Welding Spout Ribs Localized Heating
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Solution Overview
Problem
Existing methods for welding a removal nozzle into a plastic bag packaging are time-consuming and labor-intensive, and they do not achieve a tight, crack-resistant connection with minimal energy expenditure.
Innovation Solution
Only the outer edges of the ribs on the removal nozzle are heated to the welding temperature, deforming into a T-shape to create a large contact surface, and the design includes chambers to absorb melted plastic, ensuring a smooth and strong bond with reduced gas and fume formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire dispensing spout is heated and inserted into the bag opening while heated, then the spout can be welded to the bag, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
Instead of heating the entire dispensing spout, the invention applies heat locally only to the outer edges of the ribs in the welding area. This localized heating approach reduces the time and energy required for the welding process while still achieving a reliable weld connection between the spout and the bag opening.
2Reliability
If the outer edges of the ribs are heated to welding temperature and pressed against the film, then a tight connection is achieved, but the entire spout heating process consumes excessive energy
Solution Approach 1:
The invention applies thermal energy locally only to the outer edges of the ribs rather than heating the entire spout. This localized energy application achieves the necessary welding temperature at the contact points with the bag film, ensuring tight connection while dramatically reducing overall energy consumption.
Solution Approach 2:
The welding area is segmented into discrete ribs with outer edges that are individually heated. This segmentation allows the heating process to target only the specific areas that need to be welded, rather than heating the entire spout structure, thus reducing energy consumption while maintaining connection integrity.
3Ease of manufacture
If smooth weld surfaces are used, then the welding process is simple, but gases between the surfaces cause poor weld quality
Solution Approach 1:
Instead of using smooth symmetrical weld surfaces, the invention introduces asymmetric rib structures with outer edges that deform into T-shapes during welding. This asymmetric geometry creates channels and cavities that allow gases to escape during the welding process, preventing gas pockets from compromising weld quality while maintaining manufacturing simplicity.
4Strength
If the ribs deform into T-shape in cross-section, then a large contact surface is created for force transfer, but the heating process becomes more complex
Solution Approach 1:
The ribs are pre-formed with a specific geometry that includes outer edges designed to deform into T-shapes during the welding process. This preliminary structuring ensures that when heat is applied and the material softens, the ribs naturally deform into the desired T-shape configuration, creating large contact surfaces for force transfer without requiring complex real-time shaping equipment.
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 achieves a tight, crack-resistant connection with reduced production time and energy, maintaining the purity and rigidity of mono-material polyethylene bags while providing an aesthetically smooth surface.
Implementation Method 1
the outer edges of the ribs in the weld area are heated to welding temperature without contact, using radiant heat or laser beams
Implementation Method 2
the outer edges of the ribs in the weld area are heated to welding temperature without contact, using radiant heat or laser beams
Implementation Method 3
when pressed against the inner wall of the film in the molten state, the outer edges of the ribs deform into a T-shape in cross-section
Implementation Method 4
the outer edges of the ribs of the sealing area are heated to the welding temperature and, in their molten state, placed between the edges of the pouch plastic film. The pouch plastic film is then pressed against the outer edges of the ribs
Data Source
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AI summary
The invention relates to a method for welding in a removal connection, with its welding region having ribs between the flexible plastic films of a bag packaging, wherein the outer edges of the ribs of the welding region are heated to the welding temperature and in the molten state are put between the edge regions of the bag plastic films and the films are pressed onto the outer edges of the ribs, the outer edges of the ribs being deformed with a T-shaped cross-section when pressed in the molten state against the inner film wall, in order in this way to form an enlarged bearing surface on the inner film wall, and the one-, two- or multi-layer films of the bag packaging are made of the same plastic or the same type of plastic as that of the removal connection.