Dynamic Adhesive Application in Custom Roll-Formed Containers
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Solution Overview
Problem
Fulfillment centers face challenges in efficiently processing large volumes of orders due to the use of non-customized, fixed-size containers that lead to waste, environmental impact, and logistical complications, necessitating improved packing technologies and recyclable materials.
Innovation Solution
The development of roll-formed containers made from recyclable materials, such as fiber-based or paper-based materials, which are custom-sized to fit items using rollers and folders, and equipped with crease patterns and adhesive application systems, allowing for efficient formation and sealing of containers without scrap, and integration with sensor systems for dimension determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed-size containers are used for packing items, then container availability and simplicity are improved, but waste increases and environmental impact worsens
Solution Approach 1:
The patent implements a dynamic container sizing system where the container dimensions are adjusted in real-time based on the measured dimensions of the item being packed. The roll-formed container system uses variable roller positions and adjustable folding mechanisms to create custom-sized containers on-demand, transforming the static fixed-size container approach into a dynamic adaptive system that eliminates waste while maintaining manufacturing efficiency
Solution Approach 2:
The system changes the physical parameters of the container (length, width, height) based on the item dimensions detected by sensors. The roll-formed packaging material is dynamically configured through adjustable rollers and folders that modify the container parameters in real-time, allowing the same packaging system to produce various sizes without waste
2Loss of substance
If custom-sized containers are implemented, then waste reduction and environmental impact improvement are achieved, but processing complexity and device complexity increase
Solution Approach 1:
The patent replaces complex mechanical measurement and sizing systems with optical sensors and automated control systems. Sensors capture item dimensions and the controller automatically adjusts the roll-formed container parameters, substituting manual or mechanical sizing complexity with automated optical-mechanical integration that simplifies the overall process
Solution Approach 2:
The roll-formed container system serves multiple functions: it measures, forms, seals, and customizes containers in a single integrated process. The same rolling and folding mechanism can produce various container sizes and configurations, reducing the need for multiple specialized devices and simplifying the overall system complexity
3Productivity
If roll-formed containers with dynamic adhesive application are used, then processing speed and throughput are improved, but adhesive application complexity increases
Solution Approach 1:
The adhesive application system operates continuously as the packaging material moves through the roll-formed container process. Adhesive is applied in real-time during the forming operation rather than in separate discrete steps, maintaining continuous production flow and eliminating downtime while the adhesive width and placement are dynamically adjusted based on container size
4Ease of operation
If fixed-size containers are used, then packing simplicity is maintained, but item movement and damage risk increase
Solution Approach 1:
The container size dynamically adapts to match the item dimensions, creating a custom-fit enclosure that prevents item movement during transit. The roll-formed system adjusts the container interior volume to closely match the item being packed, eliminating the excessive space in fixed-size containers that causes shifting and damage while maintaining simple automated operation
Data Source
AI summary
Systems and methods are disclosed for dynamic adhesive application for roll-formed containers. In one embodiment, an example system may include a first conveyor configured to convey a packaging material, and an adhesive application system configured to apply adhesive to the packaging material, the adhesive application system having an adhesive applicator configured to dispense adhesive, and an applicator support assembly configured to support the adhesive applicator. The adhesive support assembly may be configured to move the adhesive applicator in two dimensions, where the adhesive application system can apply adhesive along three edges of the packaging material.