Pre-folded Box Packaging with Adjustable Panel Cutting
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Solution Overview
Problem
Existing packaging systems face challenges in creating optimal custom-sized boxes for items of varying sizes and quantities, particularly in automating the packaging process, as they often result in suboptimal volume and difficulty in handling items of different shapes and sizes.
Innovation Solution
A system and method that utilize a pre-folded cardboard box with an open top and side, allowing for customization of the length and height to accommodate various items, using a cutting unit to shorten panels and introduce crease lines for efficient folding and closure, enabling the use of standard blanks to form a variety of box sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-sized boxes are created from scratch for each shipment, then box dimensions can be perfectly adapted to items, but the process becomes complex and time-consuming
Solution Approach 1:
The system pre-folds cardboard blanks into boxes with standard configurations before shipment. These pre-folded boxes are stored and can be quickly assembled by adding items, eliminating the need for complex on-demand folding operations while maintaining good dimensional adaptation
Solution Approach 2:
The system dynamically selects from multiple pre-folded box types with different dimensions based on the specific item characteristics. Rather than creating a completely custom box each time, the system chooses the most appropriate pre-folded box type and adjusts it as needed, balancing adaptability with process simplicity
2Productivity
If multiple box sizes are stored for different items, then packaging efficiency improves, but storage space requirements increase
Solution Approach 1:
The packaging system segments the box creation process into pre-folded standard components that can be quickly assembled. By having pre-folded boxes ready in various sizes, the system enables efficient packaging selection without needing to store complete assembled boxes for every possible item combination
Solution Approach 2:
The system changes the physical state of the cardboard from flat blanks to pre-folded three-dimensional box structures. This transformation allows the same cardboard material to be efficiently stored in compact forms and then rapidly converted into various box configurations as needed
3Adaptability or versatility
If manual packaging is used for varied items, then flexibility in handling different shapes and sizes is maintained, but automation level decreases
Solution Approach 1:
Items are pre-sorted and pre-positioned in standardized containers before reaching the automated packaging system. This preliminary organization allows automated machines to handle varied items efficiently by working with pre-prepared item groups rather than individual pieces, maintaining flexibility while enabling automation
Solution Approach 2:
The system uses universal pre-folded box designs that can accommodate multiple item types and configurations. These standardized box prototypes serve multiple functions across different packaging scenarios, allowing automated systems to handle diverse items using the same basic packaging approach
Data Source
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AI summary
A system for automatically packaging items that vary in size and number for shipment, comprising a packaging station for holding a pre-folded cardboard box (10) to receive one or more items (26, 28, 30, 32) to be packaged, said pre-folded cardboard box (10) having a bottom panel (12), two side panels (14, 16) and a first end panel, the first end panel being joined to each of said side panels (14, 16), the side panels (14, 16) and the end panel being erected from the bottom panel (12) to form a box having an open top and an open side, the bottom panel (12) having an end portion intended to form a second end panel, each side panel having an end portion intended to form a corner panel, at least one cutting unit for adjustably shortening the end portions of the side panels (14, 16) and the end portion of the bottom panel (12) and at least one folding unit for folding the corner panels and the second end panel to close said open side of the box.