Web-Type Packaging Forming with Angled Edges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging methods either produce aesthetically suboptimal packaging with sharp edges or require complex and costly processes to achieve visually appealing angled or crimped edges, and often necessitate precise positioning of prefabricated containers for reliable sealing.
Innovation Solution
A packaging machine and method that integrates a forming station for deep-drawing containers with angled or rounded edges, a combined sealing and lid cutting station, and transverse and longitudinal cutting devices to separate packaging precisely along the outer contour, allowing for cost-effective production of visually appealing packaging without the need for precise container positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If packaging is produced by deep-drawing from foil material and sealing with a lid film, then packaging can be produced inexpensively with airtight sealing, but the edge is formed by a horizontally running flat edge section that is sharp-edged and does not meet optical design demands
Solution Approach 1:
The packaging cavities are pre-formed in the foil material before filling and sealing operations. This preliminary forming creates the base structure with integrated angled edge sections that will define the final package shape, eliminating the need for post-forming operations and enabling cost-effective production of aesthetically pleasing packaging
2Shape
If the rim of the package base is desired to have an angled or crimped shape, then visual appeal is improved, but the packaging cannot be manufactured usefully since the cutting of the package base and lid materials must be done at two spaced apart planes
Solution Approach 1:
The cutting operations for both the package base and lid materials are merged into a single plane operation. The packaging cavities are formed and positioned such that both the base material and lid material can be cut simultaneously at the same plane, dramatically simplifying the manufacturing process while enabling angled or crimped edge shapes
3Shape
If prefabricated containers are used and then filled with goods, then containers can have angled or bent edges for improved appearance, but the containers must be precisely positioned individually before filling and sealing
Solution Approach 1:
The containers are pre-formed in a web-like structure with integrated positioning features that automatically align them during the filling and sealing process. This preliminary arrangement eliminates the need for individual precise positioning operations, reducing manufacturing complexity while maintaining the desired angled or bent edge shapes
4Productivity
If lid film is sealed onto several packaging cavities at the same time in one step, then productivity is improved, but the packaging cavities must be grouped beforehand which increases process complexity
Solution Approach 1:
The packaging cavities are pre-formed in a continuous web-like structure that naturally groups them in the desired configuration before sealing. This preliminary web formation enables multiple cavities to be sealed simultaneously in one step without requiring additional grouping operations, thereby increasing productivity while avoiding increased process complexity
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
Enables the production of packaging with visually appealing angled or rounded edges while maintaining cost-effectiveness and efficient processing, ensuring reliable transport and avoiding sharp edges, as the packaging is only separated at the end of the process and the lid material is not cut sharp-edged.
Implementation Method 1
packaging bottom parts are first formed in the foil material from a web of foil material, mostly plastic foil, by means of deep drawing
Implementation Method 2
a film material is sealed along a peripheral edge as a lid onto the respective packaging bottom parts
Implementation Method 3
the packaging produced is separated by the material of the packaging bottom parts and the lid being cut through simultaneously along the outer contour of the packaging to be produced
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method is described for manufacturing a package with the following steps: Forming a container (13) in the web of a first web-type material (7); then sealing a cover (14) onto the manufactured container inside an outer contour of the package to be manufactured; and then separating the container (13) from the first web-type material (7) along the outer contour of the package to be manufactured and outside of the outer contour of the cover (14) sealed thereupon.