Expandable Paper Mesh for Uniform Cushioning Orientation
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Solution Overview
Problem
Automated packaging systems face challenges in efficiently orienting and organizing items of varying sizes and shapes within flexible packaging, leading to unfavorable orientations and potential jamming, especially when using gravity-induced packaging with non-uniform padding materials like paper meshes that lose cushioning effectiveness.
Innovation Solution
An automated packaging system that uses a clamshell bucket to conformally package items within a laminate layer, which includes a pre-conditioned expandable paper mesh for uniform expansion, ensuring efficient item orientation and minimizing package volume, combined with a robotic arm for repositioning and adhesive application for secure sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If items are inducted into flexible packaging via gravity, then packaging speed is improved, but items end up in unfavorable orientations and can become stuck in the package
Solution Approach 1:
The system performs preliminary actions by pre-forming the flexible package to a predetermined volume that matches the item volume, and by using a bucket to temporarily hold and organize items before induction. This preliminary organization ensures items are properly oriented before gravity induction occurs, preventing them from becoming stuck or improperly positioned while maintaining high packaging speed.
Solution Approach 2:
The patent introduces intermediary devices between the item source and the final package: a bucket serves as an intermediate holding and organizing station, and a pre-formed flexible package acts as an intermediate structure. These intermediaries allow gravity induction to occur efficiently while ensuring proper item orientation through the buffering and organizing effect of the bucket and pre-formed package structure.
2Productivity
If the package is preformed to match item volume, then packaging efficiency is improved, but items may become stuck and require significant repositioning efforts
Solution Approach 1:
The system pre-forms the flexible package to a predetermined volume that closely approximates the volume of the item to be packaged. This preliminary action ensures efficient space utilization and packaging efficiency while preventing items from becoming stuck, as the pre-formed structure is specifically tailored to accommodate the item's dimensions and shape.
3Object-affected harmful factors
If padding materials like paper meshes are used, then cushioning is provided, but cushioning qualities diminish when mesh components are not oriented uniformly
Solution Approach 1:
The system changes the physical state and orientation parameters of the paper mesh padding material through a mesh conditioning mechanism. This mechanism ensures uniform orientation of the mesh components before the item is packaged, transforming the padding material from a random or non-uniform state to a uniformly oriented state that provides optimal cushioning protection.
4Adaptability or versatility
If translation of combined items and padding occurs during package formation, then flexible packaging is achieved, but items shift and interfere with package formation
Solution Approach 1:
The system performs preliminary actions by pre-forming the flexible package to the correct volume and by organizing items in a bucket before induction. This preliminary preparation ensures that when the package is formed and sealed, minimal translation of items and padding occurs, maintaining item position stability while still achieving the necessary flexibility for conformal packaging.
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 system effectively packages items with improved orientation and reduced jamming, maintaining organization and cushioning effectiveness, enhancing the efficiency and reliability of the packaging process.
Implementation Method 1
pre-conditioned expandable paper mesh for uniform expansion
Implementation Method 2
adhesive application for secure sealing
Data Source
AI summary
A method of preparing a packaging laminate includes conveying a mesh of paper material having perforations against a rigid edge causing, at substantially each perforation, a mesh portion at the leading side to have an average elevation lower than that of a mesh portion on the trailing side of the perforation. The method includes expanding the perforations into cells separated from one another by legs interconnected by nodes defined in the mesh Top and bottom surfaces of the legs and nodes are reoriented from an initial orientation substantially parallel with a direction of conveyance of the mesh to an expanded orientation oblique to the direction of conveyance, such that, in the expanded orientation, the top surfaces of the nodes are substantially parallel with each other. The method includes attaching an outer liner to at least some of the bottom surfaces so as to form the packaging laminate.