Foil Closure Sealing Machine With Inductive Heating and Rotary Grippers
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Solution Overview
Problem
The manufacturing of plastic and glass bottles with foil caps is costly in terms of materials and energy, and existing sealing technologies lack accuracy and efficiency.
Innovation Solution
A rotary turret-based container sealing machine with inductive heaters and gripper assemblies that securely hold bottles, allowing for precise sealing of foil caps using inductive heating and pressure, combined with a machine for manufacturing closures with a wider recess portion, enabling more secure and efficient sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plastic or glass bottles with foil caps are used, then container strength and sealing are achieved, but manufacturing cost and energy consumption increase
Solution Approach 1:
The patent employs composite materials by combining aluminum foil for the closure with plastic for the bottle body. The aluminum foil cap provides superior strength and sealing properties, while the plastic bottle offers lightweight construction and lower energy consumption during manufacturing compared to traditional glass or all-plastic alternatives. This composite approach resolves the contradiction by achieving high reliability through the aluminum component while maintaining energy efficiency through the plastic container body.
2Manufacturing precision
If conventional sealing machines are used, then sealing function is provided, but sealing accuracy and efficiency are insufficient
Solution Approach 1:
The patent replaces conventional mechanical heating systems with inductive heating technology. The inductive heater generates electromagnetic fields that directly induce currents in the aluminum foil cap, providing rapid and precise heating. This substitution dramatically improves sealing accuracy by enabling controlled thermal processing and enhances productivity through faster heating cycles compared to traditional contact-based mechanical heating methods.
Solution Approach 2:
The sealing machine incorporates a rotary turret with multiple sealing heads that can dynamically adjust their positions and orientations. The gripper assemblies are designed to rotate and adapt to different bottle positions, allowing the system to maintain optimal sealing contact dynamically. This dynamic capability enables the machine to handle varying bottle types and sizes while maintaining high sealing accuracy and efficiency.
3Strength
If gripper arms contain metallic materials, then structural strength is achieved, but inductive heating accuracy deteriorates due to interference
Solution Approach 1:
The patent extracts metallic materials from the gripper arm construction to eliminate interference with inductive heating. The gripper arms are fabricated from non-conductive materials such as ceramic or plastic, which do not interact with the electromagnetic fields generated by the inductive heater. This extraction of metal from the gripper structure allows the inductive heating system to operate with full precision and efficiency while the gripper maintains sufficient strength through alternative material selection and structural design.
Solution Approach 2:
The patent changes the material parameters of the gripper arms by selecting non-conductive materials with appropriate mechanical properties. By transitioning from metallic to ceramic or plastic materials, the system achieves the necessary structural strength while simultaneously eliminating electromagnetic interference. This parameter change in material composition resolves the contradiction between gripper strength requirements and inductive heating accuracy.
4Strength
If closure recess is narrow, then manufacturing simplicity is maintained, but sealing strength and security are reduced
Solution Approach 1:
The patent applies local quality by creating a wider recess portion in specific areas of the closure where enhanced sealing strength is required. The closure features a non-uniform structure with a widened recess at the sealing interface, while other portions maintain their original dimensions. This localized structural modification provides improved sealing performance and security without significantly increasing overall manufacturing complexity, as the wider recess is concentrated only where needed for enhanced bonding with the bottle opening.
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 reduces material usage, enhances sealing accuracy and strength, and improves energy efficiency in bottle manufacturing while providing a secure and recyclable container with high resistance to internal pressures.
Implementation Method 1
an inductive heater arranged to inductively heat a foil closure of a container
Data Source
AI summary
A machine for manufacturing a closure that has: a workspace for receiving a blank, a rim punch arranged to engage a blank received within the workspace, a center punch arranged radially inside the rim punch, the center punch arranged to engage the blank received within the workspace to form a closure, and an ejection pin arranged to cause the center punch to move such that the closure disengages from the rim punch.