Thermoforming Machine Movable Forming Wall Section Undercut
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Solution Overview
Problem
Thermoforming packaging machines struggle to produce upright standing packagings with undercuts while avoiding collisions between the packaging and the lower forming or sealing tool, as the side walls opposite the undercut are inclined, limiting packaging volume and requiring complex tooling arrangements.
Innovation Solution
A thermoforming packaging machine with a forming station and sealing station that includes movable forming wall sections and sealing seam support sections, allowing for vertical undercuts and independent side wall formation, preventing collisions through pivotable and movable parts driven by a common mechanism, such as pneumatic or electric drives, and a return mechanism for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If an inclined lifting unit is used to form the undercut, then the undercut can be produced on the side wall, but the opposite side wall becomes inclined towards the interior of the packaging tray, reducing packaging volume
Solution Approach 1:
The lifting unit is made movable and adjustable in position, allowing it to be repositioned along the side wall of the packaging tray. This dynamic positioning capability enables the formation of undercuts without compromising the volume of opposite side walls, as the lifting unit can be precisely positioned to affect only the intended side wall while keeping other walls vertical and volume-maximizing.
Solution Approach 2:
The lifting unit is divided into multiple independently controllable segments or positioning points along the side wall. This segmentation allows selective lifting at specific locations to create undercuts on one side wall while maintaining vertical configuration on opposite side walls, thereby preserving maximum packaging volume.
2Shape
If the lifting unit is arranged at an inclination to produce the undercut, then the undercut can reach below the sealed seam for upright standing, but the packaging tray collides with the lower deep drawing die when opening the forming station
Solution Approach 1:
The lifting unit and die are both made dynamically adjustable. The lifting unit can be repositioned to form undercuts at optimal depths below the sealed seam for upright standing, while the die positioning can be dynamically adjusted during the opening phase to avoid collision with the packaging tray, allowing deep undercuts without harmful collisions.
Solution Approach 2:
The lifting unit forms the undercut in advance during the closing phase of the forming station, before the opening phase begins. This preliminary formation of the undercut ensures that the packaging tray achieves the necessary geometry for upright standing before any opening movements occur, allowing the die and tray to be positioned to avoid collision during the subsequent opening phase.
3Object-affected harmful factors
If the side wall opposite the undercut is formed parallel to the undercut but inclined towards the interior, then collision is avoided, but the packaging volume is limited
Solution Approach 1:
The positioning of the lifting unit is made dynamically adjustable, allowing it to be precisely positioned to form undercuts on one side wall while maintaining vertical configuration on opposite side walls. This dynamic control enables collision avoidance through proper positioning rather than through volume-reducing inclined configurations.
Solution Approach 2:
The lifting unit positioning creates an asymmetric configuration where one side wall has an undercut while the opposite side wall remains vertical. This asymmetric approach allows the undercut side to achieve the necessary geometry for upright standing while the opposite side maintains maximum volume potential with a vertical configuration, avoiding the symmetric inclined configuration that reduces volume.
Data Source
AI summary
The disclosure is directed to a thermoforming packaging machine (1) for producing upright standing packagings (21) with an undercut (26) formed into the packaging. The machine comprises a forming station (2) with a lower forming tool (30) and/or a sealing station (3) with a lower sealing tool (40). The disclosure is characterized by the lower forming tool (30) and/or the lower sealing tool (40) comprising a movable forming wall section (32) or a movable sealing seam support section (41a), respectively, in the area of the undercut (26). The disclosure is also related to a corresponding method for producing packagings (21).