O-Ring Tool Base for Forming and Sealing Stations
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Solution Overview
Problem
Commercially available horizontal form, fill, and seal packaging machines face challenges with air leaks during vacuum and vent cycles, tool changeover complexity, reduced tooling durability, and prolonged cycle times due to fragile seals in existing forming and sealing tool designs.
Innovation Solution
The new design incorporates a plurality of small o-rings positioned inside the forming and sealing o-ring tool bases, which interact with nozzles to provide a more reliable and durable sealing method, reducing air leaks and cycle times, and features squeeze limiters to extend seal gasket life, while simplifying tool changeover by reducing weight and allowing only bottom sub-assemblies to be removed during tool exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long seal is positioned on the top surface of the forming and sealing base, then sealing coverage is achieved, but the seal becomes fragile and prone to air leaks during tool changeover
Solution Approach 1:
The patent divides the single long seal into multiple small o-rings positioned inside the o-ring tool base. Each o-ring is housed in its own o-ring hole, creating segmented sealing points that are more durable and less prone to failure during tool changeover operations.
Solution Approach 2:
The o-rings are nested inside the o-ring tool base structure, specifically positioned within o-ring holes that are integrated into the base. This nesting protects the o-rings from external damage and provides a more robust sealing mechanism compared to surface-mounted seals.
2Loss of time
If vacuum and vent cycles are directed through the internal structure of the base, then cycle time is reduced, but air leaks may occur if sealing is insufficient
Solution Approach 1:
The vacuum and vent cycles are directed through multiple segmented o-ring sealing points rather than a single long seal. This segmentation allows for more precise control of vacuum/vent flow paths while maintaining sealing integrity, reducing cycle time without compromising reliability.
Solution Approach 2:
The o-rings serve as intermediaries between the vacuum/vent nozzle and the internal structure of the base. They mediate the sealing function while allowing the vacuum and vent cycles to efficiently pass through the tooling structure, achieving both speed and reliability.
3Adaptability or versatility
If the entire forming and sealing tool assembly is replaced during tool changeover, then complete tool exchange is achieved, but weight and complexity increase
Solution Approach 1:
The tooling system is segmented into modular components: the forming and sealing bases remain fixed to the machine structure, while only the bottom sub-assemblies need to be removed during tool changeover. This segmentation reduces the weight of moving parts and simplifies the changeover process.
Solution Approach 2:
The tooling design transitions from a static full-assembly replacement system to a dynamic modular system where only necessary components (bottom sub-assemblies) are exchanged. This dynamic approach optimizes tool changeover efficiency while reducing operational weight.
4Force
If the seal gasket is directly subjected to chamber force, then sealing pressure is effective, but the seal gasket wears out quickly
Solution Approach 1:
The squeeze limiters are positioned beforehand to cushion and limit the force applied to the seal gasket. These limiters prevent the chamber from bottoming out on the seal gasket, providing protective cushioning that extends the seal's service life while maintaining effective sealing pressure during normal operation.
Solution Approach 2:
The squeeze limiters act as intermediaries between the chamber force and the seal gasket. They mediate the force transmission, allowing effective sealing pressure to be applied during operation while preventing excessive force that would cause premature wear or bottoming out.
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 ensures reliable vacuum and vent cycles, accelerates machine indexing, simplifies tool changeover, and extends the life cycle of seal gaskets, resulting in improved machine performance and reduced maintenance needs.
Implementation Method 1
a plurality of small o-rings, positioned inside the forming and sealing o-ring tool base, said o-rings, when interacting with the nozzle protruding from the forming or the sealing base, provide more dependable and more durable, method of sealing off the internal structure from the environment
Implementation Method 2
shortening the vacuum and vent cycle times
Data Source
AI summary
Forming and sealing tool assemblies, utilized in conjunction with the commercially available, horizontal, form, fill and seal packaging machines, manually interchangeable with other forming and sealing tools assemblies, modifiable to accommodate the varying product shapes and sizes.1. The forming tool assembly, designed to form the bottom portion of the package, is sub-divided into two sub-assemblies, the top and the bottom. a. The top sub-assembly, comprises of a forming chamber, and a forming heater. The bottom sub-assembly, releasably attached to a forming base containing a nozzle directing the vacuum and vent cycles, comprises of a forming o-ring tool base, a forming tool and a plurality of forming tool inserts.b. When utilizing the forming tool assembly, the packaging machine feeds into the forming station the first layer of the packaging film, where said packaging film is engaged by the top and the bottom sub-assemblies of the forming tool assembly, wherein i. the top sub-assembly projects the heat onto the packaging film, positioned directly above the forming pockets of the forming tool, andii. the bottom sub-assembly, using the vacuum and vent cycles traveling from the vacuum system, through the forming base nozzle, through the air dispersing pocket shapes of the forming o-ring tool base, through the forming pockets of the forming tool, into the small air holes of the forming tool inserts, pulling the packaging film up against the bottom and side panels of said forming inserts, causing the packaging film to retain the shape of said forming tool inserts, thus pre-forming the bottom portion of the package.2. The sealing tool assembly, designed to form the top portion of the package, is sub-divided into two sub-assemblies, the top and the bottom. a. The top sub-assembly, comprises of a sealing chamber, and a sealing heater. The bottom sub-assembly, releasably attached to a sealing base containing a nozzle directing the vacuum and vent cycles, comprises of a sealing o-ring tool base, a sealing tool with squeeze stoppers, and a sealing gasket.b. When utilizing the sealing tool assembly, the packaging machine using the conveying chain, transfers the pre-formed, and filled with product, bottom portion of the package, into the sealing station. Here, the machine feeds the second layer of the packaging film, and engages the top and the bottom sub-assemblies of the sealing tool assembly, wherein i. the top sub-assembly, while generating the heat, is lowered and sandwiches together, the first layer (forming the bottom of the package) and the second layer (forming the top portion of the package) of the packaging film, against the seal gasket protected by the squeeze limiters, andii. the bottom sub-assembly, using the vacuum and vent cycles traveling from the vacuum system, through the sealing base nozzle, through the air dispersing pocket shapes of the sealing o-ring tool base, into the sealing pockets of the sealing tool, evacuates the excess air from the interior of the package, sealing together the first and the second layer of the packaging film, completing the forming and sealing process of the package.