Double Layer Air Enclosure Leakage Prevention
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Solution Overview
Problem
Conventional air packing bags made from polyethylene are prone to leakage when pierced, leading to loss of cushioning protection and damage to packed articles, as independent check valves in each air cylinder do not prevent entire air from leaking out when one cylinder is broken.
Innovation Solution
A double layer air cylinder type air enclosure is manufactured using a middle film and inner/outer films, with check valves and air passageways formed through hot sealing, allowing air to fill and compress, sealing the passageway to prevent leakage, and maintaining cushioning protection even if one air chamber is broken.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If independent check valves are used in each air cylinder, then air leakage is prevented in unbroken cylinders, but cushioning protection is lost when parts are broken
Solution Approach 1:
The air enclosure is divided into multiple independent air chambers separated by a middle film, where each chamber has its own check valve. This segmentation ensures that when one chamber is punctured, only that specific chamber loses air while other chambers remain intact and continue to provide cushioning protection.
Solution Approach 2:
The invention transitions from a single-layer air cylinder design to a double-layer structure with inner and outer films creating multiple air chambers. This dimensional change from one chamber to multiple chambers allows the system to maintain cushioning functionality even when individual chambers are compromised.
2Object-affected harmful factors
If polyethylene air bags are used, then cushioning function is provided, but they are easily pierced by sharp angles
Solution Approach 1:
The air enclosure uses a composite structure with multiple film layers (inner film, middle film, outer film) and incorporates heat-sealed check valves. This composite design enhances the overall strength and resistance to piercing compared to single-layer polyethylene bags, while maintaining the cushioning function.
3Device complexity
If a single air chamber is used, then simple structure is achieved, but entire air leaks when one cylinder is broken
Solution Approach 1:
The air enclosure is divided into multiple independent air chambers separated by a middle film, where each chamber has its own check valve. This segmentation ensures that when one chamber is punctured, only that specific chamber loses air while other chambers remain intact and continue to provide cushioning protection.
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
The double layer design ensures that air is not entirely leaked out, maintaining cushioning protection and preventing damage to packed articles, as each air chamber is independent and can continue to provide shock absorption when one is compromised.
Implementation Method 1
a first hot sealing apparatus, used for hot-sealing the plurality of inner films and the middle film to allow check valves with an air passageway to be respectively formed
Implementation Method 2
when air enters the air chamber via the air passageway to cause the air chamber to be filled with air and expanded, air in the air chamber compresses the check valve to seal the air passageway
Data Source
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AI summary
An apparatus and method for manufacturing a double layer air cylinder type air enclosure uses a middle film conveying unit to provide a middle film, a plurality of inner film conveying units to provide a plurality of inner films to stack on two sides of the middle film, a first hot sealing apparatus to hot-seal the plurality of inner films and the middle film to allow two sides of the middle film to be respectively formed with a check valve with an air passageway, an outer film conveying unit to provide two sheets of outer film to respectively stack on the outside of the check valve and a second hot sealing apparatus to hot-seal the plurality of outer films and the middle film to allow an air storable air chamber to be formed between the middle film and the each sheet of outer film. Whereby, air enters the air chamber causes the air chamber to be filled with air and expanded via the air passageway, air in the air chamber compresses the check valve to shield the air passageway to enable air in the air chamber not to be leaked out to attain to the air locking.