Ultrasonic Sealing Tool with Segmented Beads for Gusseted Pouches
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Solution Overview
Problem
Gusseted and zippered pouches are difficult to seal due to variations in layer thickness, leading to leak points and unreliable seals, especially when using ultrasonic or heat sealing technologies, and existing solutions for vertical form fill and seal equipment result in unattractive and unreliable side seals.
Innovation Solution
A sealing tool with a specially configured anvil and horn featuring distinct gusset and zipper sealing sections, including barrier and protective sealing beads, and a knife slot to create simultaneous side seals without excessive power draw or zipper damage, allowing for reliable and attractive seals across the entire length of the pouch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If heat sealing technology is used for gusseted bags, then seal width can be made wide, but hermetic seal reliability is poor
Solution Approach 1:
The sealing tool divides the seal into multiple discrete beads (first bead, second bead, third bead) with different heights and functions. The first bead creates the primary hermetic seal, the second bead reinforces it, and the third bead provides additional support, collectively achieving both wide coverage and high reliability.
Solution Approach 2:
Each sealing bead is designed with specific local properties: the first bead has maximum height for hermetic sealing, the second bead has intermediate height for reinforcement, and the third bead has minimum height for support. This localized differentiation optimizes each region's contribution to overall seal performance.
2Reliability
If ultrasonic sealing with single seal bead is used, then hermetic seal can be created, but bond strength is fragile and unable to withstand abuse
Solution Approach 1:
The single seal bead is segmented into three distinct beads with different heights and functions. The first bead provides hermetic sealing, the second bead adds reinforcement, and the third bead provides additional support, collectively enhancing both hermeticity and bond strength to withstand real-world abuse.
Solution Approach 2:
The sealing structure creates a composite seal system where multiple beads of varying depths work together, similar to composite materials combining different properties. The varying bead depths create a multi-layered sealing architecture that distributes stress and enhances overall strength.
3Manufacturing precision
If contoured cross seal anvil is used, then seal quality improves, but leak occurs at two layer section on extreme outer edges
Solution Approach 1:
The sealing tool uses multiple discrete beads instead of a continuous contoured surface. The first, second, and third beads are positioned at specific locations, with the outermost beads providing sealing at the extreme edges where contoured anvils fail, preventing leaks at two-layer sections.
Solution Approach 2:
The sealing tool design incorporates a mirrored configuration with beads positioned symmetrically on both sides. This copying approach ensures consistent sealing pressure and geometry across the seal width, preventing the edge leaks that occur with asymmetric contoured anvils.
4Reliability
If ultrasonic sealing is used on zipper end, then seal can be created, but excessive power draw occurs due to melting excessive plastic
Solution Approach 1:
The sealing beads are designed with different heights optimized for local conditions. The reduced-height beads in certain regions minimize the amount of plastic melted, reducing power consumption while maintaining adequate sealing in those specific locations.
Solution Approach 2:
Instead of using excessive compression across the entire seal width, the tool applies targeted sealing pressure only where needed through strategically positioned beads. This partial action approach creates necessary seals without unnecessarily melting excessive plastic, reducing power draw.
5Reliability
If traditional sealing tool is used, then seal can be created, but zipper is damaged and seals are unattractive
Solution Approach 1:
The sealing beads are positioned and sized to create seals only in specific locations without interfering with the zipper structure. The localized sealing action preserves the zipper's appearance and functionality while achieving reliable seals in the required areas.
Solution Approach 2:
The seal is segmented into discrete beads positioned away from the zipper teeth, preventing damage to the zipper mechanism. This segmentation allows the zipper to maintain its structural integrity and aesthetic appearance while the beads create effective seals in the pouch body.
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 provides reliable, attractive, and leak-free side seals for gusseted and zippered pouches, reducing power consumption and preventing zipper damage, while maintaining the integrity of the seal across varying pouch sizes and shapes.
Implementation Method 1
The ultrasonic sealing tool includes an anvil with a sealing surface and a horn with a sealing surface facing the sealing surface of the anvil. The ultrasonic sealing tool delivers ultrasonic vibrations via at least one of the anvil and the horn to create a closure seal
Implementation Method 2
The closure seal including a first seal created by the first bead and at least one second seal created by the at least one second bead, the first seal having a weld depth greater than a weld depth of the at least one second seal
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A sealing tool (100) includes an anvil (102) and a horn (106), at least one of which includes a sealing surface (104) having a gusset sealing section (112) and a zipper sealing section (114), each configured differently than the other. The gusset sealing section (112) includes a plurality of sealing beads (120, 122) including a gusset section barrier sealing bead (120) having a first height and a protective sealing bead (122) having a second height, the second height being smaller than the first height. The zipper sealing section (114) includes a zipper section barrier sealing bead (124) extending and a tapered section (126) adjacent to the zipper section sealing bead (124), the tapered section (126) tapering from a larger height adjacent to the zipper section sealing bead (124) to a smaller height as a distance away from the zipper section sealing bead (124) increases.