Sleeved Container Laser Cutting for Wrinkle-Free Curved Ends

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Solution Overview

Problem

Existing methods for forming heat-shrunk sleeved containers often result in 'smiling' or wrinkling of the film and are unable to achieve curved endings, which can reduce consumer appeal and are not cost-effective to produce.

Innovation Solution

The method involves removing a part of the sleeve after heat shrinking, using techniques such as laser cutting, to prevent disturbances and create curved endings, with the removal unit positioned downstream from the heat oven to minimize deformation and improve production efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If heat shrinking is used to attach the sleeve to the container, then the sleeve is securely attached to the container, but disturbances such as smiling or wrinkling of the film occur

Engineering Contradiction:

Improvesleeve attachment strengthVSAvoidfilm surface smoothness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The sleeve is divided into two functional parts: a heat-shrunk portion that provides secure attachment to the container, and a non-heat-shrunk portion that remains smooth and wrinkle-free. This segmentation allows each part to serve its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The problematic heat-shrunk portion is extracted and removed from the final product. Only the necessary attachment portion undergoes heat shrinking, while the remaining sleeve portion is removed to eliminate disturbances like smiling and wrinkling that would otherwise affect the entire sleeve.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If a straight ending of the sleeve is used, then the sleeve can be properly heat shrunk, but consumer appeal is reduced

Engineering Contradiction:

Improvesleeve heat shrinking capabilityVSAvoidsleeve ending shape

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The sleeve is segmented into a heat-shrunk attachment portion and a separate non-heat-shrunk ending portion. This allows the attachment portion to maintain its straight shape for proper heat shrinking while the ending portion can be formed with curved shapes to enhance consumer appeal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the sleeve have different quality requirements: the attachment portion requires straight edges for proper heat shrinking, while the ending portion benefits from curved shapes for aesthetic appeal. This local differentiation of quality attributes resolves the contradiction.

Inventive Principle:

Principle #3Local quality

3Shape

If a part of the sleeve is removed after heat shrinking, then curved endings can be obtained and disturbances are reduced, but additional processing steps are required

Engineering Contradiction:

Improvesleeve ending curvatureVSAvoidnumber of processing steps

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

Traditional mechanical cutting methods are replaced with laser cutting technology. This substitution enables precise removal of the sleeve portion with minimal mechanical contact, reducing the risk of additional deformations while maintaining the benefits of curved endings and disturbance reduction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If laser cutting is used to remove the sleeve part, then precise removal is achieved with minimal damage to the container, but energy consumption increases

Engineering Contradiction:

Improvesleeve removal precisionVSAvoidlaser energy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The laser cutting process is applied locally only to the specific portion of the sleeve that needs to be removed, rather than cutting the entire sleeve. This localized application minimizes energy consumption while achieving the required precision for creating curved endings and removing disturbances.

Inventive Principle:

Principle #3Local quality

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

This approach reduces disturbances like 'smiling' and allows for the production of sleeved containers with curved endings, enhancing consumer appeal while maintaining low production costs, by using laser cutting to detach a part of the sleeve after heat shrinking.

Implementation Method 1

removing the part of the sleeve comprises laser cutting the part out of the sleeve

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

laser cutting the part out of the sleeve

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

attaching the sleeve to the container being conveyed by heat shrinking

Methodology Applied

Scientific EffectHeat shrinking: Thermal Contraction

Data Source

PatentUS9776756B2Method and system for forming sleeved containers

Publication Date: 2017.10.03 FUJI SEAL INTERNATIONAL INC

AI summary

The invention relates to a system and method for forming sleeved containers. The system includes a conveyor for transporting a row of containers, a sleeving unit for arranging sleeves around containers and a heat oven for attaching the sleeve around the container by heat shrinking. The conveyed containers are provided with a sleeve and the sleeved container is transported in the oven to allow the sleeve to shrink. According to the invention, part of the sleeve is removed using a removal unit. The part is removed after heat shrinking. Removing the part allows to uncover part of the container otherwise covered by sleeve.