Tray Packaging Assembly via Mechanical Insertion
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Solution Overview
Problem
Existing packaging methods for multi-part packaging with tray-like lower and upper parts are inefficient due to adhesive connections that damage the packaging, reduce production speed, and require special fastening means, leading to unsightly and costly production processes.
Innovation Solution
An automated method where individual product groups and upper packaging parts are connected outside the lower packaging part to form a displaceable setting unit, which is then moved and inserted into the lower part, using a gripping means that releases to form a secure, damage-free, and attractive packaging without special connecting means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive connection is used to join lower part and upper part, then packaging assembly is simplified, but packaging quality deteriorates due to damage and unsightly appearance
Solution Approach 1:
The harmful adhesive connection is extracted and removed from the packaging system. Instead of bonding parts together, the invention uses a mechanical interlocking mechanism where the upper part is inserted into the lower part without adhesives, eliminating the source of damage and aesthetic defects while maintaining assembly simplicity.
Solution Approach 2:
A geometric intermediary mechanism is introduced between the lower and upper parts. The upper part features a insertion geometry that fits into a corresponding recess in the lower part, creating a damage-free connection through shape complementarity rather than chemical bonding.
2Ease of manufacture
If adhesive connection is used to join packaging parts, then assembly is simplified, but production speed decreases
Solution Approach 1:
The time-consuming adhesive application process is extracted and removed. The mechanical insertion mechanism allows for rapid assembly without the need for adhesive dispensing, positioning, and curing operations, thereby increasing production speed while maintaining assembly simplicity.
3Ease of manufacture
If lid part is placed over product group and side walls are raised, then packaging is formed, but product group is susceptible to damage
Solution Approach 1:
The upper part is pre-formed with a insertion geometry that allows it to be placed over the product group without requiring the side walls to be raised or collapsed. This preliminary geometric preparation eliminates the mechanical stress and damage risk associated with wall deformation during assembly.
4Loss of substance
If manual creation of U-shaped lid is used, then material-saving packaging is achieved, but production speed remains low and cost increases
Solution Approach 1:
The upper part is designed with self-aligning geometric features that automatically position itself correctly over the product group during automated insertion. This self-service mechanism eliminates the need for manual dexterity and complex positioning operations, enabling high-speed automated production while maintaining material efficiency.
Data Source
Figure 1A~1F
Figure 2~3
Figure 4
AI summary
The method involves removing a product group from a product supply device by a gripping unit (81), and providing a package with a package upper part. The product group and the package upper part are connected with a movable setting unit (3) outside of a package lower part (11), after removing the product group from the product supply device. The setting unit is vertically moved with the packing lower part by the gripping unit. An access of the gripping unit at the setting unit is released for obtaining the filled package. An independent claim is also included for a device for implementing a method for filling a package with a group of individual products.