Packaging forming and sealing system with crush protection and motorized chute-type gate.

Description

1 / 12 Packaging forming and sealing system with crush protection and motorized chute-type gate. Field of application

[001] This patent application refers to a novel unit packaging system designed to package products such as ampoules, blisters and similar items in flexible or thermoformed packaging. The system integrates assisted opening of the packaging, controlled product insertion and secure thermal sealing, applicable in automated production lines in the pharmaceutical, hospital, cosmetic and food sectors, where precision, product integrity and operational safety are essential. Field of invention

[002] The invention is situated in the field of ampoule and vial labeling machines and cutting and unitizing of solids. Persuasion

[003] The evolution of packaging technologies has been a determining factor in the advancement of multiple industrial sectors, particularly those where precision, product integrity, and operational safety are crucial.

[004] Unit packaging, or unit dose, is fundamentally designed as a dose of medicine prepared in an individual package for convenience, safety and monitoring.

[005] The importance of unit dose systems in the healthcare sector is multifaceted. They contribute significantly to improving patient safety by reducing medication errors and concerns about inappropriate dosages. Additionally, they facilitate monitoring through electronic documentation, often made possible by scannable codes, and increase convenience for users.

[006] It is known to those skilled in the art that unit packaging systems for pharmaceutical, hospital and food products are mostly composed of simple heat-sealing mechanisms, direct insertion systems Petition 870250044050, dated 05 / 28 / 2025, page 5 / 30 2 / 12 of the product and basic packaging opening methods that use air blowing or mechanical elements.

[007] A common problem in existing equipment is the use of sealing jaws that operate with direct pressure, without incorporating active safety systems against product crushing. This lack of protection can result in damage to products that are misaligned or have been improperly inserted into the packaging.

[008] Regarding opening the packaging, most known solutions employ the direct application of compressed air. This method lacks precise control over the formation of the packaging opening, which can be problematic.

[009] Another limitation observed in traditional systems is the excessive heating of the packaging assembly. High temperatures in this area can impair the quality of the thermal printing performed on the packaging, as well as compromise the effectiveness of the seal.

[010] Additionally, it is not common practice in current systems to reuse air for cooling the former, which negatively impacts the thermal efficiency of the packaging process.

[011] Conventional product insertion systems generally use static hoppers that lack synchronized retention mechanisms or active control over product release. This characteristic can lead to insertion failures and compromise the integrity of the final packaging.

[012] Finally, the methods for cutting or perforating packaging are predominantly fixed and lack programmable flexibility, making it difficult to configure connected or separate packaging strips according to the user's specific needs.

[013] In this context, new technologies aimed at improving product safety, operational accuracy, thermal efficiency and configuration flexibility in packaging forming and sealing systems are welcome and represent a desirable advance in the segment in question. State of the art Petition 870250044050, dated 05 / 28 / 2025, page 6 / 30 3 / 12

[014] The current state of the art anticipates some patent documents that deal with packaging machines and systems, such as JP 6101243 B2 entitled “BLISTER PACKAGING MACHINE” - although it details mechanisms for the blister packaging process, the document does not clearly show the integration of an active anti-crushing system with automatic calibration, an assisted packaging opening that combines special gate geometry with former cooling by air reuse, an insertion funnel with a motorized gate capable of rebound movements for precise product accommodation, nor the programmable flexibility of cutting and perforating the packaging, aspects that are distinctly addressed and solved by the present invention.

[015] Document JP 6950029 B2 “BLISTER PACKAGING MACHINE” focuses on the mechanisms and processes for forming the packaging, including aspects of thermoforming, heating devices, and molding. Although it details the blister cavity creation stage, the document does not explicitly and integrally address the specific solutions of the patent application in question relating to secure sealing with an active anti-crushing system by magnetic repulsion, optimized control of the opening of the already formed packaging through a gate with special geometry, thermal management of the former by reusing air to preserve the quality of printing and sealing, precise product insertion by means of a funnel with a motorized gate with re-cutting capability, or flexibility in cutting and perforating configuration.

