Vertical Flap Spreading Head for Packaging Containers

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Solution Overview

Problem

In packaging lines, the manual operation of spreading top flaps of packaging containers is repetitive, labor-intensive, and affects production efficiency and reproducibility, especially in high-production-rate environments, requiring multiple operator stations and increasing costs and floor space.

Innovation Solution

An automatic device with vertically mobile flap spreading heads equipped with first and second blades mounted on pivots, actuated to rotate and fold the flaps outward, integrated into a packaging container filling station, utilizing lateral drive belts and a horizontal upper routing belt for efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual flap spreading operation is used, then flexibility in handling different carton types is maintained, but labor intensity increases and production efficiency decreases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidlabor intensity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The device enables automatic flap spreading where the machine performs the task previously requiring human operators. The spreading head with blades automatically inserts into the carton and folds the flaps outward without human intervention, transforming a manual self-service task into an automated process that increases productivity while reducing labor intensity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical system (human hands and arms performing repetitive folding motions) with an automated mechanical system. The spreading head mounted on a vertical guide rail, actuated by a drive mechanism, substitutes human operators to perform the flap spreading task, thereby improving production efficiency and reducing labor requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If multiple operator stations are deployed to handle high production rates, then productivity increases, but occupied floor surface and costs increase

Engineering Contradiction:

Improveproduction rateVSAvoidoccupied floor surface

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The automated flap spreading device is designed as a universal solution that can handle various carton types and sizes. By mounting the spreading head on a vertical guide rail with adjustable positioning, a single device replaces multiple operator stations, maintaining high production rates while reducing the occupied floor surface area and associated costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If manual flap spreading is performed, then adaptability to different carton configurations is maintained, but reproducibility and consistency cannot be guaranteed

Engineering Contradiction:

ImprovereproducibilityVSAvoidautomation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the variable human mechanical system with a controlled automated mechanical system. The drive mechanism actuating the spreading head ensures consistent, repeatable flap spreading actions across all cartons, guaranteeing reproducibility and consistency while managing automation complexity through a relatively simple vertical rail and blade assembly design

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Automatically spreads the top flaps of packaging containers, ensuring consistent opening and reducing operator dependency, thereby enhancing production efficiency and reducing the need for additional operator stations and floor space.

Implementation Method 1

first and second flap spreading blades (1211, 1212) mounted on pivots (1213) and an actuator (1221, 1222) adapted to command rotation of the first and second blades

Methodology Applied

Scientific EffectRotation:

Implementation Method 2

the first and second blades on rotating coming into contact with first and second flaps and causing spreading thereof by folds

Methodology Applied

Scientific EffectMechanical Force:

Implementation Method 3

lateral drive belts in parallel alignment with a routing path of the empty and open container to transport the container

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 4

a horizontal upper routing belt for evacuating a container having the facing first and second flaps folded toward the exterior of the container, the driving of the container being brought about by rotation of the horizontal upper routing belt in rubbing contact with top edges of the container

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11174054B2Device for spacing a flap before filling for packaging containers such as cardboard boxes and equipped filling stations

Publication Date: 2021.11.16 BOBST MEX SA

AI summary

According to the invention, the device comprises at least one flap spreading head (12a, 12b), the flap spreading head being vertically mobile for insertion thereof into a container (3) to be processed and including first and second flap spreading blades (1211, 1212) mounted on pivots and an actuator (1221, 1222). The actuator is adapted to command rotation of the flap spreading blades that on rotating come into contact with flaps (R1a, R1b) and bring about spreading thereof by folds toward the exterior of the container.