Automated Comminuted Silicon Packaging via Folded Channel Vacuum Welding
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Solution Overview
Problem
Current methods for packing comminuted silicon are not fully automated, leading to potential contamination and economic inefficiencies due to manual component steps and the use of suction probes for sealing.
Innovation Solution
A fully automated method involving the use of inner and outer bags, where the inner bag is filled, welded using a vacuum welder through a channel formed by folding the bag, and then transferred into an outer bag for additional welding, minimizing contamination and manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual component steps are used in the packing process, then flexibility and adaptability are maintained, but contamination risk increases and economic efficiency decreases
Solution Approach 1:
The patent replaces manual mechanical operations with automated systems. A robotic arm with gripper automatically transfers silicon chunks from the weighing container to the bag, eliminating manual handling that causes contamination. The sealing mechanism is also automated, with the seal head automatically positioning and sealing the bag opening without human intervention.
Solution Approach 2:
The system performs packing operations autonomously without continuous human intervention. The robotic arm automatically positions and places chunks, the sealing mechanism automatically seals the bag, and the system can handle multiple bags sequentially. This self-service capability maintains purity while improving economic efficiency through automation.
2Reliability
If a suction probe is used for sealing the bag, then the bag can be evacuated and sealed, but contamination risk increases due to external material introduction
Solution Approach 1:
The patent extracts and eliminates the suction probe from the sealing process. Instead of introducing an external tool that risks contamination, the system uses a seal head that contacts only the bag material and silicon chunks already within the controlled environment. The sealing mechanism applies heat and pressure directly to the bag opening without requiring probes or tools that could introduce impurities.
Solution Approach 2:
The seal head acts as an intermediary between the sealing mechanism and the bag, providing a controlled interface that prevents contamination. The seal head is designed to contact only the bag material and can be easily cleaned or replaced, ensuring that no external contaminants are introduced during the sealing process.
3Strength
If plastic bags are used for packing comminuted silicon, then the bags can be sealed and transported, but tears may arise during filling due to sharp edges
Solution Approach 1:
The patent employs protective measures before filling occurs. The bag is positioned within a protective frame or guide structure that prevents direct contact between sharp silicon edges and the bag walls during filling. The robotic arm carefully controls the placement of chunks, and the sealing mechanism is designed to avoid concentrating stress on vulnerable bag areas, thereby preventing tears before they can occur.
4Volume of moving object
If the bag is evacuated prior to sealing, then a more compact bag size is achieved, but contamination risk increases from suction probe material
Solution Approach 1:
The patent removes the suction probe from the evacuation process and replaces it with a sealed chamber system. The bag is placed in a vacuum chamber where air is evacuated from the chamber, not directly from the bag through a probe. This eliminates the contamination risk while still achieving compact bag size through vacuum compression.
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 achieves high purity and economic advantages by ensuring minimal contamination during the packing process and reducing material usage through precise bag sizing and automation.
Implementation Method 1
A vacuum welder applied to the fold from outside sucks air out of the inner bag through the channel and welds the inner bag
Data Source
AI summary
A method of automatic packing of comminuted silicon includes providing an inner bag in a first shaping vessel, spreading out an opening of the inner bag and positioning the opening above a lip of a first filling funnel of a filling unit, and filling the inner bag with comminuted silicon. The comminuted silicon passes through the filling funnel into the inner bag. The inner bag is welded in a welding unit. The opening of the inner bag is folded together by inward folding of two opposite inner bag sides such that two inner bag edges formed by the folding-together are opposite and parallel to one another and form a fold with a channel. A vacuum welder is applied to the fold and welds the inner bag. The inner bag is transferred into an outer bag. The outer bag is welded.