Rotating Carousel Thermoforming Station for Flexible Container Production

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Solution Overview

Problem

Conventional thermoforming machines for thermoplastic sheet-like blanks in continuous FFS packaging lines lack flexibility, operate at low speeds, and require extensive modifications to accommodate different container diameters, making them uneconomical and space-incompatible.

Innovation Solution

A thermoforming station with a continuously rotating carousel equipped with radially spaced thermoforming heads that receive and deform heated thermoplastic sheet-like blanks into containers, allowing for continuous processing and efficient handling, and featuring a method that includes feeding blanks to the heads, deforming them into container shape, and releasing them at an angularly spaced region.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional linear machines are used for thermoforming, then the machine structure is simple and easy to manufacture, but the flexibility to accommodate different container diameters is extremely low and extensive modifications are required

Engineering Contradiction:

Improveflexibility to accommodate different container diametersVSAvoidmachine structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by replacing the fixed linear machine structure with a rotating carousel that continuously moves blanks through the thermoforming process. The carousel allows the machine to dynamically adapt to different container diameters by adjusting the positioning of heating zones and forming tools relative to the rotating blanks, eliminating the need for extensive structural modifications when changing container sizes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotating carousel design serves multiple functions simultaneously: it transports blanks, provides continuous heating, enables thermoforming, and facilitates container ejection. This multi-functional approach allows a single machine structure to handle various container diameters and types, improving versatility without requiring separate dedicated sections for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If intermittent operation is used to move disks and containers to fixed stations, then the machine structure is simpler, but the processing speed is low

Engineering Contradiction:

Improveprocessing speedVSAvoidcontinuous rotation mechanism

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements continuous operation by rotating the carousel continuously through the entire thermoforming process. Blanks are fed onto the rotating carousel, heated, formed, and ejected in a continuous flow rather than being moved intermittently between fixed stations. This continuous rotation eliminates idle time and significantly increases processing speed while maintaining manageable mechanical complexity through standardized carousel components.

Inventive Principle:

Principle #20Continuity of useful action

3Volume of moving object

If a spool is used to feed thermoplastic material, then material supply is continuous, but the volume occupied is considerably greater than sheet-like blanks

Engineering Contradiction:

Improvespace occupied by material storageVSAvoidmaterial feeding efficiency

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

The patent replaces the permanent, space-consuming spool system with disposable or recyclable sheet-like blanks that are fed individually or in batches onto the rotating carousel. These blanks occupy minimal storage space compared to a spool while maintaining continuous material supply capability. The blanks can be easily replaced and disposed of after use, eliminating the need for large material storage volumes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 higher speed processing, continuous thermoforming, improved manipulation of blanks, and increased reliability, ease of implementation, and cost-effectiveness, overcoming the limitations of prior art by allowing flexible adaptation to different container sizes without significant machine modifications.

Implementation Method 1

receive at least one heated thermoplastic sheet-like blank

Methodology Applied

Scientific EffectThermal softening: Heating

Implementation Method 2

plastically deforming said blanks until they are brought to the shape of a container

Methodology Applied

Scientific EffectPlastic deformation: Deformation

Data Source

PatentUS11691328B2Station for thermoforming thermoplastic sheet-like blanks for thermoforming lines and a corresponding method

Publication Date: 2023.07.04 IMA IND MASCH AUTOMATICHE SPA

AI summary

A station for feeding closing seals for containers, which includes at least one fixed magazine of seals which is provided with an outlet from which the seals can be taken individually. The station includes a carousel for feeding seals which can rotate with respect to a first central rotation axis and is provided with pickers which are radially spaced apart from the first rotation axis. The pickers are individually rotatable about a second rotation axis which is not parallel to the first axis of the carousel. During the rotation of the carousel, at least one picker can is configured to rotate about the second axis from a position for taking the seal from the magazine to a position for releasing the seal.