Inflation Sealing Device PTFE Release Film
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Solution Overview
Problem
Existing methods for manufacturing inflatable flexible structures for packaging are inefficient due to material wastage, poor alignment, and susceptibility to under-inflation or leakage, as well as issues with film layers sticking to machine surfaces during the inflation and sealing process.
Innovation Solution
A web inflation device with a mechanism to inflate and seal films using a fluid, featuring a sealing mechanism with a heating element and post-seal control elements made of polytetrafluoroethylene (PTFE) to improve seal quality and a material release structure that reduces the force required to separate the sealed plies, ensuring efficient and reliable inflation and separation of cushions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat is used to bind two layers of film together forming a seal, then sealing strength is improved, but the films may stick to machine surfaces
Solution Approach 1:
A release film is introduced as an intermediary between the heated sealed plies and the machine surfaces (rollers, belts, or chains). This release film prevents direct contact and adhesion between the hot film and machine surfaces, eliminating the sticking problem while allowing the seal to maintain its strength. The release film acts as a temporary barrier that facilitates smooth passage through the sealing and cooling zones.
2Manufacturing precision
If high pressure is used in the sealing mechanism, then seal quality is improved, but the force required to separate sealed plies increases
Solution Approach 1:
The release film serves as a mediator between the sealed plies and the separation mechanism. It reduces the adhesion force between the sealed layers by providing a low-friction interface, thereby decreasing the force required to separate the plies after sealing while maintaining high seal quality through adequate sealing pressure.
Solution Approach 2:
The introduction of the release film changes the friction parameter at the interface between sealed plies and machine surfaces. By selecting a release film with appropriate surface properties (low coefficient of friction), the separation force is reduced without compromising the seal integrity, as the seal forms before the plies contact the release film.
3Ease of operation
If films are delivered to the nozzle with freedom and slack, then alignment control is simplified, but inflation efficiency decreases
Solution Approach 1:
The films are pre-aligned and tensioned in a controlled manner before reaching the inflation nozzle. This preliminary alignment action ensures that the films are properly positioned and taut, eliminating the need for complex real-time alignment control during inflation while maximizing inflation efficiency. The alignment is established upstream, allowing the nozzle to operate at optimal speed.
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 device enhances the efficiency and speed of forming inflated cushions by minimizing material wastage, improving alignment, and reducing the likelihood of under-inflation or leakage, while also preventing the film layers from sticking to machine surfaces, resulting in more effective packaging solutions.
Implementation Method 1
The sealing mechanism may include a heating element that heats the plies to form the seal
Implementation Method 2
The first post-seal control element may be made from a material having a low coefficient of friction, such as polytetrafluoroethylene (PTFE)
Data Source
AI summary
The present disclosure is related to an inflation and sealing device that can include low or non-stick surfaces and bump-off elements to prevent sticking to a holding region proximal to the exit from the inflation and sealing device.