Interchangeable Tray Packaging Station with Dynamic Sealing
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Solution Overview
Problem
Conventional heat-sealing machines for packaging trays are limited in accommodating trays of different dimensions and formats, and they cannot perform vacuum/gas heat-sealing or 'skin' packaging, often resulting in machine shutdowns and inefficiencies due to the need for frequent component substitutions.
Innovation Solution
A packaging device with a heat-sealing and cutting station featuring interchangeable lower receptacles and upper bell-shaped elements, capable of accommodating various tray sizes, combined with vacuum generation and a heating plate that can move to achieve 'skin' packaging, along with a measurement system to select the appropriate components and minimize film waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heat-sealing machines use dedicated lower dies and heat-sealing plates for specific tray types, then heat-sealing precision is improved, but adaptability to different tray dimensions and formats deteriorates
Solution Approach 1:
The patent implements a universal lower die design with an adjustable positioning system that can accommodate multiple tray formats and dimensions. The die includes adjustable elements that can be repositioned to match different tray perimeters, allowing a single die to perform heat-sealing for various tray types without requiring dedicated dies for each format.
Solution Approach 2:
The heat-sealing plate is designed with dynamic adjustment capabilities, allowing its position and configuration to be modified based on the specific tray being processed. This enables the same heat-sealing plate to adapt to different tray dimensions while maintaining sealing precision through programmable control systems.
2Adaptability or versatility
If multiple lower dies of different dimensions are mounted to process different tray formats, then adaptability is improved, but device complexity increases due to the need for multiple components
Solution Approach 1:
Instead of using multiple dedicated dies, the patent employs a single universal die with adjustable positioning mechanisms. This universal die can be reconfigured to accommodate different tray formats by adjusting its positioning elements, thereby reducing the total number of components needed while maintaining the ability to process multiple tray types.
Solution Approach 2:
The die structure is divided into modular, adjustable segments that can be repositioned independently. This segmentation allows the same die body to be configured for different tray sizes by adjusting the positioning of these modular elements, eliminating the need for complete die substitutions.
3Device complexity
If the heating plate and die cutter are kept fixed relative to the die, then device simplicity is improved, but adaptability to different tray formats deteriorates
Solution Approach 1:
The heating plate and die cutter are designed with dynamic positioning capabilities that allow them to be adjusted relative to the die based on the specific tray format being processed. This dynamic adjustment is controlled through programmable systems that automatically position these components according to the selected tray dimensions, maintaining both simplicity and adaptability.
Solution Approach 2:
The heating plate and die cutter are integrated into a universal configuration system that works with the adjustable die. This allows the same heating plate and cutter to serve multiple tray formats when combined with the adjustable die positioning, eliminating the need for dedicated components for each tray type.
4Adaptability or versatility
If frequent substitution of dies, die cutters, and heat-sealing plates is performed, then adaptability to different formats is improved, but productivity deteriorates due to machine shutdowns and dead times
Solution Approach 1:
The system incorporates dynamic, programmable adjustment mechanisms that allow rapid reconfiguration of the die and heating plate positions without physical component substitution. The control system stores parameters for different tray formats and automatically adjusts the positioning of dies and heating plates by selecting pre-programmed configurations, thereby eliminating machine shutdowns and dead times associated with component changes.
Solution Approach 2:
The system pre-programs multiple tray format configurations into its control system. Before processing a new tray format, the system automatically retrieves and applies the appropriate configuration parameters, pre-positioning the die and heating plate without requiring manual intervention or component substitution, thus maintaining continuous productivity.
5Manufacturing precision
If conventional heat-sealing machines are designed for specific tray types, then manufacturing precision is improved, but ease of operation deteriorates due to training requirements and operational complexity
Solution Approach 1:
The system incorporates automated, programmable control that manages the complex positioning and adjustment of dies and heating plates. Operators simply need to select the desired tray format from a list of pre-programmed options, and the system automatically configures all components to the correct positions and settings, maintaining high heat-sealing quality while dramatically simplifying operation and eliminating the need for specialized training.
Solution Approach 2:
The system includes self-positioning and self-adjustment capabilities that automatically configure the die and heating plate based on the selected tray format. The control system manages all complex adjustments without operator intervention, allowing operators with minimal training to achieve consistent, high-quality heat-sealing results across different tray types.
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
Enables flexible packaging of trays of various dimensions and formats without component substitutions, supports vacuum/gas heat-sealing, and 'skin' packaging, reducing machine downtime and film waste while ensuring reliability and safety.
Implementation Method 1
vacuum generation means, which are adapted to create a condition of vacuum inside the chamber
Implementation Method 2
a heating plate which is adapted to heat an area of the film (5)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A device (1) for packaging trays, which comprises a heat-sealing and cutting station (3) for heat-sealing a film (5) on the rim of a tray (7) and for cutting the film (5); the heat-sealing and cutting station (3) comprises a lower supporting surface (9) which comprises a plurality of receptacles (11) configured to accommodate trays (7) of different dimensions and/or formats; the heat-sealing and cutting station (3) comprises a plurality of upper bell-shaped elements (13) that are configured to engage with the trays (7) of different dimensions and/or formats, where the bells (13) are selectively associable with the receptacles (11) as a function of the dimensions and/or formats of the trays (7) to be processed.