Packaging Machine Parallel Transport Connecting Film Troughs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging machines have a low cycle rate, limiting their efficiency in producing packaging trays with integrated structural elements.
Innovation Solution
A packaging machine that intermittently transports a film web along a first direction, forming troughs by deep-drawing, which are then connected to structural elements in a connecting station, where the structural elements are transported parallel to the film web, allowing for higher cycle rates and easy separation of the components after use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the film web is transported intermittently with troughs formed by deep-drawing and connected to structural elements in a connecting station, then the cycle rate increases, but the device complexity increases due to the additional connecting station and parallel transport mechanism
Solution Approach 1:
The packaging process is divided into separate functional stations: a forming station for creating troughs in the film web, and a connecting station for attaching structural elements. This segmentation allows each station to operate independently and simultaneously, increasing the overall cycle rate while managing complexity through functional decomposition.
Solution Approach 2:
The transport direction of the structural elements is arranged parallel to the film web transport direction, rather than perpendicular or intersecting. This dimensional arrangement allows both the film web and structural elements to be conveyed simultaneously through the connecting station without interference, enabling higher productivity while maintaining manageable device complexity.
2Productivity
If the structural elements are transported parallel to the film web in the connecting station, then the cycle rate increases, but the transport system complexity increases
Solution Approach 1:
The transport systems for the film web and structural elements are merged into a single connecting station, where both are conveyed parallel to each other. This combination allows the connection operation to occur during the transport phase itself, eliminating separate positioning and handling steps, thereby increasing cycle rate while keeping the transport system relatively simple.
Solution Approach 2:
Instead of transporting structural elements perpendicular to or intersecting with the film web path, they are conveyed parallel to the film web in the same directional plane. This dimensional arrangement simplifies the transport system geometry while enabling simultaneous conveyance and connection, improving productivity without significantly increasing complexity.
3Reliability
If the troughs are connected to structural elements while the film web is at a standstill or being transported, then the connection quality is maintained, but the production speed is reduced
Solution Approach 1:
The connection between troughs and structural elements is performed continuously during the transport of the film web, rather than requiring the film web to stop at each connection point. This continuous operation maintains connection quality through stable sealing processes while significantly improving production speed by eliminating idle time between connections.
Solution Approach 2:
The connecting station is designed to handle both the film web and structural elements in parallel transport, allowing the connection operation to occur in the same directional flow rather than requiring perpendicular or stopping-based operations. This enables continuous production while maintaining reliable connections.
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 achieves higher cycle rates and provides enhanced mechanical properties and insulation for packaging trays, ensuring effective preservation and protection of contents while allowing for easy handling and separation of components.
Implementation Method 1
While the film web is at a standstill, the troughs are formed into the film web, in particular by deep-drawing. For this purpose, the film web is usually heated up.
Implementation Method 2
The structural element can also be used for insulation, in particular when the package contents have been heated.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a packaging machine in which a film web is transported intermittently along a first transport direction and depressions are formed in the film web at the same time and these depressions are each joined in a connecting station to a structural element, the structural elements and/or a material web from which the structural elements are produced being transported along a second transport direction. The present invention further relates to a method for producing a package and to a package.