Induction Sealing Head for Lighter, Lower-Energy Tray Packaging
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Solution Overview
Problem
Existing heating and sealing heads for packaging machines are heavy, large, energy-inefficient, and have suboptimal calorimetric performance, making them cumbersome to handle, assemble, and install, and increasing energy consumption.
Innovation Solution
A heating and sealing head using an electromagnetic inductor body to induce parasitic electric currents for heat generation, replacing traditional electric resistances, which includes a ferromagnetic intermediate heat storage plate and laminar thermal welding plates to enhance heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electric resistances are used for heating, then the heating and sealing head can achieve sealing function, but the weight and dimensions increase, making it heavy and large
Solution Approach 1:
The patent replaces traditional electric resistance heating elements with an electromagnetic induction heating system. The induction coil generates a magnetic field that induces eddy currents in the ferromagnetic intermediate plate, which then generates heat through resistive heating of the plate material itself. This substitution of heating mechanism reduces the weight and dimensions of the heating head while maintaining sealing functionality.
Solution Approach 2:
The patent introduces a ferromagnetic intermediate heat storage plate as an intermediary between the electromagnetic induction coil and the sealing surface. This intermediate plate serves multiple functions: it concentrates the induced heat, stores thermal energy, and transfers heat efficiently to the sealing surface. This intermediary enables compact design while maintaining effective heating performance.
2Reliability
If traditional electric resistances are used for heating, then the sealing function is achieved, but the dimensions of the heating and sealing head increase
Solution Approach 1:
The electromagnetic induction heating system replaces bulky electric resistance heating elements with a compact coil structure. The induction coil can be designed with smaller dimensions while generating sufficient heat through electromagnetic induction, thereby reducing the overall length and dimensions of the heating and sealing head.
Solution Approach 2:
The patent changes the heating mechanism from direct resistive heating to electromagnetic induction heating, fundamentally altering the physical parameters of the heating system. This parameter change enables more efficient heat generation with smaller components, reducing the dimensions of the heating head while maintaining sealing effectiveness.
3Temperature
If traditional electric resistances are used, then heating is provided, but energy consumption increases by 50-60%
Solution Approach 1:
The electromagnetic induction heating system replaces traditional electric resistance heating, which directly converts electrical energy to heat through resistance. Induction heating is more efficient because it generates heat directly in the ferromagnetic intermediate plate through electromagnetic induction, reducing energy losses and lowering overall energy consumption by 50-60%.
Solution Approach 2:
The patent changes the energy conversion pathway from direct electrical resistance heating to electromagnetic induction heating. This parameter change improves energy efficiency by reducing heat losses and enabling more direct energy transfer to the sealing surface, thereby reducing energy consumption while maintaining effective heating capability.
4Reliability
If traditional electric resistances are used, then sealing is achieved, but calorimetric performance is suboptimal
Solution Approach 1:
The ferromagnetic intermediate heat storage plate acts as an intermediary that improves calorimetric performance by concentrating and storing thermal energy. This intermediate plate efficiently transfers heat to the sealing surface, reducing energy losses and improving overall thermal efficiency compared to direct electric resistance heating.
Solution Approach 2:
The electromagnetic induction heating system replaces traditional electric resistance heating, improving calorimetric performance through more efficient heat generation and transfer. The induction system minimizes energy losses and provides better thermal efficiency, reducing energy waste while achieving effective sealing.
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 new design reduces weight and dimensions, lowers energy consumption by 50-60%, and improves calorimetric performance, allowing faster temperature reach and cooling, facilitating handling and assembly.
Implementation Method 1
heating means (6) comprising a single electromagnetic inductor body (8) which produces the heat due to the effect of the parasitic electric currents induced by a magnetic field generated by the electromagnetic inductor body (8) itself when crossed or affected by the electric current
Implementation Method 2
heating means (6) comprising a single electromagnetic inductor body (8) which produces the heat due to the effect of the parasitic electric currents induced by a magnetic field
Implementation Method 3
an intermediate heat storage plate (15) directly facing the electromagnetic inductor body (8) and made entirely of ferromagnetic material adapted to store the heat produced by the electromagnetic inductor body (8) itself
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A heating and sealing head (1 ) for packaging machines (M1; M2; M3) of products in trays (V), comprising a fixed support group (2) provided with first actuation means (3) electrically connected to a pneumatic system (4) for delivering compressed air, and a mobile application group (5) mechanically coupled to the fixed support group (2) by means of first fixing means and comprising heating means (6) electrically connected to an electric current generator (7), preferably alternating, which activates the heating means (6) to produce heat useful for sealing a closing and packaging film to one or more trays for containing products when the trays themselves are arranged under the heating and sealing head (1) in a packaging machine (M1; M2; M3). In particular, the heating means (6) comprise an electromagnetic inductor body (8) which produces the heat due to the effect of the parasitic electric currents induced by a magnetic field generated by the electromagnetic inductor body (8) when crossed or affected by the electric current.