Flexible Envelope Bag Manufacturing with Waste-Free Hem Bonding
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Solution Overview
Problem
Existing bag manufacturing processes face limitations in speed and waste generation, require high technical expertise for adjustments, and do not effectively incorporate reinforcement layers for mechanical and thermal protection.
Innovation Solution
A process and machine that unreeled flexible material, forms hems on edges, applies adhesive, and folds them to create waste-free envelope-type bags with optional reinforcement layers, allowing for easy width adjustments and high-speed production without generating waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the tube is cut into sections with waste piece removal, then the bag manufacturing process can be completed, but waste material is generated and production speed is limited
Solution Approach 1:
The continuous strip is divided into sections by transverse cuts, but unlike prior art, the sections are designed to be joined end-to-end without waste removal. The segmentation allows for continuous production while eliminating waste generation.
Solution Approach 2:
Instead of discarding the waste piece between sections, the invention recovers it by joining the ends of adjacent sections together. The waste piece is transformed into a useful bonding area through adhesive application, converting what would be discarded material into a functional element of the bag structure.
2Ease of manufacture
If perforated lines are used for separation and tearing, then sections can be formed, but the process requires high technical expertise for adjustment when changing bag formats
Solution Approach 1:
The perforation system is made adjustable and dynamic, allowing the position and configuration of perforations to be changed easily when bag formats need to be modified. This enables quick reconfiguration without requiring complex mechanical changes to the entire system.
Solution Approach 2:
The cutting and perforation system is designed to handle multiple bag formats and types using the same basic machinery. By making the system universal, it can accommodate different widths, lengths, and configurations without requiring specialized equipment for each format.
3Strength
If reinforcement layers are added for mechanical and thermal protection, then bag strength is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention uses composite structures by combining the flexible strip material with reinforcement layers. These layers can be纸质 reinforcement, plastic film, or other materials that provide enhanced mechanical strength and thermal protection while maintaining flexibility.
Solution Approach 2:
The reinforcement layers are applied in advance during the manufacturing process, before the bags are cut and assembled. This preliminary application of reinforcement simplifies the overall process by integrating the strengthening step into the main production line rather than requiring separate post-processing operations.
4Ease of manufacture
If the strip is folded and bonded to form envelope bags, then the bag structure is created, but adhesive is required and adds to the process complexity
Solution Approach 1:
The folding and bonding process is designed to be self-service where the bag structure itself facilitates the bonding. The flaps are folded in a way that naturally positions them for adhesive application and bonding, reducing the need for complex positioning and alignment systems.
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
Enables high-speed, waste-free production of flexible bags with reinforcement layers for enhanced mechanical and thermal protection, easy format changes, and improved cutting quality.
Implementation Method 1
adhesive is applied to the hems at least over one length of the first or second flap on one seam face, the folding bringing for each edge hem against hem by the seam face in such a way as to obtain bonding of the hems to each other
Data Source
AI summary
A method for manufacturing flexible bags, including: a first strip of flexible material is unwound as a continuous sheet in a longitudinal direction; a hem is formed on each edge of the first strip and the hems are glued over at least one length of a first or a second flap on one stitching face; a fold is formed in the first strip along a transverse folding line to fold down the first flap over the second flap against an internal face of the first strip, the fold bringing, for each edge, hem against hem so as to obtain the bonding of the hems, the strip is cut along a transverse section to form the bag at the end of the operations. Machine implementing the method and bag thus obtained.