Reconfigurable Blank Case Forming System
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Solution Overview
Problem
Current methods for forming cases, particularly from corrugated fibreboard, are complex and inefficient, leading to unstable stacking and increased shipping costs due to asymmetric pre-folded blanks, and require secondary containers for bulk shipping, while also limiting the ability to top-load certain products.
Innovation Solution
A method and system for forming containers from generally flat, reconfigurable blanks using a blank support device and rotating apparatus to create a tubular configuration, allowing for easy modification to accommodate different sizes and enabling top-sealing of cases at the filling location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blanks are pre-folded and pre-glued to form tubular configuration for easy erection, then case formation is simplified and erection is easier, but stacking stability deteriorates and shipping costs increase due to asymmetric shape
Solution Approach 1:
The patent applies preliminary action by pre-creasing the blank in specific patterns before shipping. These pre-creases allow the blank to be quickly transformed into a case at the point of use without requiring complex folding operations or pre-gluing, thus maintaining stacking stability while simplifying final assembly.
Solution Approach 2:
The patent segments the case formation process into two distinct stages: (1) shipping pre-creased blanks in a stable flat configuration, and (2) transforming to the final case shape at the point of use. This segmentation allows optimization of each stage independently - stability during shipping and ease of assembly during formation.
2Ease of operation
If blanks are pre-folded and pre-glued to form tubular configuration, then erection is easier, but shipping efficiency deteriorates requiring secondary containers
Solution Approach 1:
The patent performs preliminary creasing of the blanks in advance, but maintains them in a flat, space-efficient configuration for shipping. This preliminary preparation enables rapid erection at the destination without compromising shipping density, eliminating the need for secondary containers.
Solution Approach 2:
Instead of pre-forming the tubular shape and shipping in that configuration, the patent inverts the approach by shipping flat blanks with pre-marked creases and transforming to the tubular shape only when needed. This inversion optimizes both shipping efficiency and erection ease.
3Adaptability or versatility
If complicated folding and gluing systems are used to form top-loadable cases from flat blanks, then top-loading capability is achieved, but device complexity increases
Solution Approach 1:
The patent applies preliminary creasing to the blanks that guides the folding process. These pre-marked creases ensure accurate folding without requiring complex positioning systems, and the design allows top-loading capability to be achieved through simple manual or automated folding operations.
Solution Approach 2:
The pre-creased blank design allows the material itself to guide the folding process. The creases act as self-aligning features that ensure proper case formation without requiring complex external guidance systems, reducing device complexity while maintaining top-loading capability.
Data Source
AI summary
A system and method are disclosed for forming a container from a generally flat re-configurable blank. A first portion of an outward facing surface of a blank support device is positioned proximate a first portion of a blank while the blank is in a first orientation. While the first portion of the blank is maintained in the first orientation, a second portion of said blank is rotated from the first orientation, around a second portion of the outward facing surface of the blank support device to form a blank that has a generally tubular configuration. The system and method may provide that during the rotating of said second portion of said blank, the blank is engaged on a surface side which forms an inner surface of the generally tubular configuration. Also disclosed is a system and method that includes retaining a reconfigurable blank in a holding apparatus; applying adhesive to a surface of the blank while said blank is retained in the holding apparatus.