[016] US patent 4,875,329 “WRAPPING MACHINE, PARTICULARLY FOR BLISTER PACKS AND THE LIKE, WITH SYNCHRONIZED PLURAL DRIVING MEANS” aims to improve operational flexibility; however, the document focuses on motor coordination and does not detail solutions for problems of sealing safety, opening and insertion accuracy, specific thermal management of the former, or cutting flexibility as proposed by the present invention.

[017] Document EP 0 936 990 B1 “SMALL-SCALE BLISTER PACKER” focuses on improving tool change efficiency and compact design, not addressing the technical problems solved by the present invention, such as: a system of Petition 870250044050, dated 05 / 28 / 2025, page 7 / 30 4 / 12 sealing with active protection against product crushing; an assisted packaging opening system with a specific geometry former and motorized gate; a former cooling system by air reuse; an insertion funnel with motorized gate for recutting movements; or a configurable cutting knife for full cut or perforation.

[018] In view of the above, it is observed that conventional unit packaging systems, including those described in the cited documents, lack robust safety mechanisms against crushing, precise control in the opening and product insertion stages, efficient thermal management of the former and flexibility in the final configuration of the packaging, including cutting and perforation. Problems with the technique and proposed solution.

[019] Traditional unit packaging systems have several limitations that are overcome by the present invention.

[020] Safety Problem in Sealing: Conventional equipment lacks obstacle detection and reaction systems during the sealing process. This can cause the crushing of poorly positioned products, resulting in product losses and potential damage to the equipment. The present invention solves this problem through an active anti-crushing system, which automatically calibrates the safe operating distance and acts instantly upon detecting interference.

[021] Problem of Controlling the Opening of the Packaging: The traditional method of opening by blowing air generates instability, especially for lightweight products such as small blisters, and may even expel them from the packaging. The invention overcomes this deficiency by means of a forming device synchronized with the insertion system, which uses the geometry of the gate to keep the packaging open at the moment of insertion, eliminating air reflux.

[022] Thermal Problems in Printing and Sealing: Traditional systems do not adequately control the former's heating, which impairs the quality of thermal printing and sealing. The invention solves this limitation with an integrated cooling system that reuses the air from the opening to cool the former, improving thermal stability and, consequently, the quality of the final product. Petition 870250044050, dated 05 / 28 / 2025, page 8 / 30 5 / 12

[023] Problem of Imprecise Product Insertion: The absence of active control in product release in traditional systems can lead to defective or misaligned insertions. The invention proposes a funnel with a gate driven by a stepper motor, which retains the product until the ideal moment and also allows rebound movements to ensure the correct placement of the item in the packaging.

[024] Problem of Flexibility in Packaging Configuration: Existing systems generally offer fixed cutting or perforating options. The invention includes a configurable knife between the jaws, allowing programming of full cuts or perforations and defining the number of connected packages, providing greater flexibility to the user. Objectives of the invention

[025] The objective of the present invention is to propose a packaging forming and sealing system with crush protection and a motorized chute-type gate capable of ensuring active safety during the sealing process, through the implementation of an anti-crushing system that automatically detects the presence of obstacles, interrupting the operation and protecting both the product and the equipment.

[026] The objective of the present invention is to propose a packaging forming and sealing system with crush protection and a motorized chute-type gate capable of increasing the efficiency and stability of packaging opening, by developing a forming system combined with air blowing and assisted geometry that keeps the packaging open without causing product expulsion, even in the case of lightweight products.

[027] The objective of the present invention is to propose a packaging forming and sealing system with crush protection and a motorized chute-type gate capable of preserving the quality of thermal printing and sealing, by introducing a passive cooling system in the former that uses residual air from the blower, preventing overheating and ensuring better visual and structural finish of the packaging. Petition 870250044050, dated 05 / 28 / 2025, page 9 / 30 6 / 12

[028] The objective of the present invention is to propose a packaging forming and sealing system with crush protection and a motorized chute-type gate capable of optimizing product insertion into the packaging, employing a funnel with a motorized gate that synchronizes the retention and release of the product, allowing rebound movements for precise accommodation and minimizing insertion failures.

[029] The objective of the present invention is to propose a packaging forming and sealing system with crush protection and a motorized chute-type gate capable of offering configuration flexibility in the cutting process, allowing the choice between total cutting or perforation of the packaging with programming of the number of packages connected, adapting the final product to the user's needs.

