Zipper Segmentation for Packaging Bags with Sliders
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Solution Overview
Problem
In the manufacturing of packaging bags with zippers and sliders, the variation in pitch length of sliders and bags leads to excess sliders on some bags, causing defects and disrupting the production chain, resulting in the entire bag being ejected and significant manufacturing overcost.
Innovation Solution
A method involving cutting the zippers to eject excess sliders, ensuring only one slider per bag, with cuts spaced at multiples of the bag pitch, and positioning sliders near cuts to maintain efficient welding and bag sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sliders are positioned on zippers with pitch variations to accommodate bag pitch variations, then the zippers can be welded continuously onto the bags, but excess sliders may end up on some bags causing defects
Solution Approach 1:
The zipper is divided into multiple segments by making cuts at regular intervals. Each segment can accommodate one slider, and the cuts separate the zipper into discrete sections that align with individual bags during welding. This segmentation ensures that even with pitch variations, each bag receives exactly one slider on its zipper segment.
Solution Approach 2:
The zippers are pre-cut into segments before being welded onto the bags. By performing the cutting action in advance and at regular intervals, the system prepares the zipper in a state that automatically accommodates pitch variations during welding, preventing excess sliders from being attached to single bags.
2Ease of manufacture
If excess sliders are present on a bag, then the bag can still be manufactured, but the bag must be ejected as defective causing production chain disruption
Solution Approach 1:
By cutting the zipper into segments at regular intervals, the system ensures that each bag receives exactly one slider. This prevents the formation of bags with excess sliders that would need to be ejected, thereby maintaining continuous production flow and eliminating defects caused by multi-slider bags.
3Adaptability or versatility
If zippers are welded with excess thickness at lateral weld zone, then the zippers can accommodate pitch variations, but the welding efficiency decreases and bag sealing is weakened
Solution Approach 1:
The zipper is cut into segments at regular intervals, creating defined endpoints for each weld zone. This segmentation allows the zipper to accommodate pitch variations through the modular structure while maintaining controlled, efficient welds at each segment boundary, preventing excess material accumulation that would hinder welding efficiency and sealing quality.
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 approach prevents production chain disruptions and overcosts by ensuring only the slider is lost, rather than the entire bag, while improving welding efficiency and bag sealing by reducing excess thickness at the lateral weld zone.
Implementation Method 1
welding, onto the scrolling film, of opening and closing zippers that include a series of operating sliders
Data Source
AI summary
A method for the manufacture of packaging bags, which includes a step of forming at least one bag in a scrolling film, welding opening and closing zippers that include a series of operating sliders onto the scrolling film, and effecting at least one cut in the zippers, where the length of the cut is greater than the length of each slider.