Integrated Bag Making Machine with Synchronized Sealing and Die-Cutting
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Solution Overview
Problem
The existing systems for producing rolls of pre-cut bags with die-cut handles are complex, costly, and inefficient, particularly due to the separation of heat-sealing and die-cutting stations and the laborious process of format changes, which leads to idle times and reduced production capacity.
Innovation Solution
A compact, integrated machine that combines heat-sealing, pre-cutting, and die-cutting stations with a stopping mechanism to maintain continuous film feeding, allowing for synchronized operations and easy format changes, along with a winding station that adjusts tension to ensure uniform rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat-sealing and die-cutting stations are separated, then each station can be optimized independently, but the overall system becomes complex and costly
Solution Approach 1:
The patent combines the heat-sealing station and die-cutting station into a single integrated machine. The heat-sealing unit with heating elements and the die-cutting unit with cutting blades are positioned adjacent to each other on the same machine frame, allowing both operations to be performed sequentially on the film without requiring separate machines. This merging reduces system complexity and cost while maintaining the ability to optimize each function independently through dedicated control mechanisms.
2Manufacturing precision
If format changes are performed manually and laboriously, then precise adjustments can be made, but idle times increase and production capacity decreases
Solution Approach 1:
The patent incorporates adjustable components that can be dynamically repositioned to accommodate different bag formats. The heat-sealing station and die-cutting station include movable elements such as adjustable heating element positions, repositionable die-cutting blades, and variable film tensioning mechanisms. These dynamic adjustments allow quick format changes without manual laborious operations, maintaining both precision and productivity by enabling rapid reconfiguration while the machine remains operational.
3Productivity
If the die-cutting station acts on moving film, then continuous production is maintained, but timing coordination between stations becomes difficult
Solution Approach 1:
The patent designs the integrated machine to maintain continuous film feeding through the heat-sealing and die-cutting stations. The film passes continuously through both units without interruption, and the machine includes mechanisms to compensate for timing variations. The heat-sealing and die-cutting operations are performed in close succession on the moving film, with the machine's control system coordinating the timing of both stations to ensure proper sequencing while maintaining continuous production flow, eliminating idle times.
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 simplifies operations, reduces idle times, and increases production capacity by synchronizing heat-sealing and die-cutting stations and enabling the production of uniform rolls on a single winding axis, making the process more efficient and cost-effective.
Implementation Method 1
a heat-sealing and pre-cutting station, to produce a strip of heat-sealed, pre-cut bags from the tubular film
Data Source
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AI summary
A machine (1) continuously fed by at least one flattened tubular film (2) made of plastic material and suitable for producing and winding at least one strip of pre-cut bags (4) with die-cut handles comprises a winding station (40) for the at least one strip of bags (4) and, for each tubular film (2), at least: - a heat-sealing and pre-cutting station (6), suitable for producing a strip of heat-sealed, pre-cut bags (4) from the tubular film (2); - means (8-14) suitable for temporarily stopping sliding of a portion of tubular film (2) with respect to the heat-sealing and pre-cutting station (6); - a die-cutting station (7), acting on the portion of tubular film (2) whose sliding is stopped by said stopping means (8-14), suitable for die-cutting the tubular film (2) or the strip of heat-sealed, pre-cut bags (4) produced by the heat-sealing and pre-cutting station (6). Either the die-cutting station (7) or the heat-sealing and pre-cutting station (6) is fixed, whilst the other station is mounted on a slide (15), movable on a support plane (16), to adapt the distance between the die-cutting station (7) and the heat-sealing and pre-cutting station (6) to the length of the bags (4) to be produced.