Split Bus Bar Assembly for Uniform Closed-Contour Heat Sealing
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Solution Overview
Problem
Uniform heat distribution in closed-contour or closed-contour heat-sealing procedures is difficult due to non-uniformity of electrical and thermal energy flow in existing systems.
Innovation Solution
A two-part split bus bar assembly with electrically insulated terminals and active heating/cooling system for uniform heat distribution, using conductive and non-conductive fluids, and PTFE coated fabric layers to maintain consistent temperature and thermal homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If closed-contour heat-seal bands with terminal tabs are used to transmit electrical current, then heat-sealing capability is achieved, but non-uniform heating occurs at tab/band junctions due to unbalanced energy transfer
Solution Approach 1:
The bus bar is divided into multiple segments (first bus bar segment, second bus bar segment, third bus bar segment) that can be independently positioned and adjusted. This segmentation allows each segment to be optimized for uniform heat distribution across different zones of the heat-seal band, eliminating the non-uniform heating problem at tab/band junctions while maintaining reliable heat-sealing capability.
Solution Approach 2:
Different portions of the bus bar are positioned at different distances from the heat-seal band to create localized variations in heat transfer. The first bus bar segment is positioned closer to provide higher heat input at specific zones, while the second and third segments are positioned at different distances to balance the heat distribution, ensuring uniform heating across the entire band including the tab/band junctions.
2Adaptability or versatility
If complex assemblages of insulative and conductive components are used in heat-seal tools, then multiple joints and support functions are achieved, but non-uniformity of surfaces and material characteristics results in uneven energy transfer
Solution Approach 1:
The patent combines multiple bus bar segments into a single integrated assembly that performs both structural support and heat transfer functions. By merging the support function into the bus bar segments themselves rather than using separate components, the design eliminates interfaces between different materials that would cause non-uniform heat distribution, while still providing the necessary structural support for the heat-seal band.
Solution Approach 2:
The bus bar segments serve multiple functions simultaneously: they provide structural support for the heat-seal band, transmit electrical current, and distribute heat uniformly across the band. This multi-functionality eliminates the need for separate insulative and conductive components that would create non-uniform surfaces and material characteristics, thereby ensuring even energy transfer.
3Temperature
If passive cooling is used to reduce heat seal band temperature during workpiece holding, then cooling capability is achieved, but control resolution and temperature uniformity are limited
Solution Approach 1:
The system transitions from passive cooling to active, dynamically controllable cooling by introducing a temperature-controlled fluid flow system. The cooling fluid can be actively pumped through channels in the bus bar segments, allowing real-time adjustment of cooling rates and temperature distribution. This dynamic control enables precise temperature management during the workpiece holding phase, significantly improving control resolution and temperature uniformity compared to passive cooling.
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
Ensures uniform heat distribution and temperature control across contoured heat-seal surfaces, reducing non-uniform heating and enhancing energy transfer efficiency.
Implementation Method 1
an opposing temperature system may provide a cooling phase in which a workpiece is cooled while held under pressure to establish the weld or heat-seal
Implementation Method 2
The cooling channels ensure the tool or electrical bus-assembly remains at a constant temperature as power is passed from the tool or electrical bus-assembly to the heat-seal band
Implementation Method 3
Characteristics of the tabs and the bands, as well as aspects of their engagement at the tab/band junction, influence how electrical and thermal energy will flow through the transition(s) at the tab/band junction
Implementation Method 4
PTFE coated fabric layers to maintain consistent temperature and thermal homogeneity
Data Source
AI summary
A split bus assembly is provided for a heat-sealing machine. The split bus assembly includes a clamp with first and second clamp segments that abut each other in face-to-face engagement. The engaging surfaces or inner walls of the clamp segments may be coated with a nonconductive material so that the clamp segments are electrically insulated with respect to each other. A tab terminal may be defined at each inner wall, constituting a zone of exposed conductive material which is configured to engage a conductive tab of a heat-seal band during use. Biasing members such as a silicone spring may be arranged in the tool to facilitate ejection of the heat-seal band during a removal procedure. The tool may be cooled by way of cooling fluid that flows through passages in the bus bars.