Flexible Package Forming Box Actuation for Stackable Shapes
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Solution Overview
Problem
Conventional vertical form, fill, and seal (VFFS) packaging machines produce flexible packages that lack rigidity, preventing them from being stacked and retaining their shape after opening and product removal.
Innovation Solution
An apparatus with a forming box and flap folding bar system that actuates to receive, retain, and release packages, incorporating ejectors and heating/cooling elements to create a cubed shape and enhance processing speed, allowing for the formation of flexible, stackable packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional VFFS packaging machines are used, then packaging speed is maintained, but package rigidity and shape retention deteriorate
Solution Approach 1:
The forming box is designed with movable walls that can dynamically adjust their position during the packaging process. The walls move from an open position to enclose the package, then to a compressed position to create the cubed shape, and finally to a release position. This dynamic adjustment allows the system to maintain high packaging speeds while simultaneously achieving rigid, shape-retaining packages through controlled compression and formation.
2Shape
If package compression is increased to improve shape retention, then package rigidity improves, but device complexity increases
Solution Approach 1:
The forming box is divided into multiple independent movable walls (first, second, third, and fourth walls) that can move separately. Each wall is controlled by its own actuator, allowing independent adjustment and compression. This segmentation enables precise control over the package formation process, achieving superior shape retention without requiring an overly complex monolithic mechanism.
Solution Approach 2:
The movable walls serve multiple functions: they guide the flexible material during formation, enclose the package, apply compression to create the cubed shape, and then release to allow package ejection. This multi-functionality reduces the need for separate dedicated components for each operation, thereby reducing overall device complexity while achieving excellent shape retention.
3Stability of the object's composition
If conventional forming methods are used, then device simplicity is maintained, but package stackability deteriorates
Solution Approach 1:
The system changes the physical parameters of the package during formation by applying controlled compression through the movable walls. This compression transforms the flexible material from a soft, non-stackable state to a rigid, cubed shape with excellent stackability. The parameter changes in package rigidity and geometry are achieved through the coordinated movement of the forming box walls.
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 apparatus increases package forming speeds and enables the creation of flexible, stackable packages with improved rigidity and shape retention, while also converting conventional packaging machines to produce such packages.
Implementation Method 1
one or more ejectors extending from the third surface or fifth surface disposed adjacent to the first surface... configured to engage the package and force the package out of the forming box
Implementation Method 2
incorporating ejectors and heating/cooling elements to create a cubed shape and enhance processing speed
Data Source
AI summary
An apparatus for forming a flexible package can include a forming box having a first, second, and third portions that cooperate to define first, second, third, and fourth walls of the forming box, and one or more forming box actuators operatively coupled to the forming box to actuate the forming box between a first position for receiving a package, a second position for retaining a package, and a third position for releasing the package. The apparatus can also include a first flap folding bar disposed upstream and adjacent a first end of the forming box, and one or more first flap folding bar actuators operatively coupled to the first flap folding bar to actuate the first flap folding bar in a direction substantially transverse to a transport path of a flexible material.