Former With Insert For Packaging Material Flow
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Solution Overview
Problem
The existing formers used in bag manufacturing and packaging machines are difficult to fabricate accurately, leading to issues like wrinkles, scratches, and tears in packaging material due to incorrect shape and dimensions, resulting in reduced quality and increased costs. Current methods rely on manual trial and error, which is time-consuming and inefficient.
Innovation Solution
A former with an insert made from thicker sheet metal, secured flush to the main former, providing additional reinforcement and a smooth surface to reduce friction and improve material flow, along with a raised textured surface to decrease friction and facilitate smooth material transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trial and error method is used to fabricate former, then final shape can be obtained, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by providing pre-calculated former design data including specific radius of curvature values (0.27mm to 0.50mm) and surface roughness specifications (<10 µm) before the manufacturing process begins. This eliminates the need for trial-and-error shaping during fabrication.
Solution Approach 2:
The patent applies parameter changes by specifying exact dimensional parameters (radius of curvature between 0.27-0.50mm, surface roughness less than 10 µm) that must be achieved during former fabrication. These predetermined parameters guide the manufacturing process to produce consistent results without repeated adjustments.
2Reliability
If former shape and dimensions are not correct within close tolerance, then packaging material quality deteriorates with wrinkles and tears, but achieving close tolerance increases manufacturing difficulty
Solution Approach 1:
The patent applies parameter changes by establishing specific dimensional parameters (radius of curvature 0.27mm-0.50mm, surface roughness <10 µm) that ensure packaging material integrity. These parameters are built into the manufacturing process to achieve consistent results without requiring excessive manufacturing complexity.
Solution Approach 2:
The patent applies segmentation by dividing the former into distinct functional zones with specific geometric parameters - the radius of curvature zone for material guidance and the surface finish zone for friction reduction. This segmentation allows each zone to be optimized independently for its specific function.
3Ease of operation
If radius of curvature of former top is increased, then material flow improves, but former size and complexity increase
Solution Approach 1:
The patent applies parameter changes by optimizing the radius of curvature to specific values (0.27mm to 0.50mm) that provide sufficient material flow smoothness while keeping the former geometry compact. This precise parameter control achieves the desired material flow without excessive size or complexity.
Data Source
AI summary
A former provides an insert at the lip of the former to enable packaging material to travel smoothly over the former. The insert lays smoothly on the top surface of the former. The insert is sized approximately one half the width of the packaging material that travels over the insert. The former provides a raised textured surface that enables the packaging material to travel over the former into the aperture. The insert constructed with a smooth top surface is located adjacent at least a portion of the aperture. The insert provides a smooth surface for the packaging material to travel across when entering the aperture.