Wide Backing Roller Sealing Inflatable Web

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Solution Overview

Problem

Existing machines for forming inflated packaging cushions face issues with alignment and tracking problems, leading to poorly-inflated, non-inflated, or prematurely deflated cushions due to suboptimal web-loading, web-feeding, and web-sealing mechanisms, resulting in web wastage and inadequate product protection during shipment and storage.

Innovation Solution

A system comprising a sealing roller and a backing roller with a sealing element, where the rollers counterrotate to advance and seal a web of inflatable containers, with the backing roller's circumferential surface extending farther into the web than the sealing roller's, and the rollers being arranged to form a nip that minimizes stress points and facilitates efficient sealing and inflation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heat-sealing is performed on the web, then sealing of containers is achieved, but the web may tear, stretch, or deform causing deflation

Engineering Contradiction:

Improvesealing reliabilityVSAvoidweb damage during sealing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The web is pre-inflated with gas through ports before sealing occurs. This preliminary inflation provides internal structural support that prevents the web from tearing, stretching, or deforming during the heat-sealing process, while still achieving reliable seals on the inflated containers

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The internal gas pressure created by preliminary inflation acts as a cushioning force that protects the web structure during sealing. This pre-established internal pressure distributes stresses uniformly, preventing localized damage that would cause deflation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If smaller, less-expensive inflation machines are used, then cost is reduced, but alignment and tracking problems occur resulting in poorly-inflated or non-inflated cushions

Engineering Contradiction:

Improvemachine costVSAvoidweb alignment and tracking

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The web handling mechanism serves multiple functions: it guides the web through the machine, maintains proper alignment during inflation, and ensures accurate positioning for sealing operations. This multi-functional design achieves precise web control in a cost-effective manner without requiring separate complex alignment systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

A guide roller or tracking mechanism acts as an intermediary element that mediates between the web and the inflation/sealing zones. This intermediary component ensures proper web alignment and tracking throughout the process, preventing poorly-inflated or non-inflated cushions while keeping the overall machine design simple and cost-effective

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If web advancement and sealing are performed simultaneously, then productivity is improved, but sealing quality may deteriorate due to web movement

Engineering Contradiction:

Improveweb advancement speedVSAvoidseal formation quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The web advancement function and sealing function are merged into a single integrated roller assembly. The roller simultaneously grips the web to advance it while applying heat and pressure to form seals. This integration ensures that sealing quality is maintained even during continuous web movement, as the sealing action occurs in sync with web advancement rather than as a separate stationary step

Inventive Principle:

Principle #5Merging (Combining)

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

The system ensures consistent and reliable production of inflated containers with improved sealing efficiency, reducing web wastage and enhancing product protection by maintaining inflation and preventing premature deflation.

Implementation Method 1

the sealing roller and backing roller counterrotate to advance the web

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

The sealing roller includes a sealing element located around a circumferential surface of the sealing roller

Methodology Applied

Scientific EffectHeat: Heating

Data Source

PatentUS20230256699A1Roller sealing machines having wide backing rollers

Publication Date: 2023.08.17 SEALED AIR U S

AI summary

A system is capable of advancing and sealing a web of inflatable containers. The system includes a sealing roller that includes a sealing element located around a circumferential surface of the sealing roller. The system also includes a backing roller positioned with respect to the sealing roller to form a nip between a circumferential surface of the backing roller and the circumferential In surface of the sealing roller. When the longitudinal edge of the web is located in the nip, the sealing roller and backing roller counterrotate to advance the web. The circumferential surface of the backing roller extends axially farther into the web than the circumferential surface of the sealing roller extends axially into the web such that backing roller contacts the web at a transverse location that is farther away from the longitudinal edge of web than the sealing roller contacts the web.