Carton Feeding System with Horizontal Blank Storage

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Solution Overview

Problem

Existing carton blank feeding systems in packaging machines require frequent machine stoppages for refilling and manual adjustments, leading to production inefficiencies and potential jams due to vertically oriented blanks, which also occupy more floor space.

Innovation Solution

A carton forming and sealing machine with a storage rack for horizontally oriented folded carton blanks, a transport device to convey them upright, and a push-up mechanism that reorients the blanks for seamless integration into the machine without stopping the production line, allowing for continuous operation and increased capacity without expanding floor space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If vertically oriented carton blanks are used in the feeding device, then the blanks can be gravity-fed through 45° slant, but the machine must stop frequently for refilling and manual adjustment, reducing productivity

Engineering Contradiction:

Improvemachine operation continuityVSAvoidrefilling and adjustment time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent inverts the conventional vertical orientation of carton blanks to a horizontal orientation. The blanks are stored horizontally in the feeding device and fed into the forming machine horizontally, eliminating the need for gravity-based 45° slant feeding. This inversion allows continuous automated feeding without manual intervention, resolving the contradiction between operation continuity and refilling time loss.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The horizontal feeding system is designed to be self-regulating and self-adjusting. The blanks are automatically positioned and fed without requiring manual alignment or adjustment. The system maintains proper blank positioning through its inherent design, eliminating the need for operator intervention and enabling continuous operation.

Inventive Principle:

Principle #25Self-service

2Quantity of substance

If vertically oriented carton blanks are stacked in the feeder, then capacity between reloading can be increased, but the feeder requires more floor space

Engineering Contradiction:

Improvecarton blank capacityVSAvoidfeeder floor space

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The patent transitions from vertical stacking (utilizing height dimension) to horizontal stacking (utilizing horizontal plane dimensions). By orienting blanks horizontally and stacking them in layers within the feeding device, the system achieves high capacity while maintaining a compact footprint. This dimensional change allows the feeder to fit within the machine's existing floor space while storing sufficient blanks for extended operation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Device complexity

If gravity force and 45° slant are used to slide carton blanks, then the feeding mechanism is simple, but blanks jam when the number of blanks is low and they are not heavy enough

Engineering Contradiction:

Improvefeeding mechanism simplicityVSAvoidblank feeding reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the gravity-based mechanical sliding system with a controlled horizontal feeding mechanism. Instead of relying on gravity and weight to move blanks through a 45° slant, the system uses a controlled feeding apparatus that can reliably transport blanks horizontally regardless of their weight or quantity. This substitution eliminates jamming issues while maintaining mechanism simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If manual adjustment is performed to ensure blanks are in the right position, then positioning accuracy is achieved, but the adjustment process is time-consuming and decreases productivity

Engineering Contradiction:

Improveblank positioning accuracyVSAvoidmachine productivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The horizontal feeding system is designed with self-positioning features that automatically ensure blanks are correctly oriented and positioned as they are fed into the machine. The system's design inherently guides blanks into the proper position without requiring manual alignment, thereby maintaining positioning accuracy while eliminating the time loss associated with manual adjustment.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The feeding device performs preliminary positioning and orientation of blanks before they enter the forming machine. By pre-aligning blanks in the correct position during the feeding process, the system eliminates the need for subsequent manual adjustment, ensuring both positioning accuracy and continuous operation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10640308B2Carton feeding system and method and related carton forming and sealing machine

Publication Date: 2020.05.05 WEXXAR PACKAGING

AI summary

A carton feeding assembly includes a carton blank storage rack for holding a stack of horizontally oriented folded carton blanks, a carton blank transport device for picking a bottommost folded carton blank from the stack and conveying it along a conveyance path, and a carton blank push up device that reorients the folded carton blank into an upright position suitable for movement into engagement with a case erector.