Induction Heating Sealing Device Uniform Splice Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing induction heating sealing devices generate non-uniform heating patterns at splice areas in packaging material, leading to inadequate melting of heat-seal plastic material and improper sealing.
Innovation Solution
The induction heating sealing device features a unique inductive element with a first leg having projections and slits, generating eddy currents that are primarily perpendicular to the advancing direction, ensuring uniform heating across the splice area by minimizing border effects and maintaining the heat-seal plastic material in a melted state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional inductive element is used for heating sealing, then the sealing process can be performed, but the heating pattern is non-uniform at splice areas leading to inadequate melting of heat-seal plastic material
Solution Approach 1:
The inductive element is divided into multiple independent coils arranged in a matrix pattern, allowing each coil to be individually controlled. This segmentation enables precise localization of eddy currents to specific areas of the packaging material, ensuring uniform heating across the entire sealing surface including splice areas.
Solution Approach 2:
Different regions of the inductive element are designed with varying coil densities and configurations to match the specific heating requirements of different areas. The matrix arrangement provides different local heating characteristics - higher density in critical sealing areas and lower density in adjacent regions, achieving optimal uniformity across the entire sealing zone.
2Temperature
If heating is applied to seal the packaging material, then the heat-seal plastic material melts and forms a seal, but border effects cause non-uniform heating distribution
Solution Approach 1:
The inductive element uses asymmetric coil configurations within the matrix arrangement, with coils positioned and sized differently to compensate for edge effects. This asymmetric design creates a more uniform magnetic field distribution that minimizes border effects and achieves homogeneous heating across the entire sealing area.
Solution Approach 2:
The matrix arrangement of multiple coils serves multiple functions simultaneously: it provides uniform heating distribution, minimizes border effects, allows independent control of different heating zones, and accommodates variations in packaging material properties. This multi-functional design makes the system universally applicable to different sealing requirements.
3Manufacturing precision
If the inductive element generates eddy currents for induction heating, then the heat-seal plastic material melts, but the heating pattern shows cold zones that prevent proper sealing
Solution Approach 1:
The system dynamically controls the activation and power level of individual coils in the matrix based on real-time feedback from temperature sensors. This dynamic adjustment ensures that all areas, including previously problematic cold zones, receive adequate heating to achieve consistent sealing quality across the entire sealing surface.
Solution Approach 2:
Temperature sensors positioned at various locations including former cold zones provide real-time feedback to the control system. The control system uses this feedback to adjust the power distribution to individual coils, ensuring that temperature uniformity is maintained and cold zones are eliminated, resulting in consistent sealing quality.
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
This design results in a significantly more uniform heating pattern, reducing the risk of incomplete sealing and enhancing the sealing process by maintaining the heat-seal plastic material in a melted state, thereby improving the integrity of the packaging material's longitudinal seal.
Implementation Method 1
the alternate current flowing inside the inductive elements generates an alternate magnetic field flux that generates eddy currents in the aluminium layer to melt the heat-seal plastic material locally
Implementation Method 2
the alternate current flowing inside the inductive elements generates an alternate magnetic field flux that generates eddy currents
Implementation Method 3
the heat-seal plastic material layer of the second longitudinal edge, which transmits heat by conduction to the first longitudinal edge and the sealing strip
Implementation Method 4
the sealing strip, the first longitudinal edge and the second longitudinal edge are pressed together, so that the heat-seal material of the sealing strip and the heat-seal plastic material layers of the first longitudinal edge and the second longitudinal edge blend completely and form the molecular bonds defining the longitudinal seal
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An induction heating sealing device (30) for sealing a packaging material comprises an electrically conductive layer and advancing, in use, along a first direction (A), said induction heating sealing device (30) comprising an inductive element (100), said inductive element (100) comprising a first leg (31) and a second leg (32) extending along said first direction (A) and within which, in use, an alternate current flows, said first leg (31) having a first body (33) facing a second body (34) of said second leg (32) and at least one projection (35) laterally projecting from said first body (33) and facing, in use, an area (53) of said packaging material to be sealed and being configured to induce, in use, an eddy current within said area (53).