Method and system for forming packages
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing reinforced packages with reinforcing layers or materials are costly due to the requirement of multiple stages or operations, which increases the production costs of specialty bags or liners used in packaging various products, including prepared food items.
Innovation Solution
A method and system for forming reinforced packages by attaching a reinforcing construct to a web of material, which is then folded and cut to create a liner with the construct, using a system that includes an attachment assembly, web edge forming assembly, and cutting assembly to efficiently produce the packages in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple stages or operations are used to manufacture reinforced packages with reinforcing layers or materials, then the package strength and integrity are improved, but the manufacturing cost and process complexity increase significantly
Solution Approach 1:
The patent combines multiple manufacturing operations (attaching reinforcing materials, folding web edges, and forming package structures) into a single integrated process. The attachment assembly simultaneously attaches the construct to the web while the web edge forming assembly folds the web, eliminating the need for separate manufacturing stages and reducing overall process complexity while maintaining package strength.
Solution Approach 2:
The manufacturing system performs multiple functions through integrated assemblies. The attachment assembly not only attaches the construct to the web but also works in conjunction with the web edge forming assembly to create the final package structure. This multi-functional approach reduces the number of dedicated machines and operations required, lowering manufacturing costs while producing reinforced packages with adequate strength.
2Manufacturing precision
If multiple stages or operations are used to manufacture reinforced packages, then the package quality and reinforcing attachment are improved, but the production time and manufacturing cost increase
Solution Approach 1:
The patent implements a continuous manufacturing process where the web material moves through the system and undergoes attachment and folding operations in a single continuous flow. The attachment assembly and web edge forming assembly operate simultaneously on the moving web, eliminating idle time between operations and maintaining continuous productive action throughout the manufacturing process, thereby improving production efficiency while ensuring consistent package quality.
Solution Approach 2:
The construct is attached to the web material before the web edge forming operation. This preliminary attachment ensures that the reinforcing material is securely in place before the web is folded into the final package configuration, guaranteeing package quality and proper reinforcing attachment while maintaining a streamlined single-pass manufacturing process that improves productivity.
3Ease of manufacture
If traditional separate processes are used for attaching reinforcing materials and folding web edges, then each operation can be optimized independently, but the overall manufacturing cost and number of manufacturing stages increase
Solution Approach 1:
The patent merges the attachment operation and web edge folding operation into a single integrated manufacturing stage. The attachment assembly and web edge forming assembly work simultaneously on the web material as it moves through the system, reducing the total number of manufacturing stages from multiple separate processes to a single coordinated operation, thereby simplifying the overall manufacturing process and reducing total manufacturing time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs by integrating the attachment and folding processes, allowing for the efficient formation of reinforced packages with a reinforcing construct, thereby minimizing manufacturing stages and costs while maintaining package integrity and functionality.
Implementation Method 1
adhering a construct to a web of material
Data Source
AI summary
A system and method for forming reinforced packages. The method can comprise forming an attached web by adhering a construct to a web of material, and moving the attached web in a downstream direction through at least a web edge forming assembly. The moving the attached web can comprise moving the construct with the web of material. The method further can include at least partially forming a folded web by folding at least a portion of the web of material as the attached web moves through the web folding assembly and forming a reinforced package comprising a liner and the construct by separating the liner from a remainder of the folded web. The construct is adhered to the liner.