Reciprocating Roller Bulge Reducer for Gable Top Cartons
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Solution Overview
Problem
Gable top cartons tend to bulge due to increased size and material efficiency improvements, which can be aesthetically unpleasing and require manual handling in downstream processes, necessitating a solution that reduces bulge without additional drives or motors.
Innovation Solution
An in-line bulge reducer integrated into form, fill, and seal packaging machines, utilizing a sprocket with petal-like elements and a reciprocating roller driven by the machine's station chain, applies an inward force to the carton side walls as they move through the sealing station, reducing bulge without separate motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If material thickness is reduced to save cost and improve material efficiency, then material weight and cost are reduced, but carton structural integrity and resistance to bulging deteriorate
Solution Approach 1:
The bulge reducer applies preliminary counteracting force to the carton side walls during the sealing process to prevent bulging from occurring in the first place. The reciprocating roller contacts the side walls and exerts inward force to counteract the outward bulging tendency caused by internal pressure and gas entrapment during sealing.
Solution Approach 2:
The bulge reduction action is performed preliminarily during the sealing process before the cartons leave the machine. The reciprocating roller applies inward force to the side walls at the critical moment when sealing occurs, preventing bulge formation before it can affect downstream handling.
2Manufacturing precision
If additional drives such as motors are added to reduce bulge, then bulge reduction capability is improved, but device complexity and cost increase
Solution Approach 1:
The bulge reducer is merged with the existing sealing station structure of the form-fill-seal machine. The reciprocating roller mechanism is integrated into the sealing station, utilizing the existing machine framework and drive system, thereby eliminating the need for separate motors and additional drives.
Solution Approach 2:
The sealing station is given multi-functionality by incorporating the bulge reduction function alongside its primary sealing function. The same structural components and drive mechanisms serve both sealing and bulge reduction purposes, making the system more versatile without adding complexity.
3Reliability
If cartons are made larger to provide longer shelf life and increased product life, then product protection is improved, but aesthetic appearance deteriorates due to package bulging
Solution Approach 1:
The reciprocating roller applies preliminary counteracting force to prevent bulge formation in larger cartons during sealing. By exerting inward force on the side walls at the moment of sealing, the system prevents the aesthetic deterioration that would otherwise occur in larger cartons with extended shelf lives.
4Volume of moving object
If carton size increases to accommodate larger products, then product capacity is improved, but downstream equipment compatibility deteriorates requiring manual handling
Solution Approach 1:
The bulge reduction action is performed preliminarily during sealing to ensure that larger cartons maintain their dimensional stability and proper shape. This preliminary shaping ensures compatibility with downstream automated equipment by preventing bulge formation that would interfere with handling and processing.
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
The bulge reducer effectively reduces carton size by applying an inward force synchronized with the machine's operation, enhancing aesthetic appeal and accommodating larger cartons without manual handling, while eliminating the need for additional drives.
Implementation Method 1
the roller is biased away from the path, as by a spring
Implementation Method 2
a cam element is mounted on the sprocket to contact a cam follower on the roller. In this manner, cam element moves the cam element into contact with the follower to reciprocate the roller
Implementation Method 3
Contacting the package side wall exert an inward force on and urges the side wall inwardly of the package
Data Source
AI summary
A bulge reducer is configured for use on a form, fill and seal packaging machine for gable top packages. The machine has a drive element and plurality of discrete package carriers for conveying the packages along a conveyance path through the machine. The bulge reducer includes a drive member operably connected to the machine station chain. A reciprocating member is operably connected to the drive member for the reciprocation toward and away from the conveyance path. The reciprocating member contacts one of the package side walls as the package moves along the conveyance path to exert an inward force on and urge the side wall inwardly of the package.