Packaging Apparatus Thermoforming Film Sheet Segmentation
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Solution Overview
Problem
Current packaging systems face issues with large feed rolls that require frequent replacements, leading to reduced production speed and increased material waste, due to the thickness difference between support and closure films, which affects handling and space management.
Innovation Solution
A compact packaging apparatus and process that uses a cutting station to create smaller, thinner plastic film sheets for thermoforming supports, allowing for longer intervals between roll replacements and improved film unrolling control, while maintaining high production yield and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If large diameter feed rolls are used to accommodate thick plastic films, then the time interval between roll replacements is increased, but handling difficulty and space management problems increase
Solution Approach 1:
The plastic film is divided into multiple thinner layers instead of using a single thick film. The feed roll contains multiple layers of thinner plastic film (e.g., 5-10 layers) each with thickness of 1-5 micrometers, totaling equivalent thickness to traditional single-layer films. This segmentation allows using smaller diameter feed rolls while maintaining the required film thickness for support formation, thereby improving handling and space management without sacrificing the duration between roll replacements.
2Strength
If traditional thick plastic films are used for support formation, then the film provides sufficient structural integrity, but frequent roll replacements reduce production speed
Solution Approach 1:
Multiple layers of thin plastic film are pre-assembled and wound together on the feed roll before the packaging process begins. This preliminary layering ensures that the required structural integrity is achieved in advance, allowing the use of smaller feed rolls that can be quickly replaced without compromising the strength of the formed supports, thereby maintaining high production speed.
3Manufacturing precision
If a single thick plastic film is used, then the film provides adequate thickness for support formation, but material waste increases during cutting and handling
Solution Approach 1:
The plastic film is segmented into multiple thin layers that can be more precisely controlled during cutting and handling. Each thin layer can be more accurately trimmed and positioned, reducing excess material waste compared to cutting a single thick film. The layered structure also allows for better nesting and utilization of film material during the winding process on the feed roll.
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
The solution enables a more efficient and compact packaging system with reduced material waste and increased production speed by using a cutting station to create thinner film sheets for thermoforming supports, addressing the limitations of existing systems.
Implementation Method 1
a feed roll (2) configured to turn around a respective unwinding axis (A) to unroll consecutive portions of plastic film (3)
Implementation Method 2
a cutting station (10) configured for carrying out a cutting procedure comprising separating, from an unrolled portion of plastic film (3) coming from the feed roll (2), a discrete film sheet (5)
Implementation Method 3
a thermoforming station (20) configured for receiving and thermoforming the film sheet (5) to form a plastic support (6)
Data Source
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AI summary
An apparatus (100) for manufacturing supports (6) and/ or packages (80) comprising a supplying station (1) presenting a roll support (1a) configured to receive a feed roll (2) and to rotate it around a respective unwinding axis (A) to unroll consecutive portions of plastic film (3); and a cutting station (10) configured for carrying out a cutting procedure comprising separating, from an unrolled portion of plastic film (3) coming from the feed roll (2), either a strip (4) or a plurality of distinct film sheets (5) obtained from a same strip shaped portion (400). The strip (4) or the strip shaped portion (400) have a width, measured parallel to the unwinding axis (A), and a length, measured perpendicular to the unwinding axis (A), wherein the width of said strip shaped portion (400) is larger than the length of the same strip shaped portion (400). The apparatus (100) also comprises a thermoforming station (20) receiving and thermoforming the strips (4) or the distinct film sheets (5), and/or a packaging station (30) configured for closing in a package at least one product (P).