Heating Body Laminated Base Material Rotary Heat Sealing
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Solution Overview
Problem
Conventional heating bodies, such as disposable warmers, face challenges in achieving sufficient strength and durability during high-speed production using rotary heat-sealing rolls, leading to issues like peeling and edge breakages when used to insert hands or hands are worn.
Innovation Solution
A heating body design featuring a laminated structure with a nonwoven fabric layer and a heat-sealable resin layer, combined with an olefin-based nonwoven fabric and resin film, bonded using rotary heat-sealing rolls, ensuring strong bonding strengths and preventing peeling, while allowing for easy insertion of body parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat sealing is performed using conventional methods with sealable nonwoven fabric, then bonding can be achieved, but sufficient strength is not obtained and peeling occurs between layers
Solution Approach 1:
The patent uses a composite base material consisting of a nonwoven fabric layer and a heat-sealable resin layer bonded together. The nonwoven fabric provides structural integrity and comfort, while the heat-sealable resin layer provides strong, reliable bonding when heat-sealed to the covering material, preventing peeling between layers.
Solution Approach 2:
The patent changes the material parameters by introducing a heat-sealable resin layer with specific melting point and bonding characteristics. This resin layer is designed to melt and bond at controlled temperatures, creating strong seals that maintain integrity under the thermal and mechanical conditions of high-speed production and use.
2Productivity
If high-speed production using rotary heat-sealing rolls is implemented, then productivity increases, but seal strength becomes insufficient due to shorter heating contact time
Solution Approach 1:
The heat-sealable resin layer is specifically formulated with thermal and rheological parameters that enable rapid bonding. The resin melts and flows quickly at the brief contact time provided by rotary heat-sealing rolls, then solidifies to form strong seals, allowing high-speed production without sacrificing seal strength.
Solution Approach 2:
The patent applies heat sealing locally only at the peripheral edge portions where the heat-sealable resin layer is positioned. This concentrated local bonding approach ensures sufficient seal strength is achieved in the critical sealing zones even with the short contact time of high-speed rotary sealing, while the rest of the material maintains its structural properties.
3Strength
If vertical seal is performed with higher surface pressure, then seal strength improves, but edge breakage occurs due to cutting of packaging material
Solution Approach 1:
The heat-sealable resin layer is positioned specifically at the peripheral edge portions to provide localized bonding. This allows the sealing pressure to be concentrated where needed for strong seals while avoiding excessive pressure on the bulk material that would cause edge breakage. The resin layer acts as a pressure-distributing medium that protects the packaging material edges.
Solution Approach 2:
The heat-sealable resin layer serves as an intermediary between the sealing process and the packaging material. It absorbs and distributes the sealing pressure, providing the necessary bond strength while protecting the packaging material edges from the high pressure that would otherwise cause breakage.
4Ease of manufacture
If multiple heat-sealing processes with different temperature settings are performed, then bonding can be achieved, but production complexity and time increase
Solution Approach 1:
The patent combines multiple sealing functions into a single heat-sealing operation. The heat-sealable resin layer is designed to perform both the bonding function and the sealing function simultaneously in one process step, eliminating the need for multiple separate heat-sealing processes with different temperature settings.
Solution Approach 2:
The heat-sealable resin layer is designed with multi-functional properties: it provides structural support, enables bonding to the covering material, and allows sealing in a single heat-sealing process. This universal material eliminates the need for multiple specialized sealing steps, simplifying the manufacturing process.
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 the production of heating bodies with excellent bonding strengths, suitable for both hand-held and wearable use, reducing defects and improving productivity and economy in manufacturing.
Implementation Method 1
heat sealing a one-surface side laminated base material comprising a first base material and a second base material, and a covering material, at a peripheral edge portion
Implementation Method 2
a sheet in which an olefin-based nonwoven fabric layer and a resin film are laminated using an olefin-based resin
Implementation Method 3
a heat-generating composition that generates heat in the presence of air
Data Source
AI summary
A heating body, in which a heat-generating composition that generates heat in the presence of air, is accommodated in a bag body formed by heat sealing a one-surface side laminated base material including a first base material and a second base material, and a covering material, at a peripheral edge portion thereof. The first base material has a nonwoven fabric layer and a heat sealable resin layer; and the second base material is a sheet in which an olefin-based nonwoven fabric layer and a resin film are laminated using an olefin-based resin. The first base material and the second base material are capable of forming a space into which a body part can be inserted or held. The heat sealable resin layer and the nonwoven fabric layer are bonded together, and the resin film of the second base material and the covering material are bonded together.