Bag Precursor Separation via Selective Perforation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing method of creating pre-opened bags for sealing products is costly and inefficient, as it requires additional time and resources for rewinding and results in rolls that are twice the size due to trapped air, with standard sizes necessitating frequent changes to the roll feeding into the machine.
Innovation Solution
A transforming machine that converts a strip of unopened tube stock into open bag precursors by using a drive motor, separation station, and pressure device to selectively separate perforations in one film layer while keeping the other intact, allowing for adjustable bag lengths without changing the roll, and integrates a perforation-seal station to form transverse seals and perforations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-opened bags are created by forming end perforations and separating perforations in a secondary operation, then bags can be opened for filling, but the roll diameter becomes twice the size due to trapped air
Solution Approach 1:
The invention creates perforations in the tube stock before rolling into bags, allowing the perforated strip to be rolled without trapping air. The pre-formed perforations enable the film to compress and conform during rolling, eliminating the air pockets that would otherwise double the roll diameter.
Solution Approach 2:
The invention segments the film into multiple layers with perforations formed between layers, allowing selective separation. The perforations are created in one layer but not others, enabling controlled opening while maintaining roll compactness through differential layer separation.
2Ease of operation
If pre-opened bags are created by rewinding open bags onto a core, then bags are opened for filling, but additional time and cost are incurred
Solution Approach 1:
The invention performs the bag opening action during the initial rolling process rather than requiring a separate secondary operation. Perforations are formed and bags are opened in the same continuous operation, eliminating the need for rewinding and a separate opening step.
Solution Approach 2:
The invention combines the perforation formation and bag opening operations into a single integrated process. The perforation device and rolling mechanism work together simultaneously, merging what were previously separate operations into one efficient step.
3Ease of manufacture
If standard size rolls are used, then manufacturing is simplified, but bag size cannot be changed without changing the roll
Solution Approach 1:
The invention makes the bag length variable by allowing the perforation device to adjust its position along the tube stock. The controller can dynamically change the perforation location to create bags of different lengths from the same roll, providing adaptability without requiring roll changes.
Solution Approach 2:
The invention makes a single roll serve multiple functions by enabling it to produce bags of various sizes. The same roll can be used for different bag lengths by adjusting the perforation positioning, making the manufacturing system universal rather than requiring dedicated rolls for each bag size.
4Quantity of substance
If more bags are present per same diameter roll, then material cost is reduced, but bag size flexibility is limited
Solution Approach 1:
The invention enables dynamic adjustment of bag length from a fixed roll size, allowing the system to optimize the number of bags per roll based on the required bag size. The perforation positioning can be changed to maximize utilization of the roll material for any given bag length requirement.
Solution Approach 2:
The invention changes the parameter of bag length by adjusting the perforation position along the tube stock. This allows the same roll to produce different numbers of bags with different lengths, optimizing material usage while maintaining flexibility.
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 reduces material costs, increases productivity, and allows for on-demand bag size changes without rolling changes, as the machine efficiently produces open bags from tube stock, optimizing the bag filling process by minimizing air trapped in the rolls and enabling continuous feeding into a bag filling machine.
Implementation Method 1
a pressure device having an actuator selectively activating the pressure device to apply pressure to the continuous strip of unopened bag precursors
Implementation Method 2
The friction bar is pressed against the first film layer and the smooth bar is pressed against the second film layer
Data Source
AI summary
Transforming machines for changing a strip of unopened bag precursors into open bag precursors are disclosed that include a drive motor, a separation station, a sensor electrically connected to a controller that is electrically connected to components of the separation station. The separation station includes a first roller, a separation roller driven by the drive motor, and a pressure device having an actuator selectively activating the pressure device to apply pressure to the strip of unopened bag precursors passing over the first roller. In operation, the controller, based on a signal from the sensor, determines when perforations are located in a gap between the pressure device and the separation roller and at that time signals the actuator to activate the pressure device, with the drive motor driving the separation roller, thereby separating the perforations in a first film layer, but not the perforations in a second film layer.