Flexible Container Support System with Rail Channel
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Solution Overview
Problem
Large volume flexible containers face challenges during filling due to their non-rigid and deformable nature, leading to deformation, improper filling, spillage, and potential collapse, requiring additional support equipment not needed for rigid containers, which increases costs and production time.
Innovation Solution
A support system comprising a top plate and base plate with parallel rails and protrusions that define a channel, providing a secure fitment position for flexible containers, allowing them to be filled efficiently without collapsing, and compatible with conventional fill lines used for rigid containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional support equipment is added to fill flexible containers, then filling stability is improved, but device complexity and cost increase
Solution Approach 1:
The support system is designed to be compatible with conventional fill lines for rigid containers, allowing the same infrastructure to serve both rigid and flexible container filling. The top plate and base plate configuration can accommodate different container types, making the system universal and avoiding the need for entirely separate support equipment for flexible containers.
Solution Approach 2:
The support system acts as an intermediary between the conventional fill line and the flexible container. It provides the necessary support and positioning functions that the flexible container cannot provide on its own, while interfacing with the existing fill line infrastructure. This mediator approach allows stable filling without requiring complete system redesign.
2Reliability
If additional support equipment is added to fill flexible containers, then filling stability is improved, but production time increases
Solution Approach 1:
The support system pre-positions and secures the flexible container on the top plate before the filling process begins. The container is properly aligned and supported in advance, preventing instability during filling and eliminating the need for time-consuming adjustments or interventions during the actual filling operation.
Solution Approach 2:
By making the support system compatible with existing fill lines, the system allows flexible containers to be filled using the same production rhythm and timing as rigid containers. This universality prevents production line slowdowns and maintains efficient throughput.
3Device complexity
If conventional fill lines are used for flexible containers, then equipment cost is reduced, but filling reliability deteriorates due to container deformation
Solution Approach 1:
The support system serves as an intermediary that bridges the gap between conventional fill line capabilities and flexible container requirements. It provides the necessary support, positioning, and stabilization functions that flexible containers lack inherently, while still interfacing with standard fill line equipment. This allows reliable filling without requiring specialized expensive equipment.
Solution Approach 2:
The support system applies localized support and constraint functions at critical points on the flexible container (through the top plate and base plate configuration). This targeted approach provides exactly the right amount of support where needed to prevent deformation and collapse, without over-engineering the entire system.
4Productivity
If flexible containers are filled without support, then production speed is maintained, but filling precision deteriorates leading to spillage and improper filling
Solution Approach 1:
The support system pre-positions and secures the flexible container on the top plate before filling begins. This preliminary action ensures the container is properly aligned, supported, and stable, enabling precise filling at full production speed without risk of deformation, spillage, or improper filling during the process.
Data Source
AI summary
The present disclosure provides a support system. In an embodiment, the support system includes a top plate and a base plate. The top plate and the base plate have a common outer perimeter. The support system includes a support structure. The support structure supports the top plate above the base plate. The support system includes a pair of parallel rails. The parallel rails extend from the top plate outer perimeter to a closed end at a center portion of the top plate. The pair of parallel rails defines a channel. The support system includes a protrusion on each respective rail. Each protrusion extends into the channel in mirror-image relation to each other. The protrusions are located a fitment width distance away from the closed end. The protrusions and the closed end together define a filling position. The support system includes a fitment for a flexible container in the channel.