[030] The objective of the present invention is to propose a packaging forming and sealing system with crush protection and a motorized chute-type gate with an excellent cost-benefit ratio. Advantages of the invention

[031] The advantages of the present invention in relation to the prior art include: • Improved accuracy in opening and inserting the product, increasing process reliability; • Improved print quality and final packaging appearance; • Reducing waste of materials and incorrectly packaged products; • Increased operational flexibility, with customization of cuts and packaging formats; • Longer component lifespan due to the use of low-wear elements, such as neodymium magnets working by repulsion, replacing springs in the safety system. Summary of the invention

[032] Describes a unit packaging forming and sealing system that integrates, in a synchronized manner, a set of assisted package opening, controlled product insertion and secure sealing with active crush protection. The system consists of three main elements that interact to optimize the packaging process: a specially designed forming mechanism and Petition 870250044050, dated 05 / 28 / 2025, page 10 / 30 7 / 12 an air blower to assist in opening the packaging; a funnel with a motorized gate that synchronizes the retention and release of the product for precise insertion; and a sealing assembly equipped with an anti-crushing safety system that can be automatically calibrated via software. This combination allows for effective opening of the packaging without risk of product displacement, correct placement of the item inside the packaging, and secure thermal sealing, even in the presence of potential failures. Additionally, the system offers customized configuration of the number of packages connected by perforation or full cut, adapting to diverse production needs. Description of the figures

[033] The following figures are presented to better explain the patent application in an illustrative and non-limiting way: Figure 1: Perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate; Figure 2: Inverted perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate; Figure 3: View of section BB of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing the insertion of the product into the packaging; Figure 4: Perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing the seal open; Figure 5: Inverted perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing the seal open; Figure 6: Perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing the anti-crushing device; Petition 870250044050, dated 05 / 28 / 2025, page 11 / 30 8 / 12 Figure 7: Perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing the packaging blower device; Figure 8: Perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing the packaging forming device; Figure 9: Perspective view of the packaging forming and sealing system with crush protection and motorized chute-type gate, showing an application with exploded detail. Detailed description of the invention

[034] The “PACKAGING FORMING AND SEALING SYSTEM WITH CRUSH PROTECTION AND MOTORIZED CHANNEL-TYPE GATE”, the subject of this patent application, comprises a forming mechanism (7) that uses pivoting oblique arms (8) and an air blower (10) for assisted opening of the packaging (1), said forming mechanism (7) has an air reuse cooling system; an insertion funnel (12) equipped with a channel-type gate (13) driven by a stepper motor (14), which controls the synchronized retention and release of the product, allows rebound movements and helps to keep the mouth (9) of the packaging (1) open during insertion; and a sealing assembly with a movable jaw (3) equipped with an active anti-crushing protection system, composed of a floating part (5), magnetic repulsion elements (6) and a sensor (S) for immediate interruption of the sealing when obstacles are detected.

