Inductive Sealing Machine with Ceramic Grippers for Foil Caps

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Solution Overview

Problem

Existing methods for sealing plastic and glass bottles with foil caps are costly in terms of materials and energy, and do not provide optimal sealing efficiency, especially for bottles with shorter necks and varied shapes.

Innovation Solution

A rotary turret-based machine with inductive heating and gripper assemblies, where the gripper arms are made of plastic or ceramic to avoid inductive heating, allowing for precise positioning and secure sealing of foil caps on bottles, including those with shorter necks, using a combination of inductive heating and pressure to achieve a strong and accurate seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal gripper arms are used to hold the container, then the gripping force and security are improved, but the arms are inductively heated which reduces positioning accuracy and limits use with shorter necks

Engineering Contradiction:

Improvegripping forceVSAvoidpositioning accuracy

Core Design Contradiction:

StrengthVSMeasurement precision

Solution Approach 1:

The patent replaces metal gripper arms with non-metallic (plastic or ceramic) arms to eliminate inductive heating. This substitution allows the gripper to approach the inductive heater much closer (minimum distance less than 3cm) without being heated, thereby maintaining positioning accuracy while still providing sufficient gripping force through optimized mechanical design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the inductive heater is positioned closer to the foil closure for more efficient heating, then the sealing efficiency is improved, but the risk of heating the gripper arms increases

Engineering Contradiction:

Improvesealing efficiencyVSAvoidgripper arm temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent eliminates the temperature problem by replacing metal gripper arms with non-metallic materials that are not susceptible to inductive heating. This allows the inductive heater to be positioned at optimal proximity to the foil closure (minimum distance less than 3cm) for maximum heating efficiency without concern for gripper arm overheating.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional sealing methods are used for glass and plastic bottles, then the sealing capability is maintained, but the material and energy costs increase

Engineering Contradiction:

Improvesealing capabilityVSAvoidenergy cost

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces traditional contact-based sealing methods with inductive heating technology. The inductive heater generates eddy currents in the conductive foil closure, heating it rapidly and efficiently without direct contact. This reduces energy consumption and eliminates the need for separate sealing processes for different bottle types (glass or plastic), as the inductive heating works uniformly across all container types.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If the gripper arms extend further around the neck to grip more securely, then the gripping security is improved, but the arms come closer to the inductive heater increasing heating risk

Engineering Contradiction:

Improvegripping securityVSAvoidinductive heating risk

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent replaces metal gripper arms with non-metallic arms, eliminating the inductive heating risk entirely. This allows the gripper arms to extend fully around the container neck (engaging more than 180° of the circumference, optionally at least 200°) to provide maximum gripping security without any risk of the arms being heated by the inductive heater.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 reduces material and energy costs while providing a more secure and accurate sealing process, capable of handling bottles with shorter necks and varying shapes, enhancing the strength and reliability of the seal.

Implementation Method 1

an inductive heater arranged to inductively heat a foil closure of a container

Methodology Applied

Scientific EffectInductive heating: Induction Heating

Data Source

PatentEP3878638B1Container sealing machine and method of sealing a container

Publication Date: 2024.04.24 FORDS PACKAGING SYST LTD

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Figure 4a~4b

AI summary

A container sealing machine comprising: a rotary turret having a plurality of sealing heads arranged to rotate about an axis of the rotary turret, each sealing head comprising: an inductive heater arranged to inductively heat a foil closure of a container, and a sealing surface arranged to exert pressure on the closure, and a plurality of gripper assemblies arranged to rotate about the axis of the rotary turret, each gripper assembly being arranged for engaging a neck of a container; a bottle and a closure for use in such a machine; and a machine and method for manufacturing such a closure.