Adaptable Sealing Station Fitting Inserts
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Solution Overview
Problem
Sealing stations face challenges in sealing packages where the product area is partially or completely above the sealing level, leading to exposure to disruptive gas flows, temperature fluctuations, and increased protective gas consumption, requiring complex and costly design modifications for different product geometries.
Innovation Solution
A sealing station with an adaptable receiving space that can be customized in shape and size using fitting inserts to accommodate various product areas, minimizing exposure to disruptive influences and allowing for efficient sealing of packages with product areas above the sealing level, including multi-layer packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the upper part is designed with fixed receiving space for products above sealing level, then the sealing process can be performed, but the device complexity increases and adaptability to different product geometries decreases
Solution Approach 1:
The upper part is designed with a movable receiving space that can be dynamically adjusted vertically. The receiving space can be positioned at different heights relative to the sealing level, allowing adaptation to various product geometries without increasing overall device complexity. This dynamic positioning capability maintains sealing reliability while reducing the need for complex fixed designs.
Solution Approach 2:
The upper part is divided into separate functional components: a movable receiving space and a sealing mechanism. This segmentation allows the receiving space to be independently adjusted for different product types while the sealing mechanism remains optimized for its function, reducing overall design complexity.
2Productivity
If the receiving space is enlarged to accommodate product areas above sealing level, then more products can be sealed, but gas flow disruptions and temperature fluctuations increase
Solution Approach 1:
The receiving space can be dynamically positioned at optimal heights for different products, minimizing the volume exposed to disruptive gas flows and temperature fluctuations. By adjusting the vertical position rather than permanently enlarging the space, the system maintains sealing capacity while reducing harmful environmental factors.
Solution Approach 2:
The receiving space is designed with differentiated zones: areas close to the sealing level maintain controlled conditions for sealing, while areas farther away can accommodate product extensions. This local differentiation allows the space to serve multiple functions without uniformly exposing all areas to harmful factors.
3Object-affected harmful factors
If protective elements are added to protect products from sealing tool influences, then product protection improves, but the device complexity and cost increase
Solution Approach 1:
Instead of adding fixed protective elements, the system uses a movable receiving space that can be positioned to naturally protect products during the sealing process. The dynamic adjustment of the receiving space provides protective functionality without requiring additional complex protective components.
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 adaptable design minimizes gas flow disruptions, reduces evacuation time, and reduces the need for extensive modifications when changing product types, enhancing the sealing process efficiency and reducing operational costs.
Implementation Method 1
sealing packages by connecting package components by applying heat and pressure, in particular by sealing or welding
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a sealing station (15) for a packaging machine, in particular for food products, for sealing packages (21) by joining package components by applying heat and pressure, in particular by sealing or welding, wherein the packages each comprise a product area containing a packaged product (10) and an edge area (55) extending alongside, in particular around, the product area, with an upper part (15a) and a lower part (15b) arranged on opposite sides of a, preferably horizontal, sealing plane (57), defining at least one chamber provided for receiving at least one package and being movable relative to each other perpendicular to the sealing plane (57) for opening and closing the chamber, wherein the upper part (15a) comprises a heatable sealing tool (59) and the lower part (15b) comprises a counter tool (61).which define a receiving space within the chamber for a respective package, wherein the sealing tool (59) and the counter tool (61) can be pressed against each other with the chamber closed and an edge area of a respective package to be acted upon being placed between them, wherein the receiving space comprises a packing space for the product area of a respective package (21) located at least partially above the sealing plane (57), wherein several separate fitting inserts (65) are provided, and wherein the packing space can be adapted to the product area of a respective package (21) with regard to size and/or shape by inserting a number n ≥ 0 of the fitting inserts (65) into the receiving space.