Dual-Heater Packaging System for Precise Film Sealing
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Solution Overview
Problem
Existing packaging technologies face challenges in controlling heat during the heat sealing of plastic films, particularly in ensuring efficient energy consumption and effective sealing of thermosensitive films, while also requiring improved control over heating surfaces to prevent distortion and ensure a perfect aesthetic appearance.
Innovation Solution
The apparatus employs a dual-heater system with independently controlled peripheral and inner heating surfaces, utilizing electrically conductive carbon structures, such as graphene layers, to precisely manage temperature and heating cycles, allowing for accurate heat sealing of plastic films to trays or other films, even with heat-shrinkable materials, and minimizing thermal distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single heating element is used for heat sealing, then the device complexity is reduced, but the temperature control precision and sealing quality deteriorate
Solution Approach 1:
The heating system is divided into two independent heating zones: a first heating element for the peripheral region and a second heating element for the inner region. Each heating element can be independently controlled to provide precise temperature management for different areas of the film during heat sealing, thereby improving sealing quality without excessive complexity
Solution Approach 2:
Different regions of the film require different heating characteristics for optimal sealing. The peripheral region and inner region are heated separately by dedicated heating elements, allowing each zone to receive customized thermal treatment tailored to its specific sealing requirements, thus enhancing overall sealing precision
2Productivity
If high temperature is applied for heat sealing, then the sealing speed and productivity are improved, but film deformation and tray distortion increase
Solution Approach 1:
The heating system is divided into two independent heating zones: a first heating element for the peripheral region and a second heating element for the inner region. Each heating element can be independently controlled to provide precise temperature management for different areas of the film during heat sealing, thereby improving sealing quality without excessive complexity
Solution Approach 2:
The control system activates the heating elements in a sequential periodic manner rather than simultaneously. The first heating element operates during a first time interval, followed by activation of the second heating element during a second time interval. This periodic activation pattern allows controlled thermal processing that achieves sealing while minimizing excessive heat exposure that would cause deformation
3Reliability
If continuous heating is applied, then the sealing completeness is improved, but energy consumption increases
Solution Approach 1:
The control system activates the heating elements in a sequential periodic manner rather than simultaneously. The first heating element operates during a first time interval, followed by activation of the second heating element during a second time interval. This periodic activation pattern allows controlled thermal processing that achieves sealing while minimizing excessive heat exposure that would cause deformation
Solution Approach 2:
The first heating element is activated before the second heating element to preliminarily prepare the peripheral region of the film for sealing. This preliminary heating action ensures that when the second heating element activates, the film is already partially prepared, allowing complete sealing with reduced total energy input compared to simultaneous or reversed 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
This approach enables precise control over heat sealing, ensuring a perfect aesthetic appearance, minimizing film deformation and tray distortion, while reducing energy consumption and allowing for efficient bonding without flaws, even with highly shrinkable films.
Implementation Method 1
utilizing electrically conductive carbon structures, such as graphene layers, to precisely manage temperature and heating cycles
Implementation Method 2
a first heating surface of the peripheral heater to heat seal a peripheral region of the plastic film... a second heating surface of the inner heater to heat at least a portion of an inner zone of the plastic film
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A packaging apparatus comprising: a packaging assembly (8) configured for receiving at least one support (4) and for tightly fixing a film (18) to the support (4), the packaging assembly (8) including a lower tool (22) and an upper tool (21); an inner heater (200) carried by the upper tool (21) and having a heating surface (201) configured to heat at least a part of a film portion (18a); a peripheral heater (202) carried by the upper tool (21) and positioned radially outside with respect to the inner heater (200), the peripheral heater (202) having a heating surface (203) configured to heat seal to the at least one support (4) at least a peripheral region of said film portion (18a); a supply unit (300) configured to control energy supplied to said peripheral heater (202) and to said inner heater (200); and a control device (100) acting on the supply unit (300) and configured for commanding the supply unit (300) and control a supply of energy to the peripheral heater (202) independently from a supply of energy to the inner heater (200). Use of the apparatus and process using the apparatus are also disclosed.