Rotating Flight Assembly for Continuous Carton Closure

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Solution Overview

Problem

Existing continuous motion packaging machines require separate conveyors and timing mechanisms to rotate cartons, which can lead to inefficiencies and potential machine shutdowns due to jamming issues during the closure of cartons.

Innovation Solution

A rotating flight assembly integrated into the main conveyor that rotates both the article group and carton, using a cam track and chain conveyor system to position and close carton flaps with static or rotating tucker elements, eliminating the need for separate rotation mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate conveyors and timing mechanisms are used to rotate cartons, then carton rotation and closure can be achieved, but machine complexity increases and jamming risks occur

Engineering Contradiction:

Improvecarton closure reliabilityVSAvoidconveyor system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the carton rotation function with the main conveyor by integrating rotating flights directly into the conveyor structure. The flights are attached to the conveyor belt and rotate in sync with conveyor movement, eliminating the need for separate rotation mechanisms. This merging reduces device complexity while maintaining reliable carton closure through the coordinated rotation and translation of flights.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If separate rotation mechanisms are used, then carton orientation can be controlled, but production efficiency decreases due to additional timing mechanisms

Engineering Contradiction:

Improvecarton positioning easeVSAvoidpackaging throughput

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The rotating flights serve multiple functions simultaneously: they convey cartons forward along the production line, rotate cartons to proper orientation, and position cartons for closure operations. This multi-functionality is achieved through the flight design that combines linear movement with rotational capability, eliminating the need for separate timing mechanisms and rotation devices, thereby maintaining high packaging throughput.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If separate conveyors are used for rotation, then precise carton positioning is possible, but machine shutdowns occur due to jamming

Engineering Contradiction:

Improvecarton positioning precisionVSAvoidcontinuous operation reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

By merging the rotation function into the main conveyor through integrated rotating flights, the system eliminates interfaces between separate conveyors that are prone to jamming. The flights rotate smoothly within the conveyor structure, maintaining precise carton positioning while ensuring continuous operation without shutdowns.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If multiple separate mechanisms are used, then carton closure can be achieved, but device complexity and maintenance requirements increase

Engineering Contradiction:

Improvecarton closure reliabilityVSAvoidmachine manufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent integrates rotation and closure functions into a single conveyor system with rotating flights, reducing the number of separate mechanisms that need to be manufactured and assembled. This merging simplifies the overall machine structure while maintaining reliable carton closure through the coordinated action of flights and closure elements.

Inventive Principle:

Principle #5Merging (Combining)

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

Enhances packaging efficiency by ensuring smooth carton closure without separate conveyors, reducing the risk of jamming and maintaining continuous operation, thereby optimizing production capacity.

Implementation Method 1

using a cam track and chain conveyor system to position and close carton flaps

Methodology Applied

Scientific EffectMechanical motion transformation: Mechanical Advantage

Implementation Method 2

rotates both the article group and carton

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11577915B2Continuous motion packaging machine with rotating flights

Publication Date: 2023.02.14 GRAPHIC PACKAGING INTERNATIONAL LLC

AI summary

A packaging machine for placing articles into a carton includes rotating flight assemblies that receive a carton or carton blank, and rotate the carton blank and carton with articles while the flight assemblies move downstream. The flight assemblies each include two fixed segments and one segment that includes a block and associated bracket that rotate as the flight assembly is pulled through the machine by a conveying system. A method includes carton blanks being fed by a carton feeder onto the flight assemblies. Articles are formed into an article group, which is then placed onto a carton blank. As the blank and article group move in a downstream direction, the side panels of the carton blank are wrapped around the article group and the carton and article group are rotated to assist in closing the carton end flaps.