[035] More particularly, the claimed invention relates to a “PACKAGING FORMING AND SEALING SYSTEM WITH CRUSH PROTECTION AND MOTORIZED TROUGH-TYPE GATE” - designed to operate in an integrated and synchronized manner, the system is fundamentally composed of three main sets that interact to optimize the packaging process of products, such as ampoules, blisters, etc., in packaging (1): a sealing system (i) with active crush protection; a motorized chute-type forming and opening system Petition 870250044050, dated 05 / 28 / 2025, page 12 / 30 9 / 12 packaging (ii) and a product insertion system (iii) equipped with a funnel and motorized chute. The Active Anti-Crush Protection Sealing System (i) consists of two sealing jaws: a fixed jaw (2), also called the hot jaw, and a movable jaw (3), or cold jaw. The fixed, hot jaw (2) integrates a heating system (not shown) that is electronically controlled. This heating system is typically divided into sections to maximize the use of the sealing area of ​​the packaging (1). Between the sealing sections of the fixed, hot jaw (2), a knife (4), preferably serrated, is positioned, designed to perform both full cutting and configurable perforation in the packaging (1) after sealing. The blade design favors controlled separation, allowing the formation of strips of multiple packages (1) joined by perforation or of individual packages (1), according to the programming defined by the user.The cold, movable jaw (3) is equipped with an active safety system, called an anti-crushing system, based on a floating part (5) mounted on magnetic repulsion elements, which use neodymium magnets (6), associated with the floating part (5) and another with the body of the movable jaw (3), configured to repel each other. The magnetic repulsion mechanism acts as a highly durable magnetic spring, eliminating the need for conventional mechanical springs subject to wear, allowing the floating part (5) of the movable jaw (3) to retract when it detects any obstacle between the jaws (2, 3) other than the packaging (1) being sealed. An anti-crushing sensor (S), for example, an inductive or optical sensor, is strategically positioned to monitor the movement or position of this floating part (5).Under normal operating conditions, at the end of the closing stroke, the system performs the sealing by applying a pre-calibrated pressure between the jaws (2) and (3) on the packaging (1). If recoil or an anomalous displacement of the floating part (5) occurs before the expected ideal contact point with the fixed, hot jaw (2), a point determined by an automatic calibration routine performed by the control software at the beginning of each operating cycle or setup, the system interprets the presence of a foreign body, such as a misaligned product or an operator's finger, in the sealing area. In this situation, the... Petition 870250044050, dated 05 / 28 / 2025, page 13 / 30 The 10 / 12 control software immediately triggers the stop and retraction of the sealing mechanism, preventing damage to the product and equipment, and ensuring operational safety.

[036] The Packaging Assisted Forming and Opening System (ii) consists of a forming mechanism (7) positioned at the entrance of the sealing area, which consists of a pair of pivoting arms (8), preferably made of low-friction material such as Nylon®, with a specific oblique shape to support the packaging (1), typically a pre-formed tubular film or a bag, curving its mouth (9) and creating a crease that facilitates subsequent opening through a controlled airflow (F). The opening of the mouth (9) of the packaging (1) is promoted by an air blower (10) with nozzles (P) directing the flow of compressed air into the packaging (1) at the appropriate moment of the operation. The air inlet (E) of the blower (10) and the direction of the flow are optimized for effective opening.

[037] To ensure the accuracy of this step, a photoelectric sensor (not shown) can be used to detect the position of the packaging (1), synchronizing the firing of the blower airflow (10) and the actuation of the forming mechanism (7). The body of the forming mechanism (7) is preferably made of aluminum and has internal channels that direct the return airflow from the blower (10) which would otherwise be expelled and wasted after opening the packaging (1) to promote cooling of the forming mechanism (7). The air for the forming mechanism (7) may have a specific inlet (11). This passive cooling prevents overheating of the forming mechanism (7), which could impair the quality of a thermal print made on the packaging (1) in previous or subsequent steps, or affect the integrity of the packaging itself (1) and the quality of the subsequent sealing.

[038] The Product Insertion System with Motorized Chute-Type Hopper and Gate (i) - the product insertion hopper (12) is strategically positioned above the packaging (1) opened by the forming system (ii), this hopper (12) being equipped with a motorized chute-type gate (13), with geometry, driven by a stepper motor (14) through a transmission system, such as a timing belt (15). The use of a stepper motor (14) allows high precision and dynamic control of the Petition 870250044050, dated 05 / 28 / 2025, page 14 / 30 11 / 12 moment of product retention and release. The special geometry of the trough-type gate (13), whose design is crucial for its functionality, is designed to optimize product flow and, fundamentally, to assist in maintaining the opening of the mouth (9) of the packaging (1) during insertion, preventing air reflux that could expel light products. During the packaging formation and opening phase (1), the product to be packaged is held in the funnel (12) by the trough-type gate (13), which remains in its closed or retention position. After the formation system (ii) stabilizes the opening of the mouth of the packaging (9), the control software commands the stepper motor (14) so ​​that the trough-type gate (13) opens at the exact moment, releasing the product by gravity into the packaging (1).This trough-type gate mechanism (13) with stepper motor (14) is crucial for eliminating problems frequently associated with the continuous or poorly synchronized use of air blowing, such as throwing light products out of the packaging (1) or premature closing of the mouth (9) of the packaging (1). At the moment the trough-type gate (13) opens to release the product, the airflow system of the blower (10) is preferably deactivated or reduced. The very structure and geometry of the trough-type gate (13), when opening, helps to keep the mouth of the packaging (9) shaped and open for the time necessary for the complete and correct accommodation of the product inside.Additionally, for products of large dimensions, irregular shape, or those that are inherently difficult to position correctly within the packaging (1) by simple dropping, the stepper motor control system (14) allows for quick and short opening and closing movements of the trough-type gate (13), called rebounding. These rebounding movements assist in better housing and settling of the product within the packaging (1) before the final sealing stage.

