Movable Sealer Sleds for Continuous Bag Making
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Solution Overview
Problem
Existing bag and pouch machines have limitations in flexibility and footprint due to their continuous or intermittent motion designs, which restrict their ability to switch between different applications, materials, and seal types, and often require extensive setup times and large footprints.
Innovation Solution
A machine with a track system and multiple sleds, each equipped with operating stations that move independently along the track, allowing for continuous operation without reversing direction, and a controller that adjusts operation duration and station positioning based on material thickness and user settings, enabling flexible operation and reduced footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous motion machines are used to form seals while the web moves, then productivity is improved, but the machine footprint and complexity increase due to rotary drums or shuttles requiring extensive space for each operation station
Solution Approach 1:
The patent applies dynamics by making the sealer movable rather than stationary. The sealer travels with the web through the sealing zone, converting a static multi-station system into a dynamic single-station system. This allows continuous production without requiring extensive footprint for multiple fixed operation stations.
Solution Approach 2:
The movable sealer performs multiple functions within a single traveling unit: it applies heat, applies pressure, and maintains contact throughout the sealing zone. This consolidates what would traditionally require separate stationary stations into one universal sealing device that moves with the web.
2Adaptability or versatility
If intermittent motion machines are used to perform operations while the web is stopped, then setup flexibility is improved, but productivity decreases due to repeated starting and stopping of the web
Solution Approach 1:
The patent eliminates interruptions by maintaining continuous web motion throughout the sealing process. The sealer moves synchronously with the web, ensuring that sealing action occurs continuously without stopping the web, thereby maintaining high productivity while preserving flexibility through programmable sealer motion profiles.
Solution Approach 2:
The system maintains adaptability through dynamic control of the movable sealer's position, speed, and sealing parameters while the web continues moving. This allows different sealing profiles and configurations without requiring web stops, combining flexibility with continuous production.
3Manufacturing precision
If multiple stationary operation stations are used to perform different operations, then manufacturing precision is improved, but device complexity and footprint increase
Solution Approach 1:
The patent replaces multiple stationary stations with a single movable sealer that travels through the sealing zone. The sealer maintains precise positioning relative to the web through synchronized motion control, achieving the same sealing precision as multiple stations without the associated complexity and footprint.
Solution Approach 2:
The patent merges multiple sealing functions into one traveling sealer unit. Instead of having separate heat application, pressure application, and positioning systems at different stations, all these functions are integrated into a single movable device that performs the complete sealing operation in one pass.
4Speed
If rotary drums or shuttles are used for sealing, then sealing speed is improved, but the time required for shuttle reversal and return to starting position limits overall machine speed
Solution Approach 1:
The patent extracts the time-consuming reversal and return motion from the sealing process. By making the sealer travel continuously with the web in one direction, the system eliminates the need for shuttle reversal and return trips, removing the time loss entirely from the production cycle.
Solution Approach 2:
The movable sealer maintains continuous sealing action throughout its travel with the web, without interruption for reversal or repositioning. The useful sealing action is continuous and uninterrupted, maximizing the proportion of time spent performing productive work versus idle repositioning.
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 design allows for efficient production of bags and pouches with reduced footprint, improved flexibility in switching between applications, and faster setup times, as operating stations can be automatically reconfigured without stopping the machine, enhancing operational efficiency and reducing expertise requirements.
Implementation Method 1
forming seals using sealers, heating performed by heaters
Implementation Method 2
a sealer forms a seal on the film by applying a force to the film
Data Source
AI summary
A method and apparatus for making bags or pouches is disclosed. It includes a track, at least two sleds that move on the track, and operating stations mounted on the sleds. The film moves along the track, and the sleds move with the film while performing operations on the film. The system can have the sled stationary while operating for an intermittent machine, and move to reconfigure when the film is moving. The operating stations include one or more of a sealer, a heater, a cooler, an inserter, a knife, a punch, a perforator, a static charger, and a printer. The track forms a continuous path or is linear. A controller controls the sleds and operating stations. The controller includes an operating time and/or a reconfiguration module. The operating time module is responsive to a user set material thickness or a sensed material thickness.