blank is directly applied to the box using adhesive and folding mechanisms. This extraction of the die block eliminates the need for changeover operations and stock management of multiple die blocks.
Solution Approach 2:
The wrapping machine is designed to be universal and adaptable to multiple box formats without requiring format-specific components. The positioning device and folding mechanisms can adjust to accommodate different box sizes and shapes, allowing a single machine configuration to handle various formats efficiently.
2Adaptability or versatility
If multiple die blocks of different sizes are kept in stock for different box formats, then format flexibility is achieved, but stock management problems and device complexity increase
Solution Approach 1:
The wrapping machine employs universal components that can adapt to different box formats. The positioning device includes adjustable elements that can be reconfigured for various box sizes, and the folding mechanisms are designed to accommodate different flap configurations without requiring format-specific die blocks.
Solution Approach 2:
The wrapping system incorporates dynamic and adjustable components rather than fixed, format-specific parts. The positioning device can be adjusted in real-time to accommodate different box dimensions, and the folding mechanisms can adapt their motion patterns based on the box format being processed.
3Productivity
If conventional wrapping methods are used, then the wrapping process can be completed, but creasing and imperfections occur in the wrapping blank
Solution Approach 1:
The patent introduces an intermediary adhesive layer between the wrapping blank and the box. This adhesive mediator allows the wrapping blank to be smoothly applied to the box surface, reducing friction and preventing creasing during the folding process. The adhesive enables controlled deformation without damage to the wrapping material.
Data Source
AI summary
An apparatus (1) for automatic wrapping of a wrapping blank (3) on lateral walls (202, 203, 204, 205) of a cardboard box (2), the wrapping blank (3) having a base (301) and a plurality of flaps (302, 303, 304, 305) connected thereto, comprises: a support structure (4); a plurality of folding heads (5), configured for folding and tucking in the flaps of the wrapping blank (3); a plurality of columns (7), oriented vertically and movable horizontally and vertically relative to the folding heads (5). The columns (7) may be positioned inside the box (2) on the internal face of the bottom wall (201) of the box, at least at every vertex of the box (2), so that the bottom wall (201) of the box is operatively interposed between the plurality of columns (7) and the support structure (4).