Induction Sealing Head Curved Conductor for Weak End Seals
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Solution Overview
Problem
Existing induction sealing heads for automatic machines used in forming and filling containers for pourable products result in cross seals that are weak at the ends, prone to breakage under normal mechanical stress due to reduced extension by 50-60% compared to the central area.
Innovation Solution
The induction sealing head features a tubular conductor element with curved 'U'-shaped flat walls and a narrowing at the ends, which enhances the sealing strength by directing the induced heat and magnetic field more internally, increasing the seal's resistance and robustness, while being simple and inexpensive to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tubular conductor element is used in the induction sealing head, then the sealing process can be automated and performed efficiently, but the cross seals become weak at the ends with reduced extension by 50-60%
Solution Approach 1:
The patent applies local quality by modifying the conductor element geometry specifically at the ends (curving the flat walls and adding narrowing) to concentrate magnetic field and heat generation where needed, while maintaining a different configuration in the central area. This localized geometric modification ensures that the ends receive sufficient thermal energy to create strong seals without compromising the overall sealing efficiency of the device.
2Strength
If the conductor element geometry is modified to enhance end sealing, then seal resistance increases, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent employs curvature by transforming the straight flat walls of the tubular conductor element into curved surfaces at the ends. This curvature, combined with the narrowing, creates a geometric feature that naturally concentrates the magnetic field and induced heat at the seal ends. The curved geometry is manufactured as an integrated feature of the conductor element, avoiding the need for separate components or complex assembly procedures.
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 significantly increases the resistance of cross seals at the ends, enhances the sealing capacity, and reduces production costs by minimizing material waste and shortening manufacturing time.
Implementation Method 1
an induction sealing head provided with a tubular (namely internally hollow) conductor element
Implementation Method 2
The tubular conductor element is embedded in a support body made of a plastic material which is over-moulded around the tubular conductor body itself
Implementation Method 3
The operating surface of the induction sealing head is partly formed by the tubular conductor element and partly by the support body
Implementation Method 4
an outer layer made of transparent polyethylene (heat-sealable as it melts at relatively low temperatures)
Data Source
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AI summary
Induction sealing head (16) for an automatic machine (9); the induction sealing head (16) has: a tubular conductor element (20) having at least one first flat wall (21) which defines a sealing area and has a non-straight shape; and a support body (22) of insulating material surrounding the tubular conductor element (20) and having a second flat wall (23), which is coplanar with the first flat wall (21) and surrounds the first flat wall (21); the first flat wall (21) of the tubular conductor element (20) has: one single straight central portion (26), two straight end portions (27) which are parallel and not aligned with the straight central portion (26), and two curved portions (28) which join the straight central portion (26) to the two straight end portions (27).