Lidding Web Pleating Mechanism for Indicia Alignment
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Solution Overview
Problem
Existing lidding systems for sealing open-topped containers face challenges in accurately aligning indicia on the lidding web with the containers, often requiring stretching or complex servo-driven systems, which can compromise seal quality and material integrity.
Innovation Solution
A feed control system that includes indicia sensing means, transversely extending web adjustment bars, and a programmable logic controller to form pleats in the lidding web, adjusting the position of indicia relative to the containers, eliminating the need for stretching and complex rewind systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If stretching or complex servo-driven systems are used to align indicia on the lidding web with containers, then alignment accuracy is improved, but seal quality and material integrity are compromised
Solution Approach 1:
The system dynamically adjusts the position of the lidding web by forming pleats at controlled locations along the web. This dynamic adjustment allows real-time correction of alignment deviations without stretching the material, thereby maintaining seal quality while achieving accurate indicia alignment with container flanges.
Solution Approach 2:
Instead of adjusting alignment in the linear feed direction (one dimension), the system introduces pleats that create localized dimensional changes in the transverse direction. This multi-dimensional approach allows the web to be repositioned laterally without stretching, resolving the contradiction between alignment accuracy and material integrity.
2Measurement precision
If stretching is used to align indicia on the lidding web, then alignment accuracy is improved, but material integrity is compromised
Solution Approach 1:
The system employs dynamic pleat formation that allows the lidding web to be repositioned through controlled localized deformation rather than continuous stretching. This dynamic adjustment mechanism corrects alignment errors while maintaining the overall structural integrity and strength of the material.
3Measurement precision
If complex servo-driven rewind systems are used to control lidding web feed, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The invention extracts and eliminates the complex servo-driven rewind subsystem from the lidding system. By using a simpler pleat formation mechanism driven by basic actuators, the system achieves alignment control without the complexity of servo motors, encoders, and sophisticated feedback control systems.
Solution Approach 2:
The pleats act as an intermediary mechanism that simplifies the control system. Instead of using complex servo-driven web tension and position control, the pleats provide a mechanical means to adjust web position with simple actuators, reducing overall system complexity while maintaining alignment accuracy.
4Measurement precision
If the lidding web is stretched to align indicia, then alignment accuracy is improved, but seal quality deteriorates
Solution Approach 1:
The system dynamically forms and releases pleats to adjust web position. This dynamic pleat mechanism allows the web to be repositioned without the continuous stretching that would compromise seal quality. The pleats are formed temporarily during alignment correction and then flattened out before sealing, ensuring optimal seal quality.
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
Ensures accurate alignment of indicia on the lidding web with containers without stretching the material, maintaining seal quality and simplifying the lidding process by avoiding contamination and complex servo systems.
Implementation Method 1
a web adjustment bar which extends transversely relative to the linear direction of travel of the carrier plates and which is moveable between a raised position wherein the web adjustment bar is spaced above the web of lidding material and a lowered position wherein the web adjustment bar depresses the lidding web downwardly into a space defined between two longitudinally-adjacent carrier plates so as to form a pleat in the lidding web
Data Source
AI summary
A lidding system for heat sealing a lidding web onto open-topped plastic containers includes a heat sealing head including heat sealing dies and a number of carrier plates for supporting a queue of containers. The carrier plates are displaced past the sealing head and define transverse slots between them. The system includes an optical sensor for sensing the a position of labels on the lidding web, and further includes a pair of pleating bars movable in a vertical direction and extending transversely relative to the direction of travel of the carrier plates. The system includes a PLC linked to the optical sensor for actuating displacement of the pleating bars into lowered positions wherein the bars are received in the slots to form pleats in the lidding web, thereby adjusting the position of the labels relative to the containers, in response to the labels not being sufficiently aligned with the containers.