[039] The sealing system with anti-crushing protection (i), the assisted packaging forming and opening system (ii), and the product insertion system with motorized funnel and chute type gate (iii) are controlled in an integrated and synchronized manner by dedicated software, residing in a programmable logic controller (PLC) or similar industrial control system, responsible for precisely managing and synchronizing cycle times and the sequence of operations of each Petition 870250044050, dated 05 / 28 / 2025, page 15 / 30 12 / 12 system, such as opening the packaging (1), releasing the product, sealing, and operating the safety and calibration systems.

[040] The software allows the operator to configure and store various production parameters through a human-machine interface (HMI). These parameters include, but are not limited to: * Time and temperature for sealing the jaws (2, 3); * Jaw opening distance and contact pressure for sealing, including parameters for calibrating the anti-crushing system; * Time, duration and intensity of airflow (F) for opening the packaging (1); * Opening time, retention time, speed and number of gate strikes; * Knife operating mode (selection between perforation or full cut) and the number of packages (1) per strip or set. [ 041] Software integration not only ensures accuracy and repeatability throughout the packaging process, but also improves overall equipment performance, ensures the integrity of packaged products, reduces losses and waste, and facilitates operation, format changes and system maintenance. Petition 870250044050, dated 05 / 28 / 2025, page 16 / 30

Claims

1 / 2 CLAIMS 1) PACKAGING FORMING AND SEALING SYSTEM WITH CRUSH PROTECTION AND MOTORIZED TROUGH-TYPE GATE, consisting of a sealing system (i); a packaging formation and assisted opening system (ii) and a product insertion system (iii) characterized by the sealing system (i) having active anti-crushing protection, which includes in the movable jaw (3), a floating part (5), which uses neodymium magnets (6), and a sensor (S) configured to detect the anomalous displacement of the floating part (5) in case of an obstacle (P') in the sealing area; the packaging formation and assisted opening system (ii) consists of a forming mechanism (7) with oblique pivoting arms (8) acting in conjunction with an air blower (10) to perform an assisted opening of the mouth of the packaging (9); the forming mechanism (7) is provided with internal channels for cooling by reusing air from the air blower (10);The product insertion system (iii) features a funnel (12) and a chute-type gate (13) driven by a stepper motor (14) with a timing belt (15) for selective retention and release of the product with the possibility of rebound movements for correct placement, and to assist in maintaining the opening of the packaging mouth (9) during insertion. 2) PACKAGING FORMING AND SEALING SYSTEM WITH CRUSH PROTECTION AND MOTORIZED TROUGH-TYPE GATE, according to claim 1, characterized in that the active anti-crushing protection system is automatically calibratable via software to determine an ideal contact point between the jaws (2, 3) in the absence of obstacles. 3) PACKAGING FORMING AND SEALING SYSTEM WITH CRUSH PROTECTION AND MOTORIZED TROUGH-TYPE GATE, according to claim 1, characterized by a knife (4) positioned between the sealing jaws (2, 3) being configurable to selectively perform full cut or perforation in the sealed packaging (1) programmable via software. 4) PACKAGING FORMING AND SEALING SYSTEM WITH CRUSH PROTECTION AND MOTORIZED TROUGH-TYPE GATE, according to Petition 870250044050, dated 05 / 28 / 2025, page 17 / 30 2 / 2 with claim 1, characterized by being controlled by dedicated software that synchronizes the operations of the forming mechanism (7) and the air blower (10), the trough-type gate (13), and the sealing assembly, including the active anti-crushing protection system and the knife (4), and that allows the configuration of operational parameters. Petition 870250044050, dated 05 / 28 / 2025, page 18 / 30

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