Folding Box Manufacturing Line With Dual-Layer Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging manufacturing lines have limitations in increasing the production rate of folding boxes while maintaining flexibility in box sizes and efficiency in processing.
Innovation Solution
The manufacturing line incorporates a plate element shaping unit with pairs of rotating cylindrical shafts that perform slitting, scoring, and cutting operations to create two juxtaposed folding box layers, which are then connected by attachment points and separated downstream to produce smaller box sizes and increase production capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional plate element shaping unit with four pairs of cylindrical shafts is used, then the manufacturing rate can reach up to 20,000 boxes/hour, but the production capacity is limited and cannot be increased further without changing the basic configuration
Solution Approach 1:
The patent divides a single plate element into two separate folding box layers by introducing a central transverse slit, allowing two boxes to be produced from one plate element. This segmentation doubles the production capacity without requiring a complete redesign of the shaping unit configuration.
Solution Approach 2:
The patent utilizes the transverse dimension (perpendicular to the direction of transport) by creating a central transverse slit that divides the plate element into two layers. This dimensional approach allows simultaneous production of two boxes from one plate, effectively doubling output while maintaining the existing shaft configuration.
2Productivity
If plate elements are processed one at a time through the shaping unit, then the processing is simple, but the production rate is limited to 20,000 boxes/hour
Solution Approach 1:
The plate element is segmented into two separate box layers through central transverse slitting, allowing two boxes to be produced from a single plate element. This increases the quantity of boxes per plate element from one to two, effectively doubling the production rate.
Solution Approach 2:
The patent recovers and utilizes both layers of the plate element that would otherwise be discarded or processed separately. By creating two usable box layers from one plate element, the system maximizes material utilization and increases production efficiency.
3Productivity
If the shaping unit creates only single-layer box structures, then the folding-gluing module operates at standard capacity, but the overall production output is limited
Solution Approach 1:
The plate element is divided into two separate box layers through central transverse slitting, allowing the folding-gluing module to process and produce two boxes simultaneously from one plate element. This segmentation increases overall production output while maintaining relatively simple processing operations.
Solution Approach 2:
The central transverse slitting is performed in advance during the shaping operation, creating two separate box layers before they enter the folding-gluing module. This preliminary action prepares both boxes for simultaneous folding and gluing, maximizing the output capacity of the downstream equipment.
4Productivity
If larger box sizes are produced, then fewer boxes per plate element can be created, but the box dimensions are larger; if smaller boxes are needed, the production rate increases but box size decreases
Solution Approach 1:
The plate element is segmented into two box layers through central transverse slitting, allowing flexible production of different box sizes. By controlling the slit position and plate element dimensions, the system can produce either larger single boxes or smaller dual boxes from the same plate element, providing size flexibility while maintaining high production rates.
Solution Approach 2:
The patent introduces dynamic flexibility in box size production by allowing the shaping unit to create variable slit configurations. The system can adapt between producing one large box or two smaller boxes from the same plate element, enabling dynamic adjustment of box dimensions based on production requirements.
Data Source
AI summary
The invention relates to a line for manufacturing packagings producing folding boxes from plate elements, which comprises a feeding station, a shaping unit which consecutively shapes the plate elements by slitting, scoring and cutting operations, provided with pairs of shafts and a cutting unit, which engage to produce, in the shaped plate element, two juxtaposed folding box layers, arranged transversely to the direction of transport, which are associated in series, and connected to one another by attachment points, a folding/gluing unit which forms folded assemblies by folding and gluing the shaped plate elements, a counting/ejection unit which forms stacks of folded assemblies, and a unit for separating folding boxes comprising means arranged to produce, by breaking the attachment points, two separate batches of stacked folding boxes from each stack of folded assemblies.