Expandable Protection Element for Ceramic Tile Packaging
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Solution Overview
Problem
Existing methods for protecting items in rigid packages, such as ceramic tiles, during transport are inefficient as they require manual insertion of filler materials and lack precise positioning, leading to incomplete blocking and potential damage from impact.
Innovation Solution
A positioning group that uses expandable plastic casings filled with a filler material, which are automatically positioned between items and the package walls using a robotic system, allowing for precise placement and effective damping of impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion of filler materials is used, then flexibility in handling is maintained, but productivity is reduced and positioning precision is poor
Solution Approach 1:
The protection element automatically positions itself by utilizing the expansion of filler material within its cavity to expand and block the interspace, maintaining items in position without requiring complex automated positioning systems or manual intervention
Solution Approach 2:
The protection element is divided into a casing with cavity structure that can be separately manufactured and then deployed, allowing for simplified manufacturing and automated handling while maintaining positioning functionality
2Ease of operation
If granular filler material is used, then ease of insertion is improved, but positioning precision and blocking capacity deteriorate
Solution Approach 1:
The protection element uses a casing with a cavity that can flexibly adapt to the interspace geometry while maintaining precise positioning of items, combining ease of insertion with accurate positioning capability
Solution Approach 2:
The filler material undergoes a parameter change from granular loose state during insertion to expanded solid state within the cavity, providing both ease of insertion and precise blocking capability once expanded
3Device complexity
If wedges or parallelepiped elements are used, then structural simplicity is maintained, but blocking completeness and positioning firmness deteriorate
Solution Approach 1:
The casing structure with internal cavity provides a simple yet effective geometry that can adapt to various interspace shapes, ensuring complete blocking and firm positioning without complex multi-component structures
Solution Approach 2:
The protection element combines the structural casing with expanded filler material to create a composite structure that provides both simple geometry and reliable complete blocking capability
4Stability of the object's composition
If protection elements are firmly positioned, then item stability is improved, but adaptability to package size variations deteriorates
Solution Approach 1:
The protection element transitions from a flexible state during insertion to a firmly positioned stable state once the filler material expands, providing both adaptability to different package sizes and firm stabilization of items
Solution Approach 2:
The filler material undergoes parameter changes including expansion and solidification that allow the protection element to adapt to varying interspace dimensions while maintaining firm positioning and item stability
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 solution enables efficient, automated placement of protection elements that firmly maintain items in position, reducing production time and ensuring effective impact damping, thereby enhancing the integrity of items during transport.
Implementation Method 1
a liquid form which is made to expand and solidify by means of a reagent, or a catalyst, in a manner so as to form a solid filler
Implementation Method 2
made to expand and solidify by means of a reagent, or a catalyst
Implementation Method 3
sensor means constrained to the support frame adapted to detect, in an automated manner, the position of the rigid package and/or of the items therein
Implementation Method 4
capable of effectively damping the stresses or possible impact to which the items within the package or box can be subjected
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A group for positioning an element (P) for protecting items (A), such as ceramic plates or tiles, arranged stacked inside a rigid package or box (B), at an interspace (I) present within the rigid package or box (B) around the lateral perimeter of the items (A) between the rigid package or box (B) and the items (A), comprises a support frame (2), quick coupling means (3) connectable to an arm (4) of a robot, a gripper (5) connected to the support frame (2), the gripper (5) is shaped for retaining the protection element (P) and for releasing it into the interspace (I).