Ultrasonic Sealing with Vibratable Layer for Separable Packaging

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Solution Overview

Problem

Existing methods for forming easily separable portions in packaging films, such as plasma radiation processing and ink-coated film layers, are costly, prone to contamination, and difficult to implement, especially for food and drink packaging, and struggle to balance adhesive strength with ease of separation.

Innovation Solution

The method involves using a vibratable layer, such as office paper or Teflon sheets, between the ultrasonic horn and anvil to concentrate ultrasonic vibrations, reducing friction heat and allowing for the formation of easily separable portions with controlled adhesive strength in packaging films.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plasma radiation processing is applied to improve wettability and suppress fusion, then easily separable portion is formed, but equipment cost increases and processing variation occurs

Engineering Contradiction:

Improveease of separationVSAvoidequipment cost

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent introduces a release paper as an intermediary layer between the packaging films during ultrasonic sealing. This release paper absorbs and concentrates the ultrasonic vibrations, preventing direct fusion between packaging films while avoiding the need for expensive plasma radiation equipment. The release paper acts as a mediator that enables easy separation without requiring complex processing equipment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the plasma radiation processing system with a simpler mechanical ultrasonic sealing system using a release paper. Instead of using complex plasma radiation equipment to modify surface properties, the invention uses a mechanical approach where the release paper is interposed during sealing to prevent fusion, achieving the same functional result with simpler, more cost-effective equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If ink coated film layer is formed on heat sealed surface, then easily separable portion is formed, but packed material may be contaminated with ink

Engineering Contradiction:

Improveease of separationVSAvoidcontamination risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The release paper serves as a safe intermediary layer that prevents direct contact between packaging films during sealing. Unlike ink-coated films, the release paper is food-safe and does not pose contamination risks to packed materials. It achieves the same purpose of enabling easy separation while eliminating the harmful contamination effect.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The release paper is a disposable, single-use component that is discarded after sealing. This approach is safer than permanent ink coatings because the release paper never contacts the packed material, eliminating any risk of contamination while providing the necessary non-stick surface for easy separation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of operation

If heat sealing temperature, pressure, and time are controlled to form easily separable portion, then separation is enabled, but adhesive strength decreases and material leakage occurs

Engineering Contradiction:

Improveease of separationVSAvoidadhesive strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The release paper acts as a mediator during the sealing process, physically preventing direct adhesion between packaging films. By interposing this layer, the system achieves easy separation without needing to reduce adhesive strength through temperature, pressure, or time control, thereby maintaining strong seals that prevent material leakage while enabling easy opening.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables the cost-effective and contamination-free formation of easily separable portions with adjustable joint strength, suitable for various packaging types, including microwave-safe bags, by preferentially concentrating ultrasonic vibrations on the vibratable layer, thus reducing heat transfer to the packaging films.

Implementation Method 1

a horn emitting ultrasonic waves and an anvil oppositely disposed to the horn, and vibrating the packaging films by the ultrasonic waves

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

vibrating the packaging films by the ultrasonic waves

Methodology Applied

Scientific EffectFriction heat: Friction

Data Source

PatentUS10577141B2Method for forming easily separable portion in packaging film, package bag having easily separable portion, and filling-packing machine

Publication Date: 2020.03.03 TAISEI LAMICK CO LTD

AI summary

To provide a method for readily forming an easily separable portion having an adhesive strength that is required as a package bag on packaging film, a package bag having an easily separable portion formed by this method, and a filling-packing machine utilizing this method. A method forming an easily separable portion in packaging film by interposing at least two packaging films between a horn emitting ultrasonic waves and an anvil oppositely disposed to the horn, and vibrating the packaging films by the ultrasonic waves, in which a vibratable layer is provided on the packaging film in at least one of the horn side and the anvil side.