Custom Box Forming for Stable Packaging of Varying Shipment Sets
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Solution Overview
Problem
The existing packaging systems for varying shipment sets, which include items of different sizes and quantities, face challenges such as inefficiency, waste of packaging material, and increased postage costs due to misjudgment of box sizes, and instability of items within pre-folded boxes with open sides and tops.
Innovation Solution
A system comprising a control unit that calculates custom dimensions for cardboard boxes, a box forming station, a packaging station, and a lid placing station, which creates and closes custom-sized boxes to accommodate items efficiently, including features like item arrangement guidance and special protective covers, to optimize packaging volume and prevent item displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-folded boxes with open sides and tops are used, then packaging process is simplified, but items may fall or roll out of the box
Solution Approach 1:
The patent applies preliminary action by pre-folding the box sides and top panels before item placement. The box is prepared in advance with sides erected and top panels folded into protective covers, ensuring item stability is built into the structure before packaging occurs, rather than adding constraints after items are placed
Solution Approach 2:
The box structure is segmented into functional parts: base panel, side panels that erect to contain items, and top panels that fold into protective covers. This segmentation allows each part to perform its specific function - containment and protection - while maintaining ease of assembly
2Loss of substance
If custom sized boxes are created from cardboard rolls, then packaging volume is optimized, but process time increases
Solution Approach 1:
Cardboard blanks are pre-cut and pre-creased into box configurations before use. This preliminary preparation eliminates time-consuming on-site cutting and creasing operations, allowing rapid assembly while maintaining custom sizing optimization for each shipment set
Solution Approach 2:
The system dynamically selects and prepares appropriate cardboard blanks based on the specific dimensions required for each shipment set. The pre-prepared blanks are stored and quickly deployed, combining the flexibility of custom sizing with the speed of pre-prepared components
3Volume of stationary object
If items are arranged in boxes with movable sidewalls and bottom, then packaging volume is minimized, but items may fall apart during transfer
Solution Approach 1:
Items are arranged and secured in the box before the top panels are folded into protective covers. This preliminary arrangement, followed by immediate covering, prevents items from falling apart during transfer while maintaining the volume-optimized arrangement achieved through movable walls and bottom
Solution Approach 2:
The top panels are folded into protective covers that specifically address the local need for item security at the box opening. This localized protective action secures items without requiring constraints throughout the entire box structure, preserving the volume efficiency of the movable wall design
Data Source
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AI summary
A system for automating packaging of varying shipment sets (50), comprising a control unit (10) for receiving information on the size and number of items forming a shipment set (50) and for calculating dimensions of a custom sized cardboard box (20) for packaging the shipment set, a box forming station (12) for forming said custom sized cardboard box (20) having a bottom wall, four side walls and an open top, a packaging station (14) for packaging the items forming the shipment set (50) into said custom sized cardboard box (20) and a lid placing station (16) for closing said custom sized cardboard box (30) with an appropriate lid.