Spouted Pouch Manufacturing with Top Gusset Attachment
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Solution Overview
Problem
The spouted pouch package with a spout attached to the top gusset section cannot be efficiently mass-produced due to the spout not being attached to a heat-sealed edge, leading to challenges in heat-sealing and sealing performance.
Innovation Solution
An apparatus that efficiently manufactures spouted pouch packages by forming score lines, hole formation, folding, spout attachment, and heat-sealing, allowing for reliable sealing of the top gusset section and body section edges, and includes a cutting unit to manage redundant material, ensuring accurate folding and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the spout is attached to the top gusset section instead of a heat-sealed edge, then the pouch can provide sufficient capacity without increasing width or height, but the spout cannot be attached using heat-sealing methods and efficient mass production becomes difficult
Solution Approach 1:
The apparatus performs preliminary actions by forming score lines, creating attachment holes, and pre-positioning the spout on the top gusset section before the heat-sealing process. This allows the spout to be attached at the correct location without interfering with the heat-sealing edges, enabling both the capacity benefit and mass production efficiency.
Solution Approach 2:
The manufacturing process is segmented into distinct sequential operations: score line formation, hole formation, folding, spout attachment, and heat-sealing. This segmentation allows each operation to be optimized independently, with the spout attachment occurring at the top gusset section while heat-sealing occurs at separate edges, resolving the contradiction between attachment location and production efficiency.
2Shape
If the spout is attached to the top gusset section at a central area, then the pouch maintains a compact shape, but it is not possible to use heat-sealing methods for spout attachment
Solution Approach 1:
The apparatus introduces an intermediary mechanical attachment method using a flange portion that is secured with rivets or clips, instead of directly heat-sealing the spout. This intermediary mechanism allows the spout to be attached at the central top gusset section while maintaining the compact pouch shape, and the attachment can still be performed efficiently in a mass production setting.
3Shape
If score lines are formed and the package material is folded to form gusset sections, then the pouch structure is created, but folding positions may be displaced causing side edges to be largely displaced
Solution Approach 1:
The apparatus incorporates feedback mechanisms where sensors detect the actual position of folded edges and provide real-time information to the control system. The control system then adjusts subsequent operations (such as heat-sealing positions and cutting positions) to compensate for any folding displacements, ensuring that the final pouch structure maintains the required precision despite variations in folding accuracy.
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
Enables efficient mass production of spouted pouch packages with improved sealing performance by ensuring the spout is attached to the top gusset section, reducing the need for dedicated cutters and enhancing the reliability of heat-sealing at critical boundaries.
Implementation Method 1
sealing bars 51, 52 of the second sealing unit are for heat-sealing portions of the folded package corresponding to side edges of the body section to each other
Data Source
AI summary
Score lines are formed on long, band-shaped package material M while the package material M is fed from package-material roll R. Then, a spout attachment hole is formed in a portion corresponding to a top gusset section of a pouch P. Then, the package material M is folded in a width direction of the package material so that a conveying direction of the package material M is aligned with a width direction of the pouch. Then, a spout S is attached to the spout attachment hole formed in the portion of the folded package material M which corresponds to the top gusset section. Then, a portion corresponding to a peripheral edge of the top gusset section of the pouch P and a portion corresponding to a top edge of a body section of the pouch P are heat-sealed to each other, and the package material M is cut in the width direction of the package material. Lastly, portions corresponding to side edges of the body section of the pouch P are heat-sealed to each other, and a portion corresponding to a peripheral edge of a bottom gusset section and a portion corresponding to a peripheral edge of a bottom end portion of the body section are heat-sealed to each other. Then, the heat-sealed portions formed at the portions corresponding to the side edges of the body section of the pouch P are cut so that a spouted pouch package SP is released.