Packer Machine Sealing Wrapping Sheet Reinforcement Element
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Solution Overview
Problem
Current methods for producing rigid packs of cigarettes with sealed inner wraps face challenges in maintaining high quality and productivity while minimizing damage to cigarettes during the folding and heat-sealing processes, which can cause deformation and overheating.
Innovation Solution
A packer machine and wrapping method that utilize a pre-cut wrapping sheet with a reinforcement element and a specific folding technique, including 'fin folds' and 'soap-bar folds', to create a sealed wrap with precise and squared-off folds, minimizing stress on cigarettes and allowing for high-speed production without damaging the cigarettes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is applied during heat-sealing to ensure sealing quality, then sealing reliability is improved, but cigarette damage increases
Solution Approach 1:
A protective layer is introduced between the sealing device and the cigarettes. This intermediary layer absorbs the sealing pressure and prevents direct contact between the sealing mechanism and the cigarettes, thereby ensuring proper sealing while protecting the cigarettes from damage.
Solution Approach 2:
The protective layer is positioned in advance before the sealing operation to cushion the impact of sealing pressure. This pre-positioned protective element absorbs the mechanical stress during heat-sealing, preventing transmission of damaging forces to the cigarettes while maintaining sealing effectiveness.
2Reliability
If high temperature is applied during heat-sealing to ensure sealing, then sealing reliability is improved, but tobacco overheating occurs
Solution Approach 1:
The protective layer serves as a thermal barrier between the heat-sealing device and the tobacco. This intermediary material allows heat transfer sufficient for sealing while blocking excessive heat from reaching the tobacco, preventing overheating and maintaining sealing reliability.
Solution Approach 2:
The thermal properties of the protective layer are optimized to control heat transfer during sealing. By adjusting the material composition and thickness, the heat transmission characteristics are modified to allow adequate sealing temperature while preventing excessive heat from damaging the tobacco.
3Reliability
If wrapping sheet folding is performed to create sealed wrap, then sealing functionality is improved, but cigarette deformation occurs
Solution Approach 1:
The protective layer acts as a cushioning intermediary during the folding process. It absorbs mechanical stresses and prevents direct pressure points from causing deformation to the cigarettes while still allowing the wrapping sheet to be folded into the required sealed configuration.
Solution Approach 2:
The protective layer is positioned beforehand to cushion the folding action. This pre-positioned protective element absorbs the mechanical impact during sheet folding, preventing deformation of the cigarettes while enabling the formation of the sealed wrap structure.
4Reliability
If traditional folding methods are used to create sealed wrap, then sealing is achieved, but manufacturing efficiency decreases
Solution Approach 1:
The protective layer enables more efficient folding operations by reducing the force required and preventing deformation. This intermediary allows for faster, more consistent folding cycles while maintaining sealing quality, thereby improving manufacturing efficiency without compromising reliability.
Solution Approach 2:
The protective layer modifies the mechanical parameters of the wrapping system, allowing for reduced pressure and faster folding speeds. This changes the operational parameters to enable high-speed production while maintaining sealing quality through the cushioning effect of the protective material.
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 the production of high-quality sealed packs with precise folds at high speeds, reducing cigarette damage and ensuring optimal heat-sealing without deformation or overheating, while also allowing for easy accessibility and format changes in the packer machine.
Implementation Method 1
the heat-sealing of the overlapping portions of the wrapping sheet made of waterproof material
Implementation Method 2
a reinforcement element, which is arranged inside the sealed wrap in contact with the group of cigarettes
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A packer machine (22) and wrapping method to produce a rigid pack (1) for smoking articles having: a sealed wrap (3), which is obtained by folding a wrapping sheet (10) around a group (6) of smoking articles, and an outer container (2), which is obtained by folding a blank (21) around the sealed wrap (3). The following are provided: a forming conveyor (26), which moves at least a first pocket (25) along a forming path (PI); a wrapping conveyor (27), which is designed to move the group (6) of smoking articles and the wrapping sheet (10) along a first straight and horizontal wrapping path (P2) so as to at least partially fold the wrapping sheet (10) around the group (6) of smoking articles; a first transfer station (S2), where the group (6) of smoking articles is directly transferred from the first pocket (25) of the forming conveyor (26) to the first wrapping conveyor (27); a first feeding station (S3), which is arranged downstream of the first transfer station (S2) and where the wrapping sheet (10) is coupled to the group (6) of smoking articles moving along the first wrapping path (P2); a wrapping drum (30), which supports at least one second pocket (31) designed to contain the sealed wrap (3) being formed and is mounted so as to rotate around a vertical rotation axis (32) in order to move the second pocket (31) along a second wrapping path (P3) with a circular shape; a second transfer station (S4), where the sealed wrap (3) being formed is directly transferred from the first wrapping conveyor (27) to the second pocket (31) of the first wrapping drum (30); and at least one sealing device (34; 62), which is arranged along the second wrapping path (P3) downstream of the second transfer station (S4) and is configured to seal overlapping portions of the wrapping sheet (10) in the area of a lower wall of the sealed wrap (3) being formed.