Flexible Bottom Disc for Uniform Bulk Solid Packaging
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Solution Overview
Problem
The existing methods for producing and filling paperboard packaging containers with bulk solids from the bottom often result in irregular internal pressures due to the use of rigid and inflexible bottom discs, leading to non-uniform package sizes that are difficult to stack and store effectively.
Innovation Solution
A method involving the formation of a tubular paperboard container body with a bottom disc that is pressed into a guiding channel to create a controlled pressure above ambient pressure, ensuring uniform internal pressure through the combination of gravity and internal pressure, with the bottom disc being welded to the container body while maintaining the elevated pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid and inflexible bottom disc is used to seal the packaging container from the bottom, then the sealing function is achieved, but the internal pressure becomes uncontrolled and packages become irregularly sized
Solution Approach 1:
The bottom disc is changed from a rigid, inflexible component to a flexible membrane that can dynamically adapt to pressure changes during filling. This flexible membrane allows controlled pressure buildup while maintaining sealing integrity, resolving the contradiction between reliable sealing and uniform package sizing.
Solution Approach 2:
The physical state of the bottom disc is changed from rigid to flexible, altering its mechanical properties. This parameter change enables the bottom disc to deform under pressure, allowing controlled internal pressure and uniform package dimensions while maintaining the sealing function.
2Reliability
If the bottom disc is pressed into the container to seal the opening, then the container is sealed, but uncontrolled internal pressure results in difficult-to-stack irregular packages
Solution Approach 1:
The flexible membrane bottom disc dynamically responds to internal pressure during filling, expanding uniformly to maintain consistent package shape and size. This dynamic behavior ensures uniform packages that are easy to stack while maintaining reliable sealing.
Solution Approach 2:
The bottom disc is implemented as a flexible membrane rather than a rigid structure. This flexible film allows the container to accommodate filling pressure uniformly, producing consistent package dimensions and shapes that facilitate stacking and storage.
3Productivity
If bulk solids are filled into the container from the bottom, then filling efficiency is improved, but irregular pressure distribution occurs within the container
Solution Approach 1:
The bottom disc's flexibility parameter is changed to allow it to deform under filling pressure, distributing pressure uniformly throughout the container. This enables efficient bottom filling while maintaining controlled, uniform internal pressure for consistent package quality.
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
This method ensures uniformly sized packages that are easier to stack and store, and provides improved protection against contamination and oxidation by maintaining a controlled pressure, which helps in keeping the contents fresh.
Implementation Method 1
closing the bottom body opening by pressing a bottom disc through the guiding channel and into the bottom body opening such that a pressure above the ambient pressure is produced within the packaging container
Implementation Method 2
the bottom disc having a peripheral flange surrounding a bottom disc base portion, the peripheral flange being flexed towards the upper end in the height direction (H)
Implementation Method 3
attaching the bottom disc to the inner surface of the container body wall by welding
Implementation Method 4
turning the container body such that the upper end is directed upwards in the vertical direction and the bottom end is directed downwards in the vertical direction, such that the bulk solids are compressed against the bottom disc under the combined influence of gravity and internal pressure in the container
Data Source
AI summary
A method of producing and filling a paperboard packaging container with bulk solids material comprising forming a tubular container body, closing an upper body opening of the tubular container body, filling bulk solids into the container body a bottom body opening of the tubular containing body, closing the bottom body opening, and turning container body such that an upper end is directed upwards in a vertical direction, thereby allowing improved control of the pressure within the packaging container.