Shipping Container Flap Forming and Folding Mechanism
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Solution Overview
Problem
Existing systems for optimizing the height of shipping containers are inefficient, requiring multiple stations and lengthy processes to form and close custom flaps based on the height of contents.
Innovation Solution
A system and method that uses a sled to move containers through a flap-forming station, where flaps are formed and inwardly folded based on the height of contents, and then to a lidding station where the container can be closed with a lid or by securing the flaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple stations are used to form and close container flaps sequentially, then the container closing process is complete, but the system size and processing time increase
Solution Approach 1:
The patent combines multiple discrete stations (flap formation, flap folding, and container closing) into a single integrated station. The forming assembly creates flaps, the folding assembly folds them inward, and the closing assembly secures the container all at one location, eliminating the need for multiple sequential stations and reducing system complexity while maintaining complete container closing functionality
Solution Approach 2:
The patent divides the closing mechanism into distinct functional assemblies (forming assembly, folding assembly, and closing assembly) that operate simultaneously within a single station. This segmentation allows each assembly to perform its specific function independently while coordinated through a common control system, enabling parallel operations that reduce overall processing time
2Manufacturing precision
If multiple sequential operations are performed at separate stations, then each operation is completed thoroughly, but the total processing time increases
Solution Approach 1:
The patent enables continuous operation by having the forming, folding, and closing assemblies work simultaneously in a coordinated manner. While the forming assembly creates flaps on one container, the folding assembly folds flaps on another container, and the closing assembly secures a third container, eliminating idle time between operations and maintaining continuous productive action across all assemblies
Solution Approach 2:
The forming assembly prepares flaps in advance by cutting and creasing them to the correct dimensions and fold lines before the folding and closing operations begin. This preliminary preparation ensures that when the folding assembly engages, the flaps are already properly sized and positioned, eliminating the need for adjustments during the time-critical folding and closing phases
3Productivity
If a fixed-height container system is used, then the system design is simple, but the shipping volume optimization is limited
Solution Approach 1:
The patent replaces fixed-height container sides with dynamic, adjustable flaps that can be formed to different heights based on the actual contents. The forming assembly cuts and folds the flaps to match the exact height required, allowing the container to adapt to various product dimensions while maintaining structural integrity and optimizing shipping volume for each load
Data Source
AI summary
A system for closing a shipping container that has a rectangular bottom wall, upstanding side walls extending from the periphery of the bottom wall, and an open top end, includes a sled capable of moving the container between a first station and a second station spaced from the first station, and a flap-folding assembly movable with the sled. The flap-folding assembly is configured to inwardly fold flaps of the container while the sled moves the container between the first station and the second station.