Rotating Disc Flap Folding Unit for Cardboard Case Adaptability
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Solution Overview
Problem
Existing cardboard packers require frequent adjustments to flap folders for different dimensions of cardboard cases, leading to inefficiencies in folding accuracy and process flexibility.
Innovation Solution
A flap folding unit featuring disc-like members with convex and recessed portions, connected to link arms and driven by electrical motors, allows for controlled flap engagement and rotation to fold front and rear flaps independently, enabling precise folding across varying case dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional pneumatic actuators are used to push the cardboard case upwards for flap folding, then the folding mechanism can be activated, but the device requires frequent adjustments when changing case dimensions
Solution Approach 1:
The patent replaces static pneumatic actuators with a dynamic rotating disc mechanism that can adapt its position and motion to accommodate different case dimensions. The disc rotates to different angular positions to engage with flaps at varying locations, providing dynamic adaptability without requiring manual adjustments to the folding mechanism itself.
Solution Approach 2:
The invention changes the operational parameters of the folding mechanism by using a rotating disc that can be positioned at different angles and radii. This allows the same physical mechanism to accommodate different case sizes by changing its rotational position rather than physically adjusting the mechanism's structure.
2Productivity
If the cardboard case is stationary in the machine feed direction during flap folding, then the folding action can be performed, but the process is less efficient
Solution Approach 1:
The rotating disc mechanism performs preliminary positioning actions by rotating to the correct angular position before engaging with the flap. This preliminary action ensures that the folding point is correctly positioned even as the case moves through the machine, maintaining folding accuracy while allowing continuous motion.
Solution Approach 2:
The rotating disc acts as an intermediary between the moving case and the folding action. It can rotate independently to match the position of flaps on moving cases, allowing the folding mechanism to remain stationary while the case moves continuously through the machine.
3Adaptability or versatility
If a single folding mechanism is used for all flaps, then the device structure is simpler, but it cannot fold both front and rear flaps independently
Solution Approach 1:
The patent divides the folding function into multiple independent rotating disc mechanisms, with each disc responsible for folding a specific flap. This segmentation allows each disc to be independently controlled and positioned, enabling independent folding of front and rear flaps while keeping each individual disc mechanism relatively simple.
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
The solution ensures accurate and flexible folding of cardboard case flaps regardless of dimensions, improving the efficiency and adaptability of the cardboard packing process.
Implementation Method 1
Both flap folding devices may be driven by a common electrical motor
Implementation Method 2
engagement of the disc-like member with passing flaps can be controlled. The convex portion may be a section having a circular periphery
Implementation Method 3
The disc-like member may be connected to a link arm. The link arm may extend substantially parallel with a cardboard case feeder. In an embodiment, the link arm is pivotally supported.
Data Source
AI summary
A flap folding unit is provided, comprising at least one flap folding device having a disc-like member being configured to be arranged in a first position to urge passing front flaps of an associated cardboard case to fold, and in a second position to allow unfolded rear flaps of the associated cardboard case to pass the disc-like member.