Tray Sealer Dome Die Air Convection Heating
Solution Overview
Problem
Existing tray sealers that heat skinnable top films using dome-shaped dies require complex constructions and high constructional outlay, and the heating process can cause the top film to bulge downwards, limiting the stroke of the tool lower part, especially for high products.
Innovation Solution
A tray sealer that uses air convection to heat the skinnable top film, employing a dome-shaped die with channels for thermal air convection and vacuum generation, allowing the film to be heated without compressed air and reducing the stroke of the tool lower part, while also accelerating the thermoforming process by creating a low negative pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dome-shaped die with compressed air heating is used, then the top film can be heated and deformed, but the constructional outlay becomes high and the top film bulges downwards
Solution Approach 1:
The patent replaces the mechanical compressed air heating system with a radiant heating system using heating elements positioned around the dome-shaped die. This substitution eliminates the complexity of compressed air generation and delivery mechanisms while achieving the same thermal effect on the top film, directly resolving the contradiction between heating effectiveness and constructional complexity
Solution Approach 2:
The patent introduces a radiant heating system as an intermediary between the power source and the top film. Instead of directly using compressed air to heat the film, the heating elements first convert electrical energy to thermal radiation, which then heats the top film indirectly. This intermediary approach simplifies the overall system while maintaining effective heating
2Temperature
If compressed air is used for heating, then the top film can be heated, but the top film bulges downwards during heating
Solution Approach 1:
The patent replaces the compressed air heating mechanism with a radiant heating system using heating elements. This substitution eliminates the downward pressure effect caused by compressed air delivery while maintaining effective thermal heating of the top film, thus preventing the unwanted downward bulging during the heating phase
3Adaptability or versatility
If the tool lower part has a large stroke to accommodate high products, then high products can be sealed, but the heating process is prolonged
Solution Approach 1:
The patent replaces the slow compressed air heating system with a rapid radiant heating system using heating elements positioned around the dome-shaped die. This substitution provides much faster and more uniform heating, significantly reducing the heating time required even when the tool lower part must accommodate high products with a larger stroke
Solution Approach 2:
The heating elements are positioned to provide preliminary and uniform heating of the top film before the sealing operation begins. This preliminary action ensures the top film reaches the required temperature quickly and uniformly, preventing delays in the overall sealing process even when dealing with high products
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
The air convection heating method reduces the time required for the heating phase, increases the performance of the tray sealer, and prevents premature contact between the top film and the sealing surface, enabling efficient sealing of high products with a reduced constructional complexity.
Implementation Method 1
the air, which flows through the dome-shaped die and then into the chamber, takes up the heat of the dome-shaped die
Implementation Method 2
thermal air convection from the first channel to the third channel along a side of the top film facing the dome-shaped die
Implementation Method 3
a low negative pressure already prevails in the chamber so as to accelerate the thermoforming process upwards and into the dome-shaped die by a vacuum applied from one side
Data Source
AI summary
A tray sealer including a sealing station comprising a tool upper part, a clamping frame and a tool lower part. The tool upper part may surround a dome-shaped die used for deforming a skinnable top film. First and second channels in the dome-shaped die and in the tool upper part, respectively, are connectable to one another. The tool upper part or the dome-shaped die may comprise at least a third channel communicating with a vacuum generator so as to generate a thermal air convection from the first channel to the third channel along a side of the top film facing the dome-shaped die.