Bag Machine Air Temperature Control for Consistent Seals
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Solution Overview
Problem
Existing bag making machines face inefficiencies in seal formation due to temperature control issues, heat loss, and uneven air flow distribution, leading to inconsistent seals and prolonged start-up times.
Innovation Solution
The proposed bag machine incorporates a feedback circuit connected to temperature sensors in both the manifold and heater block, allowing for precise control of air temperature near the seal bar. Additionally, insulation of the heater block and manifold reduces heat loss, and a controlled air flow restriction in the manifold ensures even air distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If heater blocks and manifolds are not insulated, then device complexity is reduced, but heat loss increases leading to prolonged start-up time and reduced energy efficiency
Solution Approach 1:
The patent applies insulation material to the heater blocks and manifolds, converting the previously harmful heat loss into a beneficial heat retention effect. This insulation layer prevents thermal energy from escaping to the surrounding environment, thereby reducing start-up time and improving energy efficiency without significantly complicating the device structure.
2Ease of manufacture
If thermocouples are placed in heater blocks, then temperature measurement is simplified, but temperature control accuracy deteriorates because heater block temperature differs from manifold air temperature
Solution Approach 1:
The patent introduces an intermediary temperature sensing approach by placing thermocouples in direct contact with the manifold air flow path rather than embedded in heater blocks. This intermediary positioning allows accurate measurement of the actual air temperature that contacts the film, providing precise feedback for temperature control while maintaining ease of installation through direct air path access.
3Manufacturing precision
If air flow restrictions are not used in manifolds, then device complexity is reduced, but air flow distribution becomes uneven leading to inconsistent seal formation
Solution Approach 1:
The patent implements air flow restrictions at specific locations within the manifold system, creating localized flow control zones. These restrictions are strategically positioned to balance air distribution across different manifold sections, ensuring uniform heat delivery to the film surface and consistent seal formation without requiring complex overall manifold redesign.
4Device complexity
If manifold air temperature is not controlled, then device complexity is reduced, but seal formation consistency deteriorates due to temperature variations
Solution Approach 1:
The patent establishes a feedback control system where thermocouples mounted on the manifold continuously monitor air temperature and transmit signals to a temperature controller. This controller adjusts heater power in real-time based on actual manifold temperature readings, maintaining consistent air temperature despite environmental variations and ensuring uniform seal quality throughout production.
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 solution enables consistent seal formation, reduces start-up time significantly, and improves energy efficiency by maintaining desired air temperatures and optimizing air flow distribution.
Implementation Method 1
A temperature sensor disposed in the manifold or in the air path provides a signal indicative of temperature of the air in the manifold or in the air path to a controller
Implementation Method 2
The heated air either heats the seal bar which heats the film, or the heated air is directed through openings in the seal bar toward the film to directly heat the film
Implementation Method 3
The heater block and manifold are insulated
Implementation Method 4
The hot air raises the temperature of the seal bar so that it can melt the film to form the seal
Data Source
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AI summary
A method and apparatus for making bags from a film that follows a film path through a bag machine includes an input section located on the film path, a sealing section located on the film path down stream of the input section, an output section located on the film path downstream of the sealing section, and a controller, connected to control the sealing section. The sealing section includes a sealer that includes a heater block and a manifold. There is an air flow path from the heater block to the manifold. Air is heated in the heater block in response to a control signal provided by the controller to the heater block. The heated air is provided through the air path to the manifold. A temperature sensor is disposed in at least one of the air path and the manifold.