Wrapping Machine Punch Mechanism for Packaging Material Tear Evaluation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wrapping machine operators face challenges in evaluating packaging materials to determine the optimal containment force for loads at minimum cost, due to the complexity of variables involved and the high costs and risks associated with traditional testing methods.
Innovation Solution
A method and apparatus that utilize a wrapping machine with a punch mechanism to simulate tears in packaging material, allowing for the determination of the payout percentage at which the material begins to propagate, form a rope, and stretch towards breaking, enabling the evaluation of packaging materials and setting up wrapping machines for efficient force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional shipping tests and containment force tools are used to evaluate packaging materials, then adequate containment force can be determined, but the process requires large sample sizes and extensive time
Solution Approach 1:
The patent creates a simplified test model using a test load with vertical sides and applies packaging material under controlled conditions. Instead of testing on actual production loads with variable geometries, the invention uses a standardized test setup that copies the essential containment force requirements, enabling faster evaluation while maintaining measurement validity.
Solution Approach 2:
The invention extracts the critical evaluation function from complex shipping tests and isolates it into a dedicated test load setup. By separating the containment force measurement from the variable elements of actual shipping conditions, the patent enables focused, repeatable testing that requires smaller sample sizes and less time while still determining adequate containment force.
2Ease of manufacture
If multiple types and gauges of packaging material are evaluated to find optimal containment force, then cost-effective solutions can be identified, but the complexity of evaluation increases significantly
Solution Approach 1:
The patent applies different packaging material types and gauges to specific test load configurations to evaluate their local performance characteristics. By testing materials in controlled local conditions rather than attempting to evaluate all possible combinations in complex shipping scenarios, the invention simplifies the evaluation process while still identifying cost-effective material selections.
Solution Approach 2:
The evaluation process is segmented into discrete test cases with standardized test loads. Each packaging material type and gauge can be evaluated independently using the same test setup, allowing systematic comparison without the complexity of evaluating all materials together in variable shipping conditions.
3Reliability
If packaging materials are tested on actual production wrapping machines, then real-world performance can be assessed, but the cost and risk discourage most companies from evaluating new materials
Solution Approach 1:
The patent performs preliminary evaluation of packaging materials using standardized test loads before committing to actual production wrapping machine testing. This preliminary action allows companies to assess new materials at low cost and low risk, identifying only those materials worthy of subsequent production testing, thereby reducing overall evaluation costs and risks.
Solution Approach 2:
The invention uses simple, inexpensive test loads that can be quickly constructed and discarded after testing. These disposable test fixtures enable repeated evaluation of different packaging materials without the need for expensive, durable test equipment, making the evaluation process accessible to most companies.
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 approach simplifies the evaluation of packaging materials by standardizing tear formation and data collection, allowing for the identification of optimal payout percentages that balance containment force and breakage risk, thereby reducing costs and improving wrapping efficiency.
Implementation Method 1
A packaging material evaluation method performed with a wrapping machine includes the following steps: A punch is extended to form a tear in the packaging material during a wrap cycle
Implementation Method 2
data collection points indicative of a payout percentage at which the tear begins to propagate, forms a rope, and stretches towards breaking
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of determining a wrap force or payout percentage at which to wrap a load (12) with packaging material (16) may include dispensing packaging material (16). The method may also include forming a tear (28) in a portion of the packaging material (16). The method may further include identifying a first payout percentage at which the tear (28) exhibits a first behavior. The method may also include identifying a second payout percentage at which the tear (28) exhibits a second behavior. The method may further include selecting a third payout percentage between the first payout percentage and the second payout percentage, for wrapping the load (12).