Packaging Bundle Tightness via Background Flat Plate
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Solution Overview
Problem
Conventional packaging machines fail to achieve optimal bundle tightness and minimize void volume within packaged items, leading to inefficiencies in material usage and production speed.
Innovation Solution
The introduction of a background flat plate during the sealing process, combined with a heat tunnel for film shrinkage, and a sealing apparatus with servo motor-controlled sealing dies that allow for variable sealing region lengths and speeds, enhances bundle tightness and reduces material usage while maintaining production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional packaging machines seal products in plastic film without a background flat plate, then the sealing process is simpler, but the bundle tightness is insufficient and void volume is excessive
Solution Approach 1:
A background flat plate is introduced as an intermediary component between the sealing apparatus and the products. This plate provides a solid support surface that enables the sealing jaws to apply pressure effectively, thereby achieving tighter bundles and reduced void volume without overly complicating the overall system
2Manufacturing precision
If more plastic film is used to package products, then product protection is improved, but material usage increases and bundle tightness decreases
Solution Approach 1:
The background flat plate acts as a mediator that allows for more efficient film utilization. By providing a solid support during sealing, it enables the film to be applied more tightly around the products, reducing the amount of film needed while achieving better bundle tightness and less void volume
3Productivity
If sealing dies move continuously at full speed, then production rate increases, but control over sealing quality decreases
Solution Approach 1:
The sealing support structure is made dynamically adjustable, allowing it to move at variable speeds and positions. This dynamic capability enables the system to maintain full production speed while providing precise control over the sealing process, ensuring high-quality seals without sacrificing productivity
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 results in tighter packages with reduced material usage, improved production rates, and cost-effectiveness by minimizing void volume and allowing for faster, more flexible packaging of items of varying sizes.
Implementation Method 1
The longitudinal edges of the plastic film are overlapped and sealed by means of a heating element with pressurized air to provide an elongated tube of film
Implementation Method 2
The flat plate applies pressure to the plastic film, thereby minimizing or eliminating the volume of space between the plastic film and product
Implementation Method 3
a heat tunnel that shrinks the film around the packaged items
Data Source
AI summary
A shippable bundled product including a plurality of paper product rolls each individually packaged by a first package material and arranged relative to one another so as to form a bundle. The bundle is packaged by a second package material. The second package material has a shrinkage factor relative to the bundle of less than zero.