High-Speed Tray Filling via Linear Shuttle Dispensing

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Solution Overview

Problem

Existing container filling lines face challenges in achieving high-speed filling of water soluble unit dose products due to space inefficiency and complex machinery requirements, particularly in managing momentum and preventing vibration or equipment damage.

Innovation Solution

A high-speed process involving a tray carriage system with linear motor vehicles, a dispensing system with a product hopper and swinging legs to funnel products into a tray, and a hood engagement system to close the tray, ensuring efficient and controlled filling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If rotary dispensing systems are used to fill many water soluble unit dose products into single containers, then the number of containers filled per unit of time increases, but the floor space required increases significantly

Engineering Contradiction:

Improvenumber of containers filled per unit of timeVSAvoidfloor space

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent employs a dynamic shuttle dispensing system where the filler moves back and forth along a linear path to fill multiple containers. This dynamic approach replaces the static rotary system, allowing high productivity with reduced floor space by utilizing linear motion instead of circumferential motion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention transitions from a two-dimensional rotary motion (circumferential path) to a one-dimensional linear motion (back and forth shuttle path). This dimensional change reduces the floor space footprint while maintaining the ability to fill multiple containers per unit time.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If shuttle dispensing systems are used to fill a large quantity of water soluble unit dose products into a single container, then the filling capacity increases, but the momentum of the filler must be managed carefully to avoid vibration and damage to equipment

Engineering Contradiction:

Improvequantity of water soluble unit dose products filled per unit of timeVSAvoidequipment damage from vibration

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent incorporates cushioning mechanisms and controlled deceleration systems that prepare for and absorb the momentum of the shuttle filler before it comes to a stop. This prevents vibration and equipment damage by dissipating kinetic energy through controlled means rather than abrupt stopping.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The system employs control systems that monitor the position, speed, and momentum of the shuttle filler in real-time. This feedback allows for dynamic adjustment of the filling process, ensuring that momentum is managed appropriately to prevent vibration and equipment damage while maintaining high productivity.

Inventive Principle:

Principle #23Feedback

3Productivity

If the speed of manufacturing lines is increased to maximize efficiency, then the number of containers filled per unit of time increases, but the complexity of machinery and controls increases

Engineering Contradiction:

Improvenumber of containers filled per unit of timeVSAvoidcomplexity of machinery and controls

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts the complex momentum management and vibration control functions into separate, dedicated control systems and cushioning mechanisms. This allows the main shuttle dispensing system to operate at high speed while the extracted subsystems handle the complexity of momentum management, preventing equipment damage.

Inventive Principle:

Principle #2Taking out (Extraction)

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 process enables high-speed, space-efficient, and simple operation for filling water soluble unit dose products into trays, minimizing equipment complexity and potential damage while maintaining product integrity.

Implementation Method 1

tray carriage system comprises a plurality of linear motor vehicles

Methodology Applied

Scientific EffectLinear motor: Linear Motor

Implementation Method 2

downstream leg pivot portion is rotatable about a downstream leg pivot nearer to said downstream end than said upstream end

Methodology Applied

Scientific EffectRotation:

Implementation Method 3

upstream leg pivot portion is rotatable about an upstream leg pivot nearer to said upstream end than said downstream end

Methodology Applied

Scientific EffectRotation:

Data Source

PatentUS12275546B2High speed filling of a tray

Publication Date: 2025.04.15 PROCTER & GAMBLE CO

AI summary

A process for packaging a product. The product is dispensed into a tray by a dispensing system while the tray is moving beneath the dispensing system. The dispensing system includes a hopper that releases products that are funneled in the tray. The dispensing system includes two legs that each rotate about a respective pivot that constrain the product as the product is transported from the hopper into the tray.