Thermoforming Machine Two-Step Heating for Film Integrity
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Solution Overview
Problem
Thermoformable materials, including biodegradable and non-biodegradable ones, tend to tear or break during or after thermoforming, and experience contraction leading to reduced inner volume in capsules produced, which is a common issue in existing thermoforming systems.
Innovation Solution
Implementing a two-step heating process for thermoformable film materials, where the film is pre-heated to a temperature between 50°C and 80°C before thermoforming, and then further heated during the thermoforming process, with a subsequent cold forming step to achieve the final shape and size, reducing the likelihood of material failure and contraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-step heating is used during thermoforming, then the process is simple and fast, but the material tends to tear or break and experiences contraction leading to reduced inner volume
Solution Approach 1:
The heating process is divided into two distinct stages: pre-heating at a first temperature (50-80°C) before thermoforming, and then heating at a second temperature during thermoforming. This segmentation allows the material to be gradually prepared for forming, reducing thermal shock and preventing tearing while maintaining process control.
Solution Approach 2:
The pre-heating step is performed in advance before the actual thermoforming operation. By pre-heating the material to a moderate temperature first, the material becomes more pliable and less prone to breaking during the subsequent forming operation, thereby improving reliability before the main action occurs.
2Shape
If high heating temperature is applied during thermoforming, then the material becomes more pliable for shaping, but the material contracts after cooling leading to reduced capsule inner volume
Solution Approach 1:
The invention changes the temperature parameter in two stages: first maintaining a moderate pre-heating temperature (50-80°C) to prepare the material, then applying the necessary heating temperature during thermoforming to achieve proper shaping. This controlled parameter change allows shape accuracy while minimizing excessive contraction.
3Productivity
If rapid heating is used during thermoforming, then the production cycle is faster, but the material tears or breaks due to thermal stress
Solution Approach 1:
By performing pre-heating before the main thermoforming operation, the material is gradually prepared and becomes more resistant to thermal stress. This preliminary action allows the subsequent rapid heating during thermoforming to proceed without causing material failure, thus maintaining both productivity and reliability.
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 significantly reduces the probability of material tearing or breaking during thermoforming and minimizes volume contraction, resulting in capsules with the desired shape and size, while maintaining the temperature integrity of the pre-heated film.
Implementation Method 1
a heating station (102) upstream of the thermoforming station (103) and adapted for carrying out a pre-heating of the predefined portions of the film
Implementation Method 2
a thermoforming station (103) configured to form the capsules by thermoforming predefined portions of the film of thermoformable material
Implementation Method 3
concurrently vacuum sucking the thermoplastic sheet through the cavities of the molding drum
Data Source
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AI summary
A thermoforming machine and a thermoforming method are provided, in particular for producing capsules for obtaining beverages. The capsules (C) are produced from a film (F) of thermoformable material by thermoforming one or more predefined portions (X) of the film. The one or more predefined portions (X) of the film of thermoformable material are pre-heated, i.e. they are heated before being subjected to thermoforming so as to minimize the probability that the film of thermoformable material tears or breaks during thermoforming or after thermoforming.