Custom Carton Height Forming with Cut-and-Crimp Flap Sizing
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Solution Overview
Problem
Conventional container sizing systems for made-to-order packages require a finite number of discrete size options, leading to waste and higher shipping costs due to varying product volumes, and are inefficient with slow processing speeds and costly machinery.
Innovation Solution
A container forming system with a frame, cut and crimp station, conveyor, and controller that customizes container sizes by forming vertical cuts and horizontal fold lines based on content volume, using a measuring plate and contact sensor to ensure precise cuts and folds, followed by lid application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional container sizing systems use a finite number of discrete size options, then manufacturing simplicity is maintained, but container fit precision deteriorates leading to waste and higher shipping costs
Solution Approach 1:
The patent implements dynamic container sizing by allowing continuous adjustment of container dimensions (particularly height) based on the actual volume of products being packaged. The sizing system transitions from fixed discrete sizes to a dynamic, on-demand sizing capability where containers can be customized to fit specific product volumes, eliminating the trade-off between precision and complexity through automated control systems.
2Adaptability or versatility
If custom-sizing machinery such as robot arms or gantries is used, then container customization capability is improved, but system complexity and cost increase
Solution Approach 1:
The patent enables containers to essentially size themselves through an automated process where the system determines the required container dimensions based on product volume, and the container is then formed or adjusted to those dimensions automatically. This self-service approach eliminates the need for complex external sizing machinery like robot arms or gantries, as the sizing function is integrated into the container formation process itself.
Solution Approach 2:
The patent replaces complex mechanical sizing systems (robot arms, gantries) with an integrated automated control system that uses sensors to measure product volume and controls container formation accordingly. This substitution transitions from heavy mechanical intervention to a more streamlined automated process that achieves the same customization capability with reduced complexity.
3Adaptability or versatility
If cut and discard excess material method is used, then container sizing flexibility is improved, but material waste increases
Solution Approach 1:
The patent applies preliminary action by determining the exact container dimensions needed before the container is formed or assembled. The system measures product volume first, calculates the optimal container size, and then forms the container to those precise dimensions from the beginning. This prevents excess material from being added and subsequently discarded, as the container is sized correctly during the formation process rather than being oversized and trimmed down.
4Adaptability or versatility
If made-to-order packaging with varying product volumes is implemented, then customer satisfaction is improved, but shipping costs increase due to inefficient space utilization
Solution Approach 1:
The patent optimizes shipping efficiency by dynamically changing container parameters (dimensions, particularly height and volume) to match the actual product volume. This ensures that containers are neither too large (wasting shipping space) nor too small (requiring additional packaging). The system adjusts container parameters based on measured product volumes, achieving both customization and shipping efficiency simultaneously.
Data Source
AI summary
A container forming system includes a frame having a first deck level and a second deck level above the first deck level. A cut and crimp station is at the second deck level, including one or more mechanisms configured to form a plurality of top flaps in an open container. A conveyor is operatively connected to the frame for movement relative to the frame to receive the open container with product therein at the first deck level and raise the open container up to the crimp and cut station at the second deck level, for forming the plurality of top flaps in the open container.