Thermoforming Die Heating Device with Localized Heat Zones
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Solution Overview
Problem
Existing heating devices for producing packaging films in deep-drawing processes result in non-homogeneous film thickness distribution, leading to mechanical instability, poor appearance, and increased material usage, which complicates production and affects product safety.
Innovation Solution
A heating device with a surface featuring depressions and a flat surrounding border, optimized to create a uniform temperature profile, ensuring homogeneous film expansion by replicating the cavity's outline and using metallic surfaces with controlled heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heating devices with flat surfaces are used, then the heating process is simple, but the film thickness distribution becomes heterogeneous
Solution Approach 1:
The heating device incorporates depressions with varying depths and a flat surrounding border area, creating non-uniform local heating zones. This allows different regions of the film to receive differentiated heat treatment, compensating for the non-uniform stress distribution during deep-drawing and achieving homogeneous film thickness distribution in the final product.
Solution Approach 2:
Instead of applying uniform heating across the entire film surface, the invention inverts the approach by creating localized heating zones through depressions. The heating device heats specific areas more intensely rather than uniformly, which compensates for the areas that will experience higher stress and greater thinning during forming.
2Productivity
If deep-drawing processes with high deformation are used, then more receiving chambers can be produced, but the film thickness distribution becomes more heterogeneous
Solution Approach 1:
The heating device uses localized depressions to create non-uniform heating patterns that specifically target areas prone to high deformation. This allows the process to handle high deformation requirements for multi-chamber production while maintaining homogeneous film thickness distribution through compensated local heating.
3Ease of manufacture
If uniform heating is applied, then the heating process is simple, but the film stretches non-uniformly causing heterogeneous thickness
Solution Approach 1:
The heating device maintains manufacturing simplicity while achieving precise thickness control through localized depressions. The depressed areas create concentrated heating zones that compensate for non-uniform stress distribution, allowing the process to remain relatively simple while producing homogeneous film thickness.
4Loss of substance
If minimal film thickness is used, then material usage is reduced, but the pouch becomes mechanically unstable and flabby
Solution Approach 1:
The negative pressure system is optimized to work in conjunction with the depressed heating device, ensuring uniform film adherence to the heating surface. This pneumatic control, combined with localized heating, allows minimal film thickness to be used while maintaining mechanical stability through homogeneous thickness distribution and proper forming.
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 the production of stable, appealing, and efficient packaging units with minimal material usage, enhancing mechanical strength and process efficiency.
Implementation Method 1
the action of heat and negative pressure, filled... While heating the film increases its plasticity
Implementation Method 2
the force resulting from the negative pressure applied to the heated film causes it to stretch and plastically deform
Data Source
AI summary
Heating device, which is set up for heating a packaging film in a deep-drawing process, in the course of which the heated packaging film is formed into the cavity of a deep-drawing die, wherein the surface area of the heating device, which is brought into contact with the film section to be formed into the cavity, has at least one recess, the opening area of which is 40 to 95% of the opening area of the cavity, and deep-drawing device, comprising this heating device.