Self-Regulating Heater for Single-Step Container Sealing
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Solution Overview
Problem
Conventional methods for making stand up pouches require multiple welding heads and steps, leading to complex and large apparatuses, uncontrolled film deformation, and high energy consumption, which complicates the sealing process and increases maintenance needs.
Innovation Solution
An apparatus with a single welding head featuring a heater with decreasing electrical resistivity, capable of self-regulation based on film thickness, allows for efficient and quick sealing of the film in a single step, reducing the need for multiple welding stations and minimizing film deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welding heads are used to ensure proper sealing of thick folded film, then sealing reliability is improved, but device complexity and size increase
Solution Approach 1:
The patent changes the electrical parameter (resistivity) of the heater material to enable adaptive heat distribution. The heater element uses material with resistivity that decreases as temperature increases, allowing it to automatically deliver more heat to thicker folded film areas while maintaining lower heat output for thinner areas, achieving reliable sealing with a single welding head
Solution Approach 2:
The heater element performs self-regulation based on the thermal feedback from different film thicknesses. The resistivity change with temperature creates an automatic feedback mechanism where the heater adapts its heat output to the local thermal conditions, eliminating the need for external control systems or multiple welding heads
2Reliability
If multiple welding stages are executed on the bottom of the pack, then sealing quality is improved, but the apparatus size along the film advancing trajectory increases
Solution Approach 1:
The patent merges multiple welding functions into a single welding head by using a heater element with special electrical properties. The heater can simultaneously provide different heat levels to different zones of the folded film in one welding pass, combining what would traditionally require multiple sequential welding stages into a single integrated operation
Solution Approach 2:
The single welding head with the special heater element performs multiple welding functions that would traditionally require separate welding heads. The heater can adapt to weld different thicknesses of film (from thin to the thick folded bottom) using the same device, making the welding head universal for all sealing requirements
3Reliability
If conventional welding heads are used, then sealing is achieved, but energy consumption increases due to multiple welding steps
Solution Approach 1:
The patent enables continuous heat application in a single welding pass rather than intermittent heating with multiple welding steps. The heater element maintains continuous contact with the film and provides continuous heat flow, eliminating the stop-start nature of multiple welding stages and reducing total energy consumption while maintaining sealing quality
4Reliability
If multiple welding heads are aligned along the folded continuous film, then sealing reliability is improved, but synchronization and alignment complexity increases
Solution Approach 1:
The patent extracts the complexity of synchronization and alignment by eliminating the multiple welding heads system. Instead of managing several independent welding units that require precise coordination, the solution uses a single welding head with an adaptive heater, removing the synchronization problem entirely
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 compact, efficient, and reliable sealing of containers with low energy consumption, reducing maintenance and allowing for flexibility in handling different film types and shapes, while minimizing film deformation and simplifying the apparatus design.
Implementation Method 1
a heater (5) at least partly made of an electrically conductive material having, at least in a predetermined temperature range, an electrical resistivity which decreases upon the increase of the temperature of the same electrically conductive material
Implementation Method 2
an electrically conductive material having, at least in a predetermined temperature range, an electrical resistivity which decreases upon the increase of the temperature of the same electrically conductive material
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The present invention regards an apparatus (1) for making containers made of sheet material comprising: a supply station (2) for supplying a film (2a) having at least one folded portion (2b) having 3 or more film flaps folded and superimposed with respect to each other; a welding station (3) configured to receive the film (2a). The welding station comprises a welding head (4) configured for welding the folded portion of the film (2a) and forming a container defining a housing compartment; the welding head (4) comprises a heater (5) made of electrically conductive material whose electrical resistivity, at least in a predetermined temperature range, decreases upon the increase of the temperature of the same electrically conductive material. The present invention also regards a method of making containers by using said apparatus.