Dual Heater Packaging System for Controlled Film Sealing
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Solution Overview
Problem
Existing packaging technologies face challenges in controlling the heating process during heat sealing of plastic films, particularly in reducing energy consumption and ensuring efficient sealing of thermo-sensitive films, while also maintaining control over the heating process for both skin packaging and modified atmosphere packaging.
Innovation Solution
A packaging apparatus with a dual-heater system, where a peripheral heater and an inner heater are controlled independently to optimize the heating cycle, including specific temperature settings and time intervals, to ensure efficient and controlled heat sealing, even with thermo-sensitive films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single heater is used for heat sealing, then the device complexity is low, but the control precision over heating process is insufficient
Solution Approach 1:
The heating system is divided into two independent heaters: a peripheral heater for sealing the outer edges and an inner heater for sealing the inner regions. Each heater can be controlled independently in terms of temperature and timing, allowing precise control over different zones of the packaging film during the heat sealing process.
2Reliability
If heating is applied continuously, then the sealing reliability is high, but the energy consumption increases
Solution Approach 1:
The heating process uses periodic action by sequentially activating the peripheral heater and inner heater at different time intervals. The peripheral heater operates first to seal the outer edges, then the inner heater operates to seal the inner regions. This staged periodic heating ensures reliable sealing while minimizing energy consumption by avoiding continuous heating of the entire area simultaneously.
3Productivity
If high temperature is applied, then the sealing speed is fast, but the film may be damaged
Solution Approach 1:
Different temperature levels are applied to different zones of the packaging film according to their specific requirements. The peripheral heater applies appropriate temperature to the outer edges, while the inner heater applies different temperature parameters to the inner regions. This localized quality approach ensures optimal sealing speed for each zone without causing damage to the thermo-sensitive film.
4Manufacturing precision
If the heating cycle is simplified, then the process time is short, but the sealing quality deteriorates
Solution Approach 1:
The peripheral heater performs preliminary sealing action on the outer edges of the packaging film first, preparing the structure before the inner heater seals the inner regions. This preliminary action ensures that the sealing process is well-organized and progresses efficiently, maintaining high sealing quality while minimizing overall process time through proper sequencing.
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 apparatus achieves improved energy efficiency and precise control over the heat sealing process, enabling effective sealing of plastic films while reducing energy consumption and ensuring reliable sealing of both thermo-sensitive and heat-shrinkable films.
Implementation Method 1
a power supply provides an electrical current to a nearby induction coil which induces an electrical current into the metal foil to develop heat which melts portions of the lid and container and fuses the lid to the container lip
Implementation Method 2
a power supply provides an electrical current to a nearby induction coil which induces an electrical current into the metal foil to develop heat
Data Source
AI summary
A process for packaging a product arranged on a support comprising unrolling a film, moving the film to a packaging assembly defining at its inside a packaging chamber, progressively moving a number of supports inside the packaging chamber of the packaging assembly, closing the packaging chamber with the film sheets held above the respective support, optionally causing one or both of: a gas withdrawal from the hermetically closed packaging chamber and gas injection of a gas mixture of controlled composition, heat sealing the film to said support, wherein the heat sealing uses one or more heaters having heating surfaces which are heated for discrete and short time periods only. An apparatus for performing the above process is also disclosed.