Flexible Layer Gripper Head for Article Array Formation

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Solution Overview

Problem

Manufacturing and shipping numerous differently sized articles pose challenges in loading them into containers due to varying arrangements and fit clearances, especially when the last article row requires deformation, and materials like PET tend to stick together, damaging liners during installation.

Innovation Solution

A head system with a flexible layer connected to a gripper that prevents contact between article rows, allowing for sequential placement without friction, even when the remaining container space is equal to or less than the article row width, using a flexible layer made of low-friction materials like Teflon to minimize damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the last article row is loaded into the container when the remaining cavity width is approximately equal to or less than the article row width, then the container can be fully utilized, but the articles may require deformation or cause damage to the liner

Engineering Contradiction:

Improvecontainer utilizationVSAvoidarticle deformation and liner damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A flexible layer is introduced as an intermediary between the article row and the container liner. This flexible layer prevents direct contact and friction between the articles and the liner, eliminating the harmful effects of deformation and damage while enabling complete container utilization. The flexible layer acts as a protective mediator that allows the article row to be positioned in the tight remaining space without transferring damaging forces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The physical state of the flexible layer is utilized to solve the contradiction. The flexible layer can deform and adapt to the confined space, changing its shape and position to accommodate the article row in the remaining cavity width. This parameter change (from a static barrier to a dynamic, adaptable element) enables the system to achieve both full container utilization and protection of articles and liner.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If multiple differently sized containers are stocked at facilities, then various article sizes can be accommodated, but the complexity and cost of inventory increase

Engineering Contradiction:

Improvearticle size accommodationVSAvoidcontainer inventory complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The flexible layer is designed as a universal component that can be used with containers of various sizes and configurations. This single adaptable element enables one container type to accommodate multiple article sizes through the same loading mechanism, eliminating the need to maintain inventories of multiple differently sized containers. The flexible layer's adaptability provides multi-functionality to the container system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If the gripper directly places the article row into the container, then the placement process is simple, but friction between articles and liner causes damage

Engineering Contradiction:

Improveplacement process simplicityVSAvoidfriction-induced damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The flexible layer serves as a mediator between the gripper-placed article row and the container liner. It maintains the simplicity of the direct placement operation while introducing a protective interface that eliminates friction-induced damage. The article row is still placed directly by the gripper, but the flexible layer intervenes at the contact point with the liner, preserving operational simplicity while preventing harmful friction.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables efficient and damage-free formation of article arrays in containers, accommodating various sizes without deformation and reducing liner damage, especially with materials like PET, by preventing contact and using low-friction surfaces.

Implementation Method 1

using a flexible layer made of low-friction materials like Teflon to minimize damage

Methodology Applied

Scientific EffectLow-friction surface: Lubrication

Data Source

PatentUS11760518B2System for forming an article array in a container

Publication Date: 2023.09.19 DYCO INC

AI summary

A head for use in forming an article array in a container cavity (“cavity”) by sequential placement of adjacent article rows in the cavity, including a gripper having a frame having a longitudinal axis, the gripper adapted to selectively engage and disengage an article row for permitting placement thereof; and a flexible layer connected to the frame and extending parallel to the longitudinal axis and positioned to one side of the gripper. During formation of the article array in the cavity, the flexible layer preventing contact between a most recently positioned article row in the cavity and a corresponding article row being positioned in the cavity, including filling a remaining unfilled portion of the cavity between a penultimate article row and the container for receiving the final article row having a width approximately equal to or less than a width of the final article row.