Rotatable Receptacle Stacking Station for Thermoforming
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Solution Overview
Problem
The efficiency of thermoforming systems is hindered by inefficient stacking processes, which require significant space and multiple cycles, leading to increased costs and reduced productivity, especially in the production of packaging materials where precise and hygienic stacking is crucial.
Innovation Solution
A stacking station with a rotatable receptacle and positioning device that generates a rotational angle offset between products, allowing for efficient stacking of identical or asymmetrical products without the need for additional spacer nubs, thereby reducing equipment requirements and cycle time while maintaining precise stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional stacking methods are used with multiple rows and different mold positions, then precise stacking distance is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent applies asymmetry by intentionally creating angular offsets between stacking nubs on different products. Instead of using symmetric stacking nubs at identical positions, the invention rotates products by specific angles (e.g., 45°, 90°, 180°) so that stacking nubs are asymmetrically positioned relative to each other. This asymmetric positioning prevents jamming while maintaining precise stacking distance, eliminating the need for complex multi-row mold systems.
Solution Approach 2:
The invention changes the angular parameter of stacking nub positioning by rotating products during the stacking process. Rather than maintaining fixed positional parameters, the system dynamically adjusts the angular orientation of stacking nubs between consecutive products. This parameter change allows identical products to be stacked with precise spacing without requiring different mold configurations or multiple product types.
2Reliability
If multiple different product types are produced with different stacking knob positions, then stacking without jamming is achieved, but productivity decreases due to alternating stacking requirements
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-positioning the angular offsets for stacking nubs before the actual stacking process. The system determines the required rotation angles (45°, 90°, 180°) in advance based on product geometry and stacking requirements. This preliminary planning allows the stacking station to efficiently rotate and stack identical products in sequence without interruption, maintaining high productivity while preventing jamming through pre-established angular relationships.
3Ease of manufacture
If products are stacked with identical spacer nub positions, then manufacturing simplicity is maintained, but products jam during stacking
Solution Approach 1:
The invention applies dynamics by introducing rotational movement to the stacking process. Instead of statically positioning stacking nubs at fixed identical locations, the system dynamically rotates products by specific angles during stacking. This dynamic angular adjustment transforms the stacking process from a static alignment task into a controlled rotational operation, allowing identical products to be stacked reliably without jamming while maintaining manufacturing simplicity.
Data Source
Figure 1a
Figure 1b~1c
Figure 2a~2b
AI summary
A stacking station (100) for a thermoforming machine (150) is designed such that a rotational angle offset (102) can be generated between products (152A, 152B) to be stacked on top of each other. This makes it possible to stack otherwise identical products, which have spacer lugs (153A) formed at approximately identical positions, in an efficient manner.