Packaging Apparatus Gusset Formation Using Compressive Elongate Members
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Solution Overview
Problem
Forming gussets in film tubes during the packaging process is complex, costly, and slows down the operating speed of form, fill, and seal (FFS) packaging machines, while achieving a neat and aesthetic appearance is difficult.
Innovation Solution
A packaging machine apparatus with a receptacle, ram, and film dispensing assembly that extends the ram to eject material into a film tube, forms a partial vacuum, and uses moveable elongate members to compressively engage the film tube, creating folded flaps while dispensing plastic film to form a sealed package with gussets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gusset-forming capabilities are added to FFS packaging machines, then the appearance quality of packaged products is improved, but the device complexity and cost increase
Solution Approach 1:
The gusset-forming function is segmented from the main sealing process and integrated into the existing jaw assembly. The elongate members with laterally extending sealing portions are divided into distinct functional zones: a compression portion for forming gussets and a sealing portion for sealing the package. This segmentation allows the gusset-forming capability to be added without requiring a completely separate mechanism, thus improving appearance quality while limiting the increase in device complexity.
Solution Approach 2:
The jaw assembly is designed to perform multiple functions: it seals the package and simultaneously forms gussets. The elongate members serve dual purposes by having both sealing portions for sealing and compression portions for gusset formation. This multi-functionality allows the machine to achieve improved appearance quality without adding separate dedicated gusset-forming equipment, thereby avoiding excessive increase in device complexity and cost.
2Manufacturing precision
If gusset-forming capabilities are added to FFS packaging machines, then the appearance quality of packaged products is improved, but the operating speed decreases
Solution Approach 1:
The gusset-forming operation is merged with the sealing operation in a single integrated action. As the jaw assembly closes to seal the package, the elongate members simultaneously compress the film to form gussets. This merging of operations means that gusset formation does not add a separate time step to the packaging cycle, thereby maintaining operating speed while achieving improved appearance quality.
Solution Approach 2:
The film is pre-formed with gusset features during the film forming process before packaging. The elongate members are designed with specific geometries that guide and shape the pre-formed film features into final gussets during the sealing operation. This preliminary preparation of the film structure allows gussets to be formed quickly during sealing without requiring complex real-time forming operations, thus preserving operating speed.
3Manufacturing precision
If complex gusset-forming mechanisms are used, then the appearance quality of gussets is improved, but the difficulty of achieving neat and aesthetic appearance increases
Solution Approach 1:
The elongate members are designed with non-uniform cross-sections and varying geometries along their lengths to create specific local compression effects. The sealing portions have different dimensions and properties than the compression portions. This local quality variation in the elongate members allows precise control over gusset formation at specific locations, achieving neat and aesthetic appearance without requiring complex overall mechanism design.
Solution Approach 2:
The film itself is designed with pre-formed features and memory that allow it to self-form into gussets when compressed by the elongate members. The film's inherent properties and pre-prepared structure enable it to automatically fold and shape into aesthetically pleasing gussets without requiring complex external forming mechanisms. The elongate members simply provide the compression force needed to activate the film's self-forming capability.
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 machine efficiently forms packages with aesthetically pleasing gussets, improving the packaging machine's gusset-forming capabilities without significantly increasing complexity or cost, and maintaining operational speed.
Implementation Method 1
retracts the ram into the receptacle to form at least a partial vacuum within the film tube between the batch of material and the ram
Data Source
AI summary
A packaging apparatus including a receptacle, a ram, a film dispensing assembly and first and second elongate members. The receptacle defines a central axis and has a dispensing end with first and second substantially linear and parallel opposed edges that define an axial limit of the dispensing end. The plastic film material forms a film tube about the receptacle. The first and second elongate members are substantially parallel with the first and second edges. In operation, the ram is extended to eject the batch of material through the dispensing end into the film tube. Retracting the ram forms a partial vacuum within the film tube between the batch of material and the ram. The first and second elongate members compressively engage the film tube between the batch of material and the dispensing end and thereby form folded flaps in the film tube. A method of packaging is also disclosed.