Movable Molding Unit for Packaging Opening Devices

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Solution Overview

Problem

Existing apparatus for forming opening devices on sheet packaging material for pourable food products are limited by low output rates and increased footprint due to the need for multiple molding units and potential errors in positioning, which can lead to damage and undesired marks on the packaging material.

Innovation Solution

The apparatus employs a molding unit with movable elements and a closed-loop track system to independently position and mold opening devices on the packaging material without stopping the material flow, allowing for precise alignment and increased output rates by using a single molding unit to form one-piece opening devices with a confetti portion and pouring element.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple molding units are used to form opening devices on packaging material, then the output rate increases, but the apparatus footprint increases and positioning errors increase

Engineering Contradiction:

Improveoutput rateVSAvoidapparatus footprint

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The mold is made movable along the packaging material web rather than being stationary. The movable mold travels with the packaging material, allowing a single mold unit to perform multiple molding operations sequentially as the material passes through, thereby increasing productivity without requiring multiple stationary mold units and reducing apparatus footprint.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The molding operation is performed continuously as the packaging material moves through the apparatus. The movable mold maintains continuous contact with the packaging material web, allowing uninterrupted formation of opening devices without stopping the material flow, thus maximizing productivity while using a single compact mold unit.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If multiple molding units are used to form opening devices on packaging material, then the output rate increases, but positioning precision deteriorates

Engineering Contradiction:

Improveoutput rateVSAvoidpositioning precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The movable mold follows the packaging material web continuously, maintaining consistent positioning relative to the material's movement. This dynamic following approach eliminates positioning errors between multiple stationary units while preserving high output rate, as the single mold unit adapts its position to match the material's progression.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The apparatus incorporates means to detect and respond to the position of the packaging material web, allowing the movable mold to be precisely positioned relative to the material at any given moment. This feedback mechanism ensures accurate positioning during high-speed operation, maintaining manufacturing precision while achieving high productivity.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If the packaging material is stopped for molding operations, then positioning accuracy improves, but the output rate decreases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidoutput rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The mold moves synchronously with the packaging material web rather than requiring the material to stop. This dynamic coordination allows the mold to maintain accurate positioning relative to the material while both continue to move, eliminating the trade-off between positioning accuracy and output rate.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The molding operation continues uninterrupted as the packaging material moves through the apparatus. The movable mold performs the molding function continuously without requiring material stoppage, maintaining both positioning accuracy and high output rate simultaneously by eliminating idle time.

Inventive Principle:

Principle #20Continuity of useful action

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

This solution significantly increases the output rate of forming opening devices while reducing the footprint of the apparatus and minimizing errors, ensuring high-quality production without the need for extensive reconfiguration when changing package formats or correcting positioning discrepancies.

Implementation Method 1

the molten plastic material is injected into the mold cavity from one side thereof and is forced to flow within the mold cavity to fill it completely

Methodology Applied

Scientific EffectFluid flow under pressure: Pressure Gradient

Implementation Method 2

conveying means for advancing the packaging material along a given path

Methodology Applied

Scientific EffectMechanical conveyance: Friction

Data Source

PatentUS10493670B2Apparatus for forming opening devices on a sheet packaging material for packaging pourable food products

Publication Date: 2019.12.03 TETRA LAVAL HOLDINGS & FINANCE SA

AI summary

There is described an apparatus for forming opening devices on a sheet packaging material for packaging pourable food products; the apparatus comprises conveying means for advancing the packaging material along a given path, at least one molding unit arranged along the path and adapted to mold one opening device on a receiving portion of the packaging material, and at least one movable element carrying the molding unit and advanced parallel to at least a portion of the path to allow the molding unit to form the opening device while the packaging material is being advanced along the path.