Food Container Web Separation Using Laser-Scored Connecting Edges
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Solution Overview
Problem
Existing methods for producing and filling food containers, particularly those made of high-tenacity materials like PET or PP, face challenges in varying container dimensions and separation due to the rigidity of cutting tools, leading to increased maintenance costs and difficulty in replicating the process.
Innovation Solution
An apparatus and method utilizing a laser emitter to create weakening portions between adjacent containers, allowing for flexible shaping and separation, which includes a device for forming and filling containers, and a separate section for the laser emitter to operate effectively on high-tenacity polymeric materials like PET and PP.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cutting blades or cutters are used to provide weakening portions at connecting edges, then the process can separate accommodation receptacles into groups, but the device complexity increases and maintenance costs rise due to the rigidity of cutting tools
Solution Approach 1:
The patent replaces the mechanical cutting system (blades and cutters) with a laser-based system. The laser emitter creates weakening portions by melting or vaporizing the polymeric material at the connecting edges, eliminating the need for complex mechanical cutting apparatus and reducing device complexity while improving ease of manufacture.
Solution Approach 2:
The patent changes the physical state and properties of the polymeric material through laser heating. By controlling the laser parameters (power, duration, focal point), the material undergoes localized melting or vaporization at the connecting edges, creating weakening portions without requiring mechanical force or complex cutting tool adjustments.
2Reliability
If cutting blades or cutters are used to provide weakening portions, then separation of receptacles is achieved, but the lifespan of blades or cutters decreases significantly, increasing maintenance costs
Solution Approach 1:
The laser-based system replaces mechanical cutting blades that suffer from wear and degradation. The laser emitter creates weakening portions through thermal processing, eliminating contact with the polymeric material and thus eliminating wear, significantly extending the duration of action of the separation system.
Solution Approach 2:
The patent effectively makes the cutting tool (laser emitter) non-consumable compared to mechanical blades. While the laser may require periodic maintenance, it does not wear down like mechanical blades, eliminating the need for frequent replacement and reducing maintenance costs over time.
3Strength
If high-tenacity materials like PET or PP are used to make containers, then container strength increases, but it becomes practically impossible to provide weakening portions without using scissors or cutters, increasing device complexity
Solution Approach 1:
The laser system changes the physical state of the high-tenacity polymeric material (PET or PP) at the connecting edges by heating it to melting or vaporization temperature. This localized thermal processing creates weakening portions in materials that would otherwise be too strong for mechanical separation, maintaining container strength while enabling separation.
Solution Approach 2:
The laser emitter applies energy locally at the connecting edges between containers, creating weakening portions only where needed. The body of the containers maintains their full strength and integrity, while the connecting edges are selectively modified to enable separation, achieving local quality change.
4Manufacturing precision
If cutting blades are positioned closer to produce incisions through substantial thickness of PET material, then weakening portions can be created, but the lifespan of cutters decreases and costs increase
Solution Approach 1:
The laser system replaces mechanical cutters that must be positioned extremely close together to penetrate thick PET material. The laser beam can be focused to a precise point and moved along the connecting edge, creating weakening portions without the need for complex positioning mechanisms or multiple blades, reducing manufacturing cost while maintaining precision.
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 flexible and cost-effective production of food containers with high industrial productivity, allowing for easy variation in container shape and separation, reducing maintenance costs and extending tool lifespan.
Implementation Method 1
providing a weakening portion (21) at a connecting edge (22) between at least two adjacent accommodation receptacles (11) by means of laser radiation (40)
Implementation Method 2
the provision step comprising a step of emitting laser radiation (40) at least on a portion of the connecting edge (22) to provide a localized reduction of the transverse cross-section of the connecting edge (22) along the weakening portion (21)
Data Source
AI summary
An apparatus for the production and filling of food containers includes at least one device for forming a sheet made of polymeric material to provide accommodation receptacles which have at least one access opening, at least one filling unit adapted to fill, through the access opening, the accommodation receptacles with at least one type of food, and at least one sealing unit to seal the access opening with a closure film. The apparatus includes at least one device for removing portions, and at least one laser emitter for providing a weakening portion at a respective connecting edge between adjacent accommodation receptacles. The polymeric material is chosen from polyethylene terephthalate and polypropylene and copolymers thereof. The apparatus includes a first section which accommodates the filling unit, the sealing unit, and the device for removing portions, and a second section, separate from the first section, which accommodates the laser emitter.