Airless Packaging Rotary Heat Sealing Device
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Solution Overview
Problem
The industrial manufacturing of 'airless' packaging for viscous products is hindered by the difficulty in securely fixing a flexible bag inside an envelope at an industrial rate, affecting the packaging's functionality and product preservation due to air introduction during product expulsion.
Innovation Solution
A device that forms a pocket from a film with precise dimensional control, grips, and welds it inside an envelope using a mobile mandrel, grippers, and a welding head with heating elements, allowing for high-rate and repeatable assembly of airless packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a flexible pouch is manually secured inside an envelope, then the packaging structure is simple, but the production speed is low and industrial scalability is poor
Solution Approach 1:
The device divides the pouch securing process into distinct operational stages: formation stage (creating the pouch from film), engagement stage (positioning pouch on mandrel), and welding stage (securing pouch to envelope). Each stage uses specialized components that work sequentially, enabling high-speed automated production while maintaining structural simplicity.
Solution Approach 2:
The mandrel serves as an intermediary tool that temporarily holds the pouch during the assembly process. The movable clamps act as intermediaries to transfer the pouch from the mandrel to the envelope. This intermediary approach enables precise positioning and secure attachment without requiring complex direct manipulation mechanisms.
2Manufacturing precision
If the pouch is secured inside the envelope, then product preservation is improved, but the positioning precision is difficult to control
Solution Approach 1:
The pouch is pre-formed with precise dimensions using the pocket formation means before being placed in the envelope. The mandrel is pre-positioned at the correct location inside the envelope, and the welding means are pre-aligned to engage with the pouch at the exact required position. This preliminary preparation ensures precise final positioning without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The device replaces manual positioning operations with automated mechanical systems. The movable mandrel provides precise positional control through guided linear motion, while the welding means use automated thermal processes to secure the pouch at exact predetermined locations, eliminating the imprecision of manual placement.
3Reliability
If the pouch is welded to the envelope, then the sealing reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The welding process utilizes phase transition of the pouch material from solid to molten state and back to solid. The welding means apply localized heat to melt the pouch material at the sealing interface, then allow it to cool and solidify, creating a strong bond between the pouch and envelope. This phase transition approach provides reliable sealing through the inherent bonding properties of the material itself, rather than requiring complex adhesive or mechanical fastening systems.
4Reliability
If the envelope is sealed hermetically, then product freshness is maintained, but the manufacturing time increases
Solution Approach 1:
The device implements continuous sealing operations where the envelope remains on the rotating mandrel throughout the entire sealing process. The welding means continuously apply heat and pressure along the sealing interface as the mandrel rotates, eliminating the need for repeated positioning and setup operations. This continuous action significantly reduces sealing time while maintaining hermetic integrity.
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
Enables the production of airless packaging at an industrial scale, ensuring precise positioning and sealing of the pocket within the envelope, preventing air introduction and maintaining product freshness.
Implementation Method 1
Each clamp (10) will be equipped with at least one suction gripping system such as a suction cup
Implementation Method 2
The welding head (35) includes a heating rib (40) designed to come tangent to the pocket (3) placed in the envelope (4)
Implementation Method 3
a welding head designed to engage with the casing when it is placed on the base... performing a continuous thermal weld inside the envelope
Data Source
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AI summary
The invention relates to a device for producing a packaging including an elastically deformable shell including a body having one open end and one end provided with a neck and a flexible tubular bag (3) including one open end and an elastically deformable shell end (4), characterised in that the device includes means for forming the bag (3) from a plastic film, means for gripping the bag (3), means for inserting the bag (3) in the shell (4) and means for sealing (40) the bag (3) in the shell (4) by performing continuous rotary heat sealing inside the shell (4).