Patterned Induction Heating Roller for Movable Web Packaging

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Solution Overview

Problem

Existing packaging apparatuses for articles enclosed between flexible sheets with thermally-activated adhesives are limited to speeds of 50-60 m/min due to insufficient adhesive transfer at higher speeds, and heating rollers face inefficiencies in heating and maintaining temperature, leading to compromised quality and speed limitations.

Innovation Solution

An apparatus and method using induction heating with thermally conductive and insulating areas on heating rollers, combined with separate overlapping and compression units, allows for rapid and localized heating of flexible sheets with thermally-activated adhesives, ensuring efficient adhesive transfer and higher production speeds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the speed of the packaging apparatus is increased beyond 50-60 m/min, then productivity is improved, but the pressure rollers are unable to give sufficient energy for correct adhesive transfer, compromising quality

Engineering Contradiction:

Improvepackaging speedVSAvoidadhesive transfer quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The heating roller heats the adhesive layer on the flexible sheet before the compression rollers apply pressure. This preliminary heating action ensures the adhesive is in the correct state for transfer, allowing the system to operate at higher speeds while maintaining quality adhesive transfer.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the purely mechanical pressure-based adhesive transfer system with a thermal field-based system. By using induction heating to heat the adhesive layer, the system enables faster operation while maintaining controlled adhesive transfer quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If heating rollers are used to activate thermally-activated adhesive, then adhesive transfer is enabled, but heat dispersion through metal components causes very large energy consumption

Engineering Contradiction:

Improveadhesive activationVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The heating roller is designed with localized heating zones corresponding to the positions where adhesive activation is needed. The roller surface has regions of different thermal properties, concentrating heat only where required rather than heating the entire roller uniformly, thus reducing energy consumption.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention replaces conventional conductive heating systems with induction heating. This substitution eliminates heat dispersion through metal components by generating heat directly in the adhesive layer through electromagnetic induction, significantly reducing energy consumption while maintaining reliable adhesive activation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If conventional heating methods are used, then adhesive heating is achieved, but thermal inertia and insulation characteristics cause slow heating and long warm-up time after prolonged stops

Engineering Contradiction:

Improveadhesive heatingVSAvoidwarm-up time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The invention replaces conventional conductive or radiant heating with induction heating. This substitution eliminates thermal inertia limitations by directly generating heat in the adhesive layer through electromagnetic induction, achieving rapid temperature rise and minimizing warm-up time after prolonged stops.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Induction heating can be applied in periodic pulses rather than continuous operation. The system can rapidly heat the adhesive layer when needed and then stop, reducing overall energy consumption and eliminating the need for prolonged warm-up periods while maintaining the ability to heat quickly when required.

Inventive Principle:

Principle #19Periodic action

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

Enables high-speed packaging without compromising package quality by rapidly heating flexible sheets with induction heating, maintaining adhesive integrity and reducing energy consumption and thermal dispersion.

Implementation Method 1

a heating device for heating thermally conductive areas, wherein the heating device comprises at least one induction heater electromagnetically coupled to the thermally conductive areas of the outer surface of the heating roller

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

the heating device comprises at least one induction heater electromagnetically coupled to the thermally conductive areas of the outer surface of the heating roller

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4151541B1An apparatus and method for heating a movable web

Publication Date: 2025.11.05 FAMECCANICA DATA SPA

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AI summary

A heating unit for heating a continuous web (18, 20), comprising a heating roller (44) rotating about an axis of rotation (46) and having an outer surface (86) comprising a pattern of thermally conductive areas (88) and thermally insulating areas (90), and at least one induction heater (98) electromagnetically coupled to the thermally conductive areas (88) of the outer surface (86) of the heating roller (44).