Interchangeable Contact Elements for Rapid Welding Format Changes
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Solution Overview
Problem
Existing welding units for automatic container forming and filling machines require extensive time and economic costs to adapt to different container formats, as they necessitate the complete disconnection and reconnection of pressure and heat applicators to new formats, and the user must maintain multiple sets of applicators for various formats.
Innovation Solution
The welding unit employs interchangeable contact elements that can be easily swapped by loosening and tightening releasable holding means, allowing adaptation to new formats without disconnecting from the heat energy supply or driving means, using contact elements with high heat conductivity materials and a wedge effect for secure heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complete pressure and heat applicators are replaced to adapt to different container formats, then format adaptability is improved, but device complexity and economic cost increase due to needing multiple complete applicator sets
Solution Approach 1:
The pressure and heat applicator is divided into two functional parts: a base body (support structure) and interchangeable contact elements (welding surfaces). The contact element can be detached and replaced independently from the base body, allowing format adaptation without replacing the entire applicator assembly. This segmentation enables users to maintain only one base body while having multiple contact elements for different formats.
Solution Approach 2:
The contact element is extracted as a separate, replaceable component from the complete pressure and heat applicator. By removing the contact element from the integrated applicator structure, the patent enables independent replacement of only the format-specific portion while retaining the heating and support infrastructure.
2Adaptability or versatility
If complete pressure and heat applicators are disconnected and reconnected for format changes, then format adaptability is improved, but loss of time increases due to extensive disconnection and reconnection procedures
Solution Approach 1:
By segmenting the applicator into a permanent base body and replaceable contact elements, the patent eliminates the need to disconnect heating elements, power supplies, and mechanical linkages during format changes. Only the contact element needs to be removed and replaced, dramatically reducing format change time.
Solution Approach 2:
The contact elements are pre-configured with mounting features that align with the base body, allowing for quick attachment without complex alignment procedures or extensive reconnection steps.
3Adaptability or versatility
If multiple complete sets of pressure and heat applicators are maintained for different formats, then format adaptability is improved, but economic cost increases due to purchasing and storing multiple complete applicator sets
Solution Approach 1:
The patent segments the applicator system into one reusable base body and multiple inexpensive contact elements. Users only need to invest in one base body and several contact elements instead of multiple complete applicator sets, significantly reducing inventory requirements and economic cost.
Solution Approach 2:
The base body is designed as a universal platform that can accommodate different contact elements for various container formats. This multi-functionality allows a single base body to serve multiple format requirements through simple contact element interchangeability.
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 solution enables quick and economical format changes with minimal adjustments, reducing the need for multiple complete welding units and allowing format changes to be performed without altering the driving or heating setups, thus saving time and resources.
Implementation Method 1
the contact element is heated by contact with the base body
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The welding unit comprises a pair of pressure and heat applicators (10) facing one another and located on opposite sides of a container precursor made of flexible heat-sealable film, heating means heating said pressure and heat applicators (10) and driving means moving said pressure and heat applicators (10) between a released position and a welding position. Each of the pressure and heat applicators (10) comprises a base body (12) heated by said heating means and connected to said driving means, a contact element (14a, 14b) configured to form a weld with a predetermined format in contact with the container precursor, and releasable holding means for fixing said contact element (14a, 14b) to said base body (12). The contact element (14a, 14b) is heated by contact with the base body (12).