On-Site Corrugated Cardboard Selection for Packaging
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Solution Overview
Problem
Existing methods for creating corrugated cardboard on-site for packaging boxes are limited in flexibility and strength, as they typically use single-faced corrugated cardboard with fixed properties, leading to inefficiencies in material usage and potential damage during shipping, especially when dealing with varying item sizes and weights.
Innovation Solution
An apparatus and method that allow selection and combination of multiple types of single-faced corrugated cardboard with different physical characteristics, along with a closing layer, to create customized cardboard with adjustable stiffness and strength, minimizing material waste and optimizing packaging for specific items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If single-faced corrugated cardboard is used for packaging, then flexibility and ease of handling are improved, but strength and protection capability deteriorate
Solution Approach 1:
The patent combines single-faced corrugated cardboard with additional flat layers to create a composite structure. This composite material maintains the flexibility of the corrugated base while adding strength through the integrated flat layers, resolving the contradiction between ease of handling and protection capability.
2Strength
If standard corrugated cardboard from stack is used, then strength and stiffness are improved, but adaptability to varying box sizes deteriorates
Solution Approach 1:
The system dynamically selects and combines different types of single-faced corrugated cardboard with varying physical characteristics based on the specific packaging requirements. This dynamic adaptation allows the same system to produce cardboard with appropriate strength for different box sizes, resolving the contradiction between stiffness and versatility.
Solution Approach 2:
The patent changes physical parameters of the cardboard by selecting different types with varying thickness, fluting size, and material composition. This parameter adjustment enables the system to optimize strength for each specific application while maintaining adaptability to different box dimensions.
3Productivity
If fixed-size panels are used, then manufacturing efficiency is improved, but material waste increases
Solution Approach 1:
The system segments the cardboard production process into modular units of different types. By having multiple single-faced corrugated cardboard types available and selecting appropriate segments for each packaging task, the system achieves efficient manufacturing while minimizing waste through precise matching of material properties to requirements.
4Ease of operation
If transverse folds are present in source material, then ease of panel connection is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system performs preliminary selection and preparation of cardboard types before the actual box formation process. By pre-selecting appropriate single-faced corrugated cardboard types and combining them in controlled conditions, the system ensures precise folding and creasing without the interference of pre-existing transverse folds, while still maintaining ease of panel connection through proper material selection.
Data Source
AI summary
An apparatus to create corrugated cardboard on the site of a system for automatically forming packaging boxes for packaging an arrangement of one or more item(s) to be shipped, said corrugated cardboard having at least one corrugated layer between two flat layers, comprising at least two supply stations for supplying two different single-faced corrugated cardboards, each single-faced corrugated cardboard comprising a corrugated layer (having a closed side with an attached flat layer and an open side opposite to said closed side, a supply station for supplying a closing layer, a microprocessor communicatively coupled to obtain information on the arrangement to be shipped, the information relating to at least one of overall dimensions, weight, shape, shipping conditions, fragility, sensitivity to moisture, value, shipping destination, and the obtained information allowing selection, based on the obtained information, of at least one of said at least two different single-faced corrugated cardboards, and an attaching station that attaches the closing layer to the selected first single-faced cardboard to sandwich the corrugated layer between the flat layer and the closing layer.