Progressive Folding Guides for Semi-Rigid Tubular Packaging

Solution Overview

Problem

Existing horizontal form, fill, and seal (HFFS) processes struggle with packaging semi-rigid materials like paperboard and cartonboard, as they tend to bulge and crease undesirably when folded in multiple directions, limiting the range of packaging materials that can be used.

Innovation Solution

A packaging apparatus with a progressive folding region featuring discrete, elongate external guide surfaces that fold packaging material about a longitudinal axis, allowing for the use of semi-rigid materials such as paperboard and cartonboard, and a forming section that includes guide members to create tubular packages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional HFFS processes fold packaging material in multiple directions simultaneously using a former, then flexible polymeric films can be wrapped efficiently, but semi-rigid materials bulge and crease undesirably due to their dead-fold properties

Engineering Contradiction:

Improvepackaging speedVSAvoidfolding precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The folding process is divided into discrete sequential steps using multiple folding members arranged in the machine direction. Each folding member performs a single folding action, and the material progresses through each stage in sequence rather than being folded simultaneously in multiple directions. This segmentation allows semi-rigid materials to be folded progressively without bulging or creasing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The folding members are configured to move or adjust to dynamically accommodate the packaging material as it progresses through the forming section. The folding members can be positioned at different locations along the machine direction to optimize the folding sequence for different material types and package configurations, enabling the system to adapt to both flexible and semi-rigid materials.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If packaging material is folded in multiple directions at the same time, then tubular package structure can be formed efficiently, but semi-rigid materials exhibit dead-fold characteristics causing creasing and bulging

Engineering Contradiction:

Improvepackage formation easeVSAvoidcreasing and bulging

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The folding process is divided into discrete sequential steps using multiple folding members arranged in the machine direction. Each folding member performs a single folding action, and the material progresses through each stage in sequence rather than being folded simultaneously in multiple directions. This segmentation allows semi-rigid materials to be folded progressively without bulging or creasing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple folding members act as intermediaries that gradually guide the packaging material from a flat configuration to a tubular structure. Each folding member provides a localized folding action, and the cumulative effect of these intermediate folding steps transforms the material shape without subjecting it to the stress of simultaneous multi-directional folding that causes creasing and bulging.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If a continuous length of packaging material is used for high-speed production, then productivity increases, but maintaining material stability during folding becomes more difficult with semi-rigid materials

Engineering Contradiction:

Improveproduction speedVSAvoidmaterial stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The folding members are configured to move or adjust to dynamically accommodate the packaging material as it progresses through the forming section. The folding members can be positioned at different locations along the machine direction to optimize the folding sequence for different material types and package configurations, enabling the system to adapt to both flexible and semi-rigid materials while maintaining stability during high-speed operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The apparatus maintains continuous operation by having multiple folding members work in sequence on the continuously moving packaging material. The folding actions are performed in an unbroken sequence as the material progresses through the forming section, eliminating interruptions while maintaining material stability through the progressive folding approach that accommodates semi-rigid materials.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS12623801B2Apparatus and method for producing tubular packages

Publication Date: 2026.05.12 INTERCONTINENTAL GREAT BRANDS LLC

AI summary

Apparatus (10) for producing tubular packages includes a packaging material dispenser (12) and a forming section (20). The forming section (20) comprises a progressive folding region (26a, FIG. 8) having a plurality of discrete, elongate external guide surfaces (50, 52, 54, 56) extending generally in the machine direction (A). The elongate external guide surfaces are spaced apart from one another and configured for contact with an outer surface of the packaging material so as to progressively guide and fold the packaging material about a longitudinal axis from a planar configuration into a tubular structure. The elongate guide surfaces may be arcuate and may be provided by means of guide rods. The apparatus may be a horizontal or vertical form, fill seal type apparatus. The packaging material (14) may be a semi-rigid packaging material such as paperboard, cartonboard, or semi-rigid plastics.