Deep-Drawing Vacuum Pressure Control for Uniform Film Thickness
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Solution Overview
Problem
Existing packaging machines face challenges in producing reliable, environmentally friendly, and cost-effective filled foil bags due to irregular dissolution times and material failures in water-soluble films, primarily caused by uneven film thickness and heterogeneous material properties during the deep-drawing process.
Innovation Solution
A deep-drawing device with a mold vacuum system that adjusts pressure continuously during thermoforming, using a switching unit to control the pressure profile and adjust the thermoforming speed, ensuring uniform film thinning and reducing the stretch rate to prevent material failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the film thickness is increased to prevent tearing and leakage, then the reliability of the packaging is improved, but the environmental impact and production costs increase
Solution Approach 1:
The patent changes the process parameters of deep drawing, specifically reducing the thermoforming speed and adjusting the vacuum pressure profile. This transforms the material properties during forming, allowing thin films to be shaped without tearing or excessive thinning, thus maintaining reliability without increasing thickness
2Strength
If the film thickness is increased to prevent defects, then the strength of the packaging is improved, but the dissolution time of water-soluble films increases
Solution Approach 1:
The patent applies parameter changes to the deep drawing process, specifically controlling the vacuum pressure and thermoforming speed to achieve uniform film thickness. This ensures the film has sufficient strength while maintaining consistent dissolution time for water-soluble applications
3Manufacturing precision
If the thermoforming speed is reduced to homogenize film thinning, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The patent implements dynamic control of the vacuum pressure during the deep drawing process. The vacuum pressure is not constant but is adjusted during the forming cycle, allowing faster overall production while achieving uniform film thickness through controlled pressure profiles during critical forming phases
4Productivity
If the vacuum pressure is increased to speed up thermoforming, then the productivity is improved, but the film experiences excessive thinning and material failure
Solution Approach 1:
The patent employs periodic or cyclic vacuum pressure application during the deep drawing process. The vacuum pressure is applied in controlled phases rather than continuously at high levels, allowing the film to form at appropriate speeds without experiencing excessive thinning or material failure
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 approach enables the production of packaging units with uniform film thickness, ensuring reliable and cost-effective manufacturing while maintaining environmentally friendly practices by setting reproducible dissolution times for water-soluble films.
Implementation Method 1
the forming vacuum device comprises at least one vacuum source for providing a vacuum
Implementation Method 2
the pressure applied to the die cavity can be continuously adjusted during thermoforming
Implementation Method 3
a heating device for heating the film before deep-drawing in the at least one die shape
Implementation Method 4
the pressure applied to the die cavity can be continuously adjusted during thermoforming
Implementation Method 5
a mold vacuum device by means of which the pressure applied to the die cavity can be continuously adjusted
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a deep-drawing device for deep-drawing film, comprising an arrangement of several die plates (9, 9'), and with at least one forming vacuum device (20), wherein the forming vacuum device (20) comprises at least one vacuum source (21) for providing a vacuum, and wherein the forming vacuum device (20) comprises at least one switching unit (22) associated with the vacuum source (21), wherein the switching unit (22) comprises a valve (23) functionally arranged between the vacuum source (21) and the at least one die shape (10), and wherein the switching unit (22) is configured in a first embodiment such that the pressure applied to the at least one die shape (10) is continuously adjustable by the switching unit (22), and wherein the switching unit (22) comprises a vacuum tank (25) functionally arranged between the valve (23) and the at least one die shape (10).