Real-time Lamination Packaging Machine for Perishable Food
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Solution Overview
Problem
Existing packaging methods require significant logistical effort and are costly due to the need for pre-manufactured composite materials that are impermeable to liquids and gases, especially when packaging perishable food products.
Innovation Solution
A method and machine that laminate a flat sheet of material with a film in real-time, creating a composite material with a receiving surface that can be used for packaging, allowing for the use of alternative materials like cardboard or paper, and sealing the product with a skin film without additional heat sealing, ensuring impermeability and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-manufactured multi-layer base elements are used to ensure impermeability to liquids and gases, then packaging quality for perishable food products is improved, but manufacturing cost and logistical effort increase
Solution Approach 1:
The patent combines the base element and the protective impermeable layer into a single integrated structure. The outer packaging element is manufactured with an integrated barrier layer that provides both structural support and impermeability to liquids and gases, eliminating the need for separate multi-layer base elements and reducing both manufacturing complexity and logistical requirements.
Solution Approach 2:
The patent employs composite material construction for the outer packaging element, combining materials with different properties to achieve both structural integrity and impermeability. The integrated barrier layer is formed from composite materials that provide gas and liquid resistance while maintaining the structural requirements for packaging support.
2Reliability
If separate multi-layer base elements are manufactured and kept in stock, then packaging performance is ensured, but device complexity and inventory requirements increase
Solution Approach 1:
The outer packaging element is designed as a universal component that performs multiple functions simultaneously: structural support, barrier protection, and product containment. This multi-functional design eliminates the need for separate specialized base elements for different packaging scenarios, reducing inventory requirements while maintaining packaging performance.
Solution Approach 2:
The patent merges the functions of structural support and barrier protection into a single integrated outer packaging element, eliminating the need to maintain separate stocks of base elements and protective layers, thereby reducing inventory complexity while ensuring packaging performance.
3Ease of manufacture
If cardboard or paper base elements are used, then cost is reduced and environmental friendliness is improved, but impermeability to liquids and gases is lost
Solution Approach 1:
The patent uses composite material construction where a cardboard or paper base is combined with an integrated barrier layer that provides impermeability to liquids and gases. This composite structure maintains the cost-effectiveness and environmental benefits of paper-based materials while adding the necessary protective barrier properties through the integrated layer.
Solution Approach 2:
The patent applies local quality enhancement by adding barrier properties specifically where needed - the integrated barrier layer is applied to the outer packaging element at the locations requiring liquid and gas resistance, while the rest of the structure can remain as cost-effective paper or cardboard 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
This approach reduces logistical effort and costs by integrating material lamination into the packaging process, enabling the use of inexpensive and environmentally friendly materials while ensuring the product is sealed effectively, maintaining the quality of perishable items.
Implementation Method 1
The laminating station (7) is configured to bond a laminating film (13) to a flat sheet of material (15) using heat and pressure
Implementation Method 2
a conveyor device (19) which is configured to convey the composite material (17) along a conveying direction (F) out of the laminating station (7), to the insertion section (9) and further to the sealing station (11)
Implementation Method 3
the sealing station (11) is configured to apply a top film (23) to the receiving surface (21) of the composite material (17) carrying the product (3), so that the product (3) is enclosed between the top film (23) and the composite material (17)
Data Source
Figure 1~4
AI summary
The method for packaging products (3) comprises producing a composite material (17) in a laminating station (7) by bonding a laminating film (13) onto a flat sheet of material (15), wherein the composite material (17) has a receiving surface (21) formed by the laminating film (13), conveying the composite material (17) by a conveying device (19) along a conveying direction (F) out of the laminating station (7), to an insertion section (9) and further to a sealing station (11), positioning a product (3) to be packaged on the receiving surface (21) of the composite material (17) in the insertion section (9) and sealing a top film (23) to the receiving surface (21) of the composite material (17) supporting the product (3) in the sealing station (11), so that the product (3) is enclosed between the top film (23) and the composite material (17).