Valve Bag Lamination for Moisture Resistance and Tearing Strength
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Solution Overview
Problem
Current valve bags, particularly those made of paper, lack resistance to moisture and are prone to tearing, making them unsuitable for small quantities of discrete parts, and the production methods for more durable plastic valve bags are complex and expensive, limiting their economic viability for small applications.
Innovation Solution
A method involving the unrolling and interlacing of two webs of material, with a sealing process creating a valve side and an opposing open side, allowing for simpler and less expensive production of valve bags using conventional machinery, using heat sealable plastic materials that are resistant to moisture and damage, and enabling easy identification and printing options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If paper valve bags are used, then the bags are simple and inexpensive to produce, but they lack resistance to moisture and are prone to tearing
Solution Approach 1:
The patent uses a composite structure consisting of an outer web and an inner web laminated together. The outer web provides mechanical strength and tearing resistance, while the inner web provides moisture resistance. This composite material structure resolves the contradiction by combining the advantages of both materials to achieve both durability and moisture protection.
Solution Approach 2:
The patent employs thin film structures for both the outer and inner webs, creating a flexible yet durable bag structure. The laminated thin films provide both mechanical integrity and moisture barrier properties, enabling the bag to resist tearing and moisture while remaining flexible for conventional manufacturing equipment.
2Reliability
If plastic valve bags are used, then the bags are resistant to moisture and damage, but the production method is complex and expensive
Solution Approach 1:
The patent divides the bag structure into two separate web layers (outer web and inner web) that are laminated together. This segmentation allows each layer to be optimized for its specific function while using conventional lamination equipment, simplifying the production process compared to forming complete plastic bags while maintaining moisture and damage resistance.
Solution Approach 2:
The patent uses a lamination process as an intermediary step to combine the outer web and inner web. This intermediary lamination technique allows the integration of two different materials using conventional equipment, avoiding the need for complex specialized machinery while achieving the desired moisture and damage resistance.
3Ease of manufacture
If conventional machinery is used for production, then the equipment cost is low, but the bags require additional sealing after filling
Solution Approach 1:
The patent incorporates the sealing function into the lamination process itself, where the outer web and inner web are sealed together along the valve side before the bag is filled. This preliminary sealing action eliminates the need for subsequent sealing steps after filling, saving time while using conventional equipment.
Solution Approach 2:
The patent merges the sealing function with the lamination process, combining two operations into one step. The sealing lines are integrated into the lamination process, allowing the outer and inner webs to be sealed together while maintaining the simplicity of using conventional machinery, thereby eliminating additional sealing time.
4Productivity
If valve bags are made for large quantities of material, then the bags are economically viable, but they are not suitable for small quantities of discrete parts
Solution Approach 1:
The patent uses parameter changes in the web dimensions and lamination specifications to accommodate different bag sizes and applications. By adjusting the dimensions and properties of the outer and inner webs, the same basic structure can be adapted for both large quantity bulk materials and small quantities of discrete parts, maintaining economic viability across different applications.
Solution Approach 2:
The patent creates a universal valve bag structure that can serve multiple functions and applications. The laminated construction with adjustable dimensions allows the same bag type to be used for both bulk materials and discrete parts, providing adaptability while maintaining the economic benefits of standardized production.
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 method enables the economical production of valve bags in various sizes and quantities, including small items, without the need for additional sealing, using materials that are resistant to moisture and tearing, thus reducing costs and improving durability.
Implementation Method 1
applying a sealing process to the combined web such that the first web is sealed to the second web along part of the valve side
Implementation Method 2
using materials that are resistant to moisture and tearing
Data Source
AI summary
A method of forming a valve bag suitable for filling with, for example, powder, grain, cement, animal foodstuffs, via a chute tube inserted into the valve, including forming a combined web from two webs of material, including steps of forming the combined web into a plurality of bag sections, sealing the bag sections at one side such that a valve portion is defined, separating the two webs and moving them outwardly until the bag sections are turned inside, and sealing the two webs to form a valve bag having an strong, effective seal and a valve portion for filling.