Thermoforming Plant Insert Welding and Laser Cutting
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Solution Overview
Problem
The manufacturing of thin plastic containers by blow molding faces issues such as irregular edge deformation, imperfect sealing, material waste, and complex plant operations due to the elastic behavior of thermoformable plastics, which complicates the insertion of inserts, welding, and cutting processes.
Innovation Solution
A plant with an insert welding station positioned before other workstations ensures optimal insert alignment and welding, using clamping means that engage the inserts rather than the edges, and incorporates laser cutting for precise and continuous cutting of thermoformed containers, reducing waste and improving process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If clamping means act on the external surface of edges or strip to move them, then movement is achieved, but surface slip causes inaccurate movement and requires large gripping force with space between containers
Solution Approach 1:
The patent introduces an intermediary element (adhesive substance or magnetic field) between the clamping means and the container edges/strip. This intermediary provides secure attachment without relying on friction alone, eliminating surface slip and enabling accurate movement without requiring large gripping forces or spacing between containers.
2Manufacturing precision
If additional clamping systems are used at the cutting station to stretch the thermoformed strip, then cutting effectiveness is improved, but device complexity increases and space between containers must be increased
Solution Approach 1:
The patent applies preliminary stretching of the thermoformed strip before the cutting operation using the improved clamping means. This preliminary action prepares the material in an optimal state for cutting, ensuring accuracy without requiring complex additional clamping systems during the cutting station itself.
3Productivity
If conventional mechanical cutting is used with shearing devices, then cutting is achieved, but material waste increases due to required spacing between successive containers
Solution Approach 1:
The patent replaces conventional mechanical shearing cutting with laser cutting technology. This substitution eliminates the need for physical contact and spacing between containers, allowing continuous cutting without material waste while maintaining high cutting speed and precision.
4Quantity of substance
If containers are made with very thin plastics materials (100-300 μm), then material utilization is improved, but edge deformation and sealing reliability deteriorate due to high working temperature and elastic behavior
Solution Approach 1:
The patent modifies process parameters including temperature control during forming, cooling rates, and timing of operations to accommodate very thin materials. These parameter changes prevent excessive deformation and maintain sealing reliability by optimizing the material's physical state throughout the manufacturing process.
Solution Approach 2:
The patent uses laser cutting instead of mechanical shearing to handle very thin materials, as laser cutting does not require mechanical contact that could deform the thin edges or compromise sealing surfaces.
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 ensures reliable, economical, and high-quality production of containers with optimal sealing and reduced material waste, facilitating accurate and efficient movement and cutting of thermoformed edges, while maintaining the chemical and physical integrity of the plastic material.
Implementation Method 1
laser cutting for precise and continuous cutting of thermoformed containers
Implementation Method 2
during the forming stage the edges of the material forming the opening area of the containers tends to deform, taking up irregular shapes because of the high working temperature
Implementation Method 3
movement of the edges of the plastics material which is being thermoformed and/or a thermoformed strip may not be accurate if clamping means acting on the external surface of the edges or strip are used, or a large gripping force is required upon them, because for example of the surface slip of the thermoformable plastic material
Data Source
Figure 1~3
Figure 4~5
AI summary
A plant for heat-welding and blow moulding containers comprising feed means (10) for feeding a thermoformable and heat-weldable plastics material in a preferred direction (A) and a plurality of stations (11, 12, 13, 14, 15) for processing the said plastics material to form the containers (50) when in use. The stations, which are located in succession along the preferred direction (A) comprise one or more filling stations to fill the containers (50) with filling material when in use, and at least one station for welding an insert (12) onto a container (50), each insert (30) defining the opening of a corresponding container (50) . The insert welding station (12) is located upstream of the said one or more filling stations in the preferred direction (A) .