Fiber Container Flange Forming Without Premature Seal Activation
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Solution Overview
Problem
Existing methods for manufacturing containers with fiber-based materials struggle to efficiently form a durable and sealable flange section using ultrasonic sonotrodes, as they often activate the sealing layer during the flattening process, leading to incomplete sealing and reduced material integrity.
Innovation Solution
A method and device utilizing an ultrasonic sonotrode arranged on one side of the spiral winding and an anvil on the opposite side to apply ultrasonic vibrations, ensuring the sealing layer remains intact while forming a flange section with multiple layers, using controlled heating and ultrasonic vibrations to enhance deformability and formability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic vibrations are applied to flatten the spiral winding, then the flange section can be formed efficiently, but the sealing layer may be activated prematurely causing incomplete sealing
Solution Approach 1:
The device is divided into two separate functional units: an ultrasonic sonotrode for flattening the spiral winding and an anvil for sealing. This segmentation allows the ultrasonic vibrations to be applied first to form the flange, and then the sealing layer is activated separately in a second step, preventing premature activation and ensuring complete sealing.
Solution Approach 2:
The ultrasonic flattening of the spiral winding is performed as a preliminary action before the sealing layer is activated. By first forming the flange section structure and then subsequently activating the sealing layer in contact with the anvil, the process ensures that the sealing function is completed only after the structural formation is finished, maintaining sealing integrity.
2Strength
If the spiral winding is flattened with high pressure, then a durable flange section is created, but the sealing layer may be damaged compromising material integrity
Solution Approach 1:
The device separates the high-pressure flattening function (ultrasonic sonotrode) from the sealing function (anvil). The ultrasonic vibrations provide the necessary pressure for durable flange formation without directly compromising the sealing layer, as the anvil is positioned to seal only after the flattening process is complete.
Solution Approach 2:
The high-pressure flattening is performed as a preliminary action before the sealing layer is subjected to pressure. The ultrasonic sonotrode first consolidates the spiral winding into a durable flange structure, and only then is the sealing layer activated against the anvil, ensuring material integrity is maintained throughout the process.
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 solution enables the creation of a robust, multi-layered flange section with an intact sealing layer, facilitating secure sealing and improved material integrity, suitable for various applications including coffee capsules.
Implementation Method 1
finishing the flange section by flattening the spiral winding while applying ultrasonic vibrations with an ultrasonic device comprising an ultrasonic sonotrode
Implementation Method 2
The ultrasonic vibrations heat the material of the shell in the region of the spiral winding for flattening
Data Source
AI summary
The invention relates to a method for manufacturing a container with a shell made of a fiber-based material, wherein the container has an open end with an opening and a closed end, wherein a flange section with a sealing surface is formed on the shell at the open end, comprising the steps: preforming the flange section by forming a spiral winding by rolling a free edge section of the shell outward, and finishing the flange section by flattening the spiral winding with an ultrasonic device comprising an ultrasonic sonotrode and an anvil, wherein the ultrasonic sonotrode for flattening the spiral winding is arranged on a side of the spiral winding in the direction of the closed end and the anvil is arranged on an opposite side of the spiral winding. The invention further relates to a device for manufacturing the container.