Inductive Sealing Bar with Embedded Coil and Planarized Interface
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Solution Overview
Problem
Sealing bars used for carton-based packages face issues with deformation due to high temperatures, leading to a damaged interface between the coil and the plastic body, which reduces the quality of the sealing process.
Innovation Solution
A method for manufacturing a sealing bar involves embedding a conductive coil with heating zones in a supportive polymeric body, planarizing both the coil and body simultaneously using a material-removing process like milling, and overmolding the coil to ensure a uniform interface, with optional magnetic inserts for enhanced sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sealing bar uses a plastic body to support the coil, then the sealing bar can be manufactured with a planar surface, but the plastic body deforms under high temperatures during sealing
Solution Approach 1:
The patent applies composite materials by combining the coil (conductive material) with a plastic body (polymer material) to create a sealing bar that integrates both structural support and heating functions. The composite structure allows the plastic body to provide mechanical support and planar surface while the coil provides the necessary heating capability for sealing operations.
2Strength
If the coil is embedded in the plastic body, then the interface is supported structurally, but the interface becomes damaged due to thermal deformation
Solution Approach 1:
The patent applies parameter changes by modifying the thermal and mechanical parameters of the plastic body through material selection and design adjustments. The plastic body is engineered to withstand the specific temperature ranges and mechanical stresses encountered during sealing operations, preventing deformation that would damage the coil interface.
3Productivity
If the sealing bar operates at high temperatures for efficient sealing, then sealing quality improves, but the plastic body deforms from its original shape
Solution Approach 1:
The patent addresses thermal expansion by designing the plastic body and coil assembly to accommodate thermal dimensional changes. The structure is engineered to allow for controlled thermal expansion and contraction during heating and cooling cycles, preventing permanent deformation while maintaining sealing effectiveness at elevated temperatures.
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 provides a robust sealing bar with a uniform interface between the coil and the supportive body, reducing the risk of deformation and improving the sealing quality by maintaining close contact and heat distribution across the sealing surface.
Implementation Method 1
The coil will consequently induce eddy currents, which causes heat to be generated in the aluminum foil
Implementation Method 2
The sealing bar includes a coil, and an electrical current is allowed to flow through the coil. The coil will consequently induce eddy currents
Implementation Method 3
The generated heat will melt the polymeric materials adjacent to the aluminum foil, whereby these layers will bond to each other
Data Source
AI summary
A method for providing an inductive sealing bar, comprises providing a conductive coil having at least one heating zone, embedding the coil in a supportive body such that the supportive body covers the entire coil along at least some part of the length of the at least one heating zone; and providing a sealing surface of the sealing bar by planarizing the coil and the supportive body such that the coil is exposed along the entire length of said at least one heating zone. The invention also relates to a sealing bar manufactured according to the method.