Induction Sealing Head Tubular Conductor Deformation
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Solution Overview
Problem
The existing methods for manufacturing induction sealing heads are costly due to the high discard rate of noble materials, particularly copper, which results in high production costs.
Innovation Solution
A method involving a tubular conductor element with a circular section that is mechanically deformed to create a 'U'-shaped configuration, then over-moulded with an insulating material, and processed to form flat walls with curved portions and a narrowing, allowing for efficient and inexpensive production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tubular conductor element is completely embedded in the support body and then processed by milling, then the sealing head can be manufactured, but a high quantity of noble materials (particularly copper) is discarded resulting in high production costs
Solution Approach 1:
The tubular conductor element is pre-formed with a specific configuration including straight portions, curved portions, and a narrowing section before being embedded in the support body. This preliminary shaping allows the final sealing head to be obtained without requiring extensive material removal through milling, thereby reducing noble material waste while maintaining manufacturing feasibility
Solution Approach 2:
The conductor element undergoes parameter changes during its formation process, including variations in cross-sectional area (narrowing) and curvature radius (curved portions). These parameter changes are implemented in the initial forming stage rather than through subsequent material removal, optimizing material utilization and reducing waste of expensive copper material
2Manufacturing precision
If conventional manufacturing methods are used with complete embedding and milling, then the sealing head structure is achieved, but production costs increase due to material discard
Solution Approach 1:
The complex geometry of the tubular conductor element including straight portions, curved portions, and narrowing sections is pre-formed before embedding. This preliminary action ensures manufacturing precision is achieved during the forming process itself rather than requiring costly material removal operations, thereby reducing production costs while maintaining structural accuracy
Solution Approach 2:
Different sections of the tubular conductor element have locally optimized qualities: straight portions for structural stability, curved portions for flexible sealing adaptation, and narrowing sections for intensified heating action. These local quality variations are implemented in the initial forming process, achieving precise structural requirements without extensive material removal and reducing overall production costs
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 approach reduces material waste, minimizes production costs, and enhances the sealing performance by creating more resistant cross seals and intensifying the heating action, resulting in a cost-effective and robust induction sealing head.
Implementation Method 1
induction sealing head provided with a tubular (namely internally hollow) conductor element
Implementation Method 2
outer layer made of transparent polyethylene (heat-sealable as it melts at relatively low temperatures)
Data Source
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AI summary
Method for manufacturing an induction sealing head (16) for an automatic machine (9); the manufacturing method provides the steps of: providing a tubular conductor element (20) with a circular section and a straight shape; mechanically processing the tubular conductor element (20) with a circular section, so as to form at least a flat wall (21) in a central portion of the tubular conductor element (20); shaping the tubular conductor element (20) so as to give the tubular conductor element (20) a final shape; and over-moulding, around the tubular conductor element (20), a support body (22) made of insulating material.