Folding Element for Tray Edge Alignment in Sealing
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Solution Overview
Problem
Tray sealing machines face challenges in aligning and sealing cardboard tray edges due to the risk of crushing from conventional sealing plates, which can lead to inadequate sealing and preheating of lid films.
Innovation Solution
A packaging machine with a sealing station featuring a folding element that gently aligns the tray edge by bending it from a vertical to a reduced inclination, allowing for precise alignment and integration of shaping and sealing processes, preventing pre-sealing of the lid film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional sealing plate presses on the tray edge from above with almost vertical force, then the sealing process can be performed, but the upright box edge can be crushed
Solution Approach 1:
The folding element performs preliminary action by folding the upright tray edge into a horizontal position before the sealing element applies pressure. This preliminary folding action prevents the edge from being crushed during sealing, as it is already in the correct horizontal orientation when the sealing plate presses down.
Solution Approach 2:
The sealing device is segmented into two functional elements: a folding element that handles the tray edge orientation and a sealing element that handles the lid film sealing. This segmentation allows each element to perform its specific function optimally without interfering with the other, preventing crushing while ensuring proper sealing.
2Productivity
If the sealing element contacts the lid film directly, then sealing can be performed, but preheating of the lid film may cause it to adhere too early
Solution Approach 1:
The folding element performs preliminary action by folding the tray edge horizontally before the sealing element contacts the lid film. This timing sequence prevents preheating of the lid film, as the folding action occurs first when the sealing element is not yet in contact with the lid film, avoiding premature adhesion.
Solution Approach 2:
The folding element acts as an intermediary between the sealing element and the lid film. It performs the edge folding function first, then the sealing element can proceed to seal the lid film without causing preheating, as the intermediary folding action has already prepared the tray edge in the correct position.
3Manufacturing precision
If the tray edge is folded into a horizontal position, then the sealing element can press better from above, but the folding process requires additional tooling
Solution Approach 1:
The folding element and sealing element are merged into a single sealing device assembly that moves together as one unit. This merging allows both folding and sealing functions to be performed in sequence within the same device structure, achieving precise edge alignment without requiring completely separate tooling systems.
Solution Approach 2:
The sealing device is designed with multi-functionality, where the same device structure performs both the folding action (through the folding element) and the sealing action (through the sealing element). This universal design reduces overall device complexity compared to having separate dedicated tools for each function.
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The invention relates to a packaging machine (1) with a sealing station (6) comprising a lower tool part (11) with at least one tray holder (10) and an upper tool part (12) with at least one sealing device (23), wherein the sealing device (23) has a sealing element (24) configured to seal a lid film (8) onto a tray rim (37) of a packaging tray (5) provided in the tray holder (10), characterized in that the sealing device (23) further comprises a folding element (25) configured to deform an edge region (18) of the packaging tray (5) provided in the tray holder (10) from a first orientation (A) into a second orientation (B) with a reduced inclination (a) relative to a horizontal support plane (L) compared to the first orientation (A).to align the tray rim (37) for a sealing process (S) relative to a sealing surface of the sealing element (24). Furthermore, the invention relates to a method for sealing a lid film (8) to a tray rim (37).