Thermoform Packaging Machine Movable Forming Tool

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Solution Overview

Problem

Existing thermoform packaging machines are limited by the time required for feeding and introducing cardboard trays into the forming station, which restricts their performance in producing gastight packages with a long shelf life.

Innovation Solution

The thermoform packaging machine features a forming station with a movable forming tool lower part that includes reception units for cardboard elements, allowing for the formation of a film web into the cardboard elements without an additional work station, enabling the use of thin film webs for gastight packing and increasing cycle output through simultaneous charging and processing of cardboard elements on both sides of the machine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional thermoform packaging machine feeds cardboard trays into the forming station using a manipulator, then the machine can produce gastight packages with long shelf life, but the performance is limited by the time required for feeding and introducing cardboard trays into the forming station

Engineering Contradiction:
Improvegastight packing capabilityVSAvoidcycle output
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The invention applies preliminary action by pre-positioning multiple cardboard trays in a magazine outside the forming station before the actual forming process. The trays are prepared and staged in advance, allowing the forming process to proceed without interruption while trays are automatically fed from the magazine to the forming station, thus eliminating the time-consuming manual or manipulator-based feeding process that limited cycle output.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The invention introduces another dimension by adding a magazine component that stores trays in a spatial arrangement external to the forming station. This magazine is positioned such that trays can be fed laterally or from the side into the forming station, creating a new spatial dimension for material supply that separates the storage function from the forming function, thereby increasing productivity without compromising the gastight packing capability.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Productivity

If additional work stations are added to charge forming tools with cardboard trays, then the forming process can be continuous, but the device complexity increases

Engineering Contradiction:
Improvecycle outputVSAvoidnumber of work stations
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The invention merges the tray storage function and the tray feeding function into a single integrated magazine component. Instead of adding separate work stations for charging forming tools with cardboard trays, the magazine combines both functions: it stores multiple trays and automatically feeds them to the forming station as needed. This integration maintains continuous forming operation while avoiding the increased device complexity that would result from adding multiple independent work stations.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The magazine serves multiple functions simultaneously: it acts as a storage repository for cardboard trays, an automatic feeding mechanism for supplying trays to the forming station, and a buffer that decouples the forming cycle from the tray supply rate. This multi-functionality allows the system to maintain high cycle output without requiring additional specialized work stations, thereby avoiding increased device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 solution reduces film consumption, provides a stable and visually attractive package, and enhances the machine's cycle output by allowing continuous operation without reducing productivity during the cardboard feeding process.

Implementation Method 1

thermoform packaging machine for forming-in a film into a cardboard element

Methodology Applied
Scientific EffectThermal forming: Heating

Data Source

PatentUS11027478B2Thermoform packaging machine and method of forming-in a film web into cardboard elements
Publication Date: 2021.06.08 MULTIVAC SEPP HAGGENMULLER GMBH & CO KG
  • US11027478B2 patent drawing
  • US11027478B2 patent drawing
  • US11027478B2 patent drawing

AI summary

A thermoform packaging machine comprising a forming station. The forming station comprises at least one forming tool lower part, the forming tool lower part may be movable transversely to an operating direction of the thermoform packaging machine. The forming tool lower part may comprise at least one reception unit with one or a plurality of troughs for receiving cardboard elements. At a forming position the forming tool lower parts are in contact with the forming tool upper parts such that the first film web may be formed-in into the forming tool lower parts. Further, the first film web may be formed-in into the cardboard elements during the forming process and, in the case of a skin film, an adhering or an adhesive connection may be established between the skin film and the inner surfaces of the cardboard elements.