Packaging Element Seal Edge Calibration via Variable Hold-Down Force
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Solution Overview
Problem
Existing packaging element production methods often result in an uneven seal edge, which can compromise the sealing integrity and lead to leakage issues when attaching the seal.
Innovation Solution
A procedure and forming device that involve providing a pre-forming made of fiber-based package material, holding it down in a drawing gap with a hold-up, converting it into a packaging element, and calibrating the seal edge with a calibration force greater than the initial holding force to smooth out folds and ensure a consistent seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the preform is drawn into the die with a punch during forming, then the packaging element is produced efficiently, but the sealing edge becomes undefined and uneven due to uneven material flow and wrinkling
Solution Approach 1:
The patent applies preliminary action by performing a calibration step after the main forming process. The hold-down device is used again with increased force to calibrate the sealing edge, smoothing out irregularities before the seal is applied. This additional step ensures the sealing edge is uniform and ready for sealing, resolving the unevenness caused by the efficient but rough forming process.
Solution Approach 2:
The patent changes the parameter of hold-down force by increasing it from the forming stage to the calibration stage. During forming, a lower hold-down force allows material flow, but during calibration, a higher force is applied to smooth the sealing edge. This parameter change enables the transition from shaping to precision finishing.
2Ease of manufacture
If the seal is attached to an uneven sealing edge, then the sealing process is simplified, but the sealing integrity is compromised leading to leakage issues
Solution Approach 1:
The calibration step serves as a preliminary action to prepare the sealing edge before seal attachment. By smoothing the sealing edge in advance, the subsequent seal application becomes reliable without complicating the overall process. The seal can be applied in the same simplified manner, but to a pre-prepared surface that ensures integrity.
3Manufacturing precision
If the hold-down force is increased during forming, then the preform material flows more controllably, but the material flow becomes restricted causing forming defects
Solution Approach 1:
The patent applies dynamics by varying the hold-down force at different stages of the process. During forming, a lower dynamic force allows material flow. After forming, the force is dynamically increased for calibration. This dynamic adjustment optimizes both material flow during forming and edge uniformity during calibration.
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 method effectively reduces unevenness in the seal edge, enhancing the sealing integrity and preventing leakage issues during the attachment of the seal, thereby improving the overall quality of the packaging element.
Implementation Method 1
Holding the preform down by means of a hold-down device in a drawing gap of the forming device with a hold-down force
Implementation Method 2
Calibrating a sealing edge of the packaging element after step c) by the hold-down device with a calibration force that is greater than the hold-down force
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A method for manufacturing a packaging element (1) comprising at least the following steps: a) providing a preform (2) consisting at least partially of a fiber-based packaging material in a forming device (3); b) holding the preform (2) in a drawing slot (5) of the forming device (3) by means of a blank holder (4) with a holding force (29); c) forming the preform (2) into the packaging element (1) with the forming device (3); and d) calibrating a sealing edge (6) of the packaging element (1) after step c) by the blank holder (4) with a calibration force (30) that is greater than the holding force (29). Furthermore, a forming device for manufacturing a packaging element (1) is proposed.