Segmented Blank Packaging for Large Flat Articles
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Solution Overview
Problem
Existing methods for packing flat articles, such as ceramic tiles, face difficulties with large dimensions, leading to mechanical failure of blanks, excessive use of packing material and glue, and inefficient storage due to the need for multiple formats and large blank sizes.
Innovation Solution
A method involving a two-stage folding process using interposed blanks with hinged flaps, where the flat article is sequentially positioned in stations with folding means to facilitate partial covering of lateral flanks and surfaces, reducing the size and complexity of the blanks required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a single large blank is used to pack large-dimensional tiles, then complete coverage is achieved, but the blank becomes too long to fold and mechanically fails
Solution Approach 1:
The single large blank is divided into multiple smaller blanks, each capable of being independently folded and applied to different sections of the tile stack. This segmentation reduces the length of each blank below the critical threshold for mechanical failure while maintaining complete coverage through coordinated application of multiple blanks.
2Length of stationary object
If a single large blank is used, then complete coverage is achieved, but folding operations become extremely difficult
Solution Approach 1:
The blank is segmented into multiple smaller units with manageable dimensions. Each smaller blank can be easily folded around the corners and edges of the tile stack without requiring complex folding operations, significantly improving ease of operation.
3Adaptability or versatility
If multiple formats of blanks are stored for different tile formats, then adaptability is achieved, but storage zone size increases
Solution Approach 1:
The segmented blank system is designed with universal applicability across different tile formats. By adjusting the number and arrangement of segments rather than creating entirely different blank formats, the same basic blank design can accommodate various tile sizes and configurations, reducing storage requirements while maintaining adaptability.
Data Source
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AI summary
The method for packing a flat article comprises following steps: positioning and article (2) at an inlet of a first station (S1) comprising first folding means (3) and a first blank (4); the conveying of the article (2) into the first station (S1) such as to enable intercepting the first blank (4) with a first lateral flank (20) of the article (2); the positioning of the semi-finished pack (100), comprising the flat article (2) and the first blank (4), at the inlet of a second station (S2) provided in cascade from the first station (S1), which comprises second folding means (5) and a second blank (6); conveying the semi- finished pack (100) into the second station (S2) such as to enable intercepting the second blank (6) with a second lateral flank (25) of the article (2); conveying the pack (101), comprising the flat article (2) and the blanks (4, 6), in outlet from the second station (S2).