Configurable Overwrap Infeed Station for Flexible Seal Placement
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Solution Overview
Problem
Packaging lines face challenges in efficiently forming longitudinal seals on rolls or packs of products like toilet tissue or towels, as existing systems struggle to adapt to varying orientations and seal locations, limiting flexibility and efficiency in packaging processes.
Innovation Solution
A packaging line with an overwrap infeed station that can adjust to form seals on either the horizontal or vertical face of tubular packages, using a configurable overwrap feed station with adjustable supports and a longitudinal seal unit capable of heating, gluing, ultrasonically welding, or laser welding the edges, allowing for flexible seal placement and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing packaging systems use fixed seal locations, then the packaging process is simple, but the system cannot adapt to varying product orientations and seal locations
Solution Approach 1:
The packaging system employs movable and adjustable components including the overwrap infeed station, longitudinal seal unit, and support structures that can be repositioned along the packaging line. This dynamic configuration allows the seal location and orientation to be changed according to different product requirements, enabling the system to adapt to varying product orientations and seal locations without requiring multiple dedicated machines
Solution Approach 2:
The longitudinal seal unit is designed with multi-functionality to perform various sealing operations (heating, gluing, ultrasonic welding, laser welding) at different locations and orientations on the package. The overwrap infeed station can accommodate different product formats and orientations, making a single packaging system capable of handling diverse packaging requirements that would traditionally require multiple specialized machines
2Productivity
If the packaging line is designed for fixed seal placement, then the machine structure is simple, but productivity is limited due to inability to handle multiple product formats
Solution Approach 1:
The packaging line is divided into modular segments including the overwrap infeed station, longitudinal seal unit, and support structures that can be independently adjusted and reconfigured. This segmentation allows each component to be optimized for specific tasks while maintaining overall system flexibility, enabling the packaging line to efficiently handle multiple product formats without requiring complete system redesign
Solution Approach 2:
The system incorporates dynamically adjustable components such as the movable overwrap infeed station and repositionable longitudinal seal unit that can be quickly reconfigured between different product formats. This dynamic capability allows the packaging line to maintain high productivity across varying product types by eliminating changeover downtime and enabling rapid adaptation to different packaging requirements
3Adaptability or versatility
If multiple machines are used to handle different seal locations, then each machine can be optimized for its specific function, but the overall system complexity and space requirements increase
Solution Approach 1:
A single packaging machine integrates multiple functions by incorporating a longitudinal seal unit capable of sealing at different locations and orientations, and an overwrap infeed station that accommodates various product formats. This multi-functional design consolidates what would traditionally require multiple separate machines into one compact system, providing seal location flexibility while minimizing the packaging line footprint
Solution Approach 2:
The patent merges the functions of multiple specialized packaging machines into a single integrated system. The overwrap infeed station, longitudinal seal unit, and support structures are combined into one cohesive machine that can perform various sealing operations at different locations, thereby reducing the overall space requirements while maintaining adaptability to different seal location requirements
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 flexible and efficient packaging by allowing seals to be formed on either the horizontal or vertical face of packages, accommodating different product orientations and formats, thereby enhancing packaging line versatility and productivity.
Implementation Method 1
the seal unit is adapted and configured to heat the edges to join together
Implementation Method 2
ultrasonically welding the edges
Data Source
AI summary
An overwrap feed station wraps a product with an overwrap material by drawing the overwrap material around the product to form a tube around the product as the product moves through the feed station. The feed station is configurable in one of first and second configurations based upon a desired location of a longitudinal seal to be formed on the tube around the product. A first former is configured to guide the overwrap material through the entrance of the feed station so that longitudinal edges of the overwrap material overlap on a first side of the tube during wrapping of the product. The second former is configured to guide the overwrap material through the entrance of the feed station so that longitudinal edges of the overwrap material overlap on a second side of the tube during wrapping of the product. The second side is transverse to the first side.