Carton Flap Folding Mechanism for Tile Packing
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Solution Overview
Problem
Existing packing systems for flat products, such as ceramic tiles and building materials, fail to effectively protect corners during conveying and storage, are not adaptable to various product sizes, and require excessive packing material, often relying on glue for assembly.
Innovation Solution
A packing apparatus with adjustable carton blanks and a handling device that uses suction cup members and pushing members to fold carton flaps around flat products, eliminating the need for glue and allowing for easy adaptation to different product sizes, while utilizing conveyors to maintain flaps in position during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional packing systems are used for flat products, then the products can be packaged, but the corners are not effectively protected during conveying and storage
Solution Approach 1:
The packing system applies different protection strategies to different parts of the product: corner protectors specifically for corners and edge bands for edges, rather than uniform packaging. This localized approach ensures corners receive targeted protection while reducing overall material usage.
Solution Approach 2:
The packaging is divided into separate functional components: corner protectors, edge bands, and flap cartons that wrap the main body. This segmentation allows each component to be optimized for its specific protective function, particularly enhancing corner protection independence from the main packaging structure.
2Reliability
If traditional packing methods are used, then products can be protected, but excessive packing material is required
Solution Approach 1:
The corner protection function is extracted from the main carton structure and implemented through separate corner protectors. This allows the main carton to use less material while corners receive dedicated protection, reducing total packing material while maintaining or improving protection effectiveness.
Solution Approach 2:
Instead of using excessive material throughout the entire packaging, the system applies material selectively: thin flap cartons for the main body, and separate corner protectors only where needed. This localized material application reduces overall material consumption while maintaining adequate protection.
3Adaptability or versatility
If fixed-size packing systems are used, then the packing process is simple, but the system cannot adapt to various product sizes
Solution Approach 1:
The packing system incorporates adjustable elements including movable conveyor belts with variable speeds, adjustable flap mechanisms, and reconfigurable positioning systems. These dynamic components allow the same packing apparatus to handle various product sizes by adjusting parameters rather than requiring complete system changes.
Solution Approach 2:
The packing apparatus is designed with multi-functional components that can perform multiple operations: the same conveyor system handles both product transport and positioning, the flap mechanism works for different carton sizes, and the corner protector application system adapts to various product dimensions. This universality reduces the need for multiple dedicated systems for different product sizes.
4Stability of the object's composition
If glue is used for assembling packing components, then the packing structure is stable, but the process becomes more complex and time-consuming
Solution Approach 1:
The system replaces adhesive bonding with mechanical interlocking mechanisms: interlocking flap structures, snap-fit corner protectors, and interlocked edge bands. These mechanical connections provide stable assembly without requiring glue application, drying time, or additional assembly steps, thereby increasing productivity while maintaining structural stability.
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 solution provides effective corner protection, reduces packing material usage, enhances productivity, and simplifies the packing process by adapting to various product sizes without the need for glue, ensuring efficient and versatile packaging.
Implementation Method 1
a handling device (10) that comprises suction cup members (11) configured for holding a carton blank (14) and moving the carton blank to a side of the flat product
Implementation Method 2
pushing members (12) configured for folding two opposite longitudinal flaps of the carton on the two opposite faces of the flat product
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A packing apparatus comprises pushers (12) that fold two opposite flaps of a carton (14) on the two opposite faces of a pile of tileβ (T) that rests on a chain conveyor (27). A belt conveyor (28) will be lifted to interact with the pile such that the lower flap of the carton is maintained pressed by the weight of the pile whilst the pile is moved away from the belt conveyor. It will thus be possible transferring1 the pile to a subsequent strapping station, maintaining the lower flap of the carton in position.