Cyclic Vacuum Forming Station for Packaging Film
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Solution Overview
Problem
Existing deep-drawing apparatuses face challenges in vacuum management, leading to leakage losses and difficulty in maintaining a consistent underpressure level, especially when deep-drawing into multiple format plates simultaneously.
Innovation Solution
A deep-drawing apparatus with a cyclically sequenced forming station and a holding vacuum channel featuring two interlocking telescopic channel portions, where the forming vacuum device is part of the cyclically moved forming station, and the holding vacuum channel has a static portion, allowing for continuous pressure transmission and precise control of vacuum levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a positionally fixed forming vacuum device and holding vacuum device are used with continuous format plate movement, then deep-drawing process can be maintained, but relative movement causes sealing difficulties and vacuum level control problems
Solution Approach 1:
The patent combines the forming vacuum device and holding vacuum device into a single cyclically moving vacuum unit that travels with the format plate. This merging eliminates the need for separate sealing mechanisms between stationary vacuum devices and moving format plates, resolving the sealing difficulties and vacuum control problems caused by relative movement.
Solution Approach 2:
The vacuum device is transformed from a static configuration to a dynamic one, where it cyclically moves synchronously with the format plate during the deep-drawing process. This dynamic arrangement maintains constant relative position, eliminating sealing issues and enabling precise vacuum level control throughout the process.
2Productivity
If format plates move continuously over stationary vacuum devices, then production can proceed, but appreciable flow losses occur at sealing points
Solution Approach 1:
By making the vacuum device move dynamically with the format plate rather than remaining stationary, the patent eliminates relative movement at the sealing interface. This removes the source of vacuum flow losses while maintaining continuous production capability through the cyclic movement of the integrated vacuum unit.
3Device complexity
If a single forming station processes one format plate at a time, then vacuum management is simpler, but productivity is limited
Solution Approach 1:
The cyclically moving forming station can simultaneously service multiple format plates positioned at different stages of the process cycle. This dynamic configuration enables parallel processing of multiple plates without complicating vacuum management, as the single moving vacuum unit maintains synchronized connection with each plate in turn.
Solution Approach 2:
The cyclic movement of the forming station ensures continuous vacuum application across multiple format plates throughout the production cycle. Each plate receives vacuum treatment at the appropriate moment in the cycle, maintaining uninterrupted productive action without requiring multiple separate vacuum systems.
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 configuration eliminates relative movement between vacuum devices, reduces leakage, enables precise vacuum control, and allows for simultaneous deep-drawing into multiple format plates, enhancing productivity and maintaining a continuous holding vacuum throughout the process.
Implementation Method 1
the film web is firstly heated to such a temperature that it is able to be plastically deformed
Implementation Method 2
the mold impressions, subsequent to the deep-drawing process, are therefore subjected to a holding vacuum, which holds the film web in its deep-drawn shape
Data Source
AI summary
The disclosure relates to a deep-drawing apparatus for deep-drawing a continuously fed film web, an associated packaging machine, and a corresponding method. A cyclically sequenced forming station, which runs along from a start position to an end position and runs back from there to the start position is provided, wherein individual format plates are sequentially firstly connected up to a forming vacuum device and then with a following holding vacuum channel. The forming vacuum device is part of the cyclically moved forming station. The holding vacuum channel includes two interlocking telescopic channel portions, a first telescopic channel portion being part of the cyclically moved forming station, and a second telescopic channel portion being mounted statically relative to the fixed machine frame.