Integrated Collapsible Carton and Container System
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Solution Overview
Problem
The existing carton-in-case method for packaging and shipping requires two separate machines for filling and reorienting cartons, leading to inefficiencies, high waste, and increased material and labor costs, with cartons often shifting during transit causing damage and unpacking inefficiencies.
Innovation Solution
An integrated collapsible container system where collapsible cartons are releasably attached to each other and the container, allowing for a single apparatus to fill and seal the cartons and container, minimizing shifting and improving packing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two separate machines are used for filling cartons and packing cases, then the filling and packing operations can be performed, but processing time increases and productivity decreases
Solution Approach 1:
The patent combines the filling machine and case packing machine into a single integrated apparatus. The filling mechanism and case packing mechanism share common components including a conveyor system, positioning mechanisms, and sealing systems, allowing both cartons to be filled and cases to be packed in one continuous operation without transferring between machines.
Solution Approach 2:
The integrated apparatus performs multiple functions through a single device: it fills cartons with product, positions filled cartons, forms cases from flat panels, places filled cartons into cases, and seals both cartons and cases. This multi-functional design eliminates the need for separate specialized machines.
2Ease of manufacture
If two separate machines are used for filling cartons and packing cases, then the operations can be completed, but material and labor costs increase
Solution Approach 1:
By merging two separate machines into one integrated system, the patent reduces material consumption through better resource utilization and lowers labor costs by consolidating operational requirements. The single apparatus reduces waste associated with multiple machine transitions and optimizes material flow from carton formation through filling to case packing.
3Productivity
If cartons are placed in containers without integration, then the cartons can be filled and packed, but cartons shift during transit causing damage
Solution Approach 1:
The patent applies preliminary action by pre-forming cases from flat panels before filling cartons and placing them in cases. The case formation is performed in advance with proper positioning features that prevent shifting during transit. The integrated system ensures cartons are securely positioned within cases before sealing, preventing movement during shipping.
4Productivity
If cases are made difficult to open, then packing efficiency may be maintained, but unpacking efficiency decreases and additional damage occurs
Solution Approach 1:
The patent incorporates segmentation through perforations in the case structure that allow for easy opening. The perforations create separation lines that enable the case to be opened along predetermined paths without damaging the contents. This segmentation feature is integrated into the case formation process, allowing the case to remain secure during shipping but open easily at the destination.
Data Source
AI summary
An integrated carton and container which includes a collapsible container and a plurality of cartons. The carton or cartons can be filled with a product or products while the carton or cartons remain integrated with the container. The carton and container are integrated in such a way that when the container is expanded into an open position, the carton or cartons correspondingly expand into an open position. The integrated carton and container may be integrated in such a way that the integrated carton and container may be filled with a product and closed on a single apparatus.