Patent Application
20220297386
The purpose of this patent application is to file a patent for the invention of a Continuous Sealing Machine for two Plastic Films. The Continuous Sealing Machine of two Plastic Films provides the means for a modernization of the plastics industry.
Machines in the plastics industry have become more efficient, have achieved better performance and precision. These characteristics have achieved important advances. However, these are the machines we know and there is a new trend to take care of the planet.
The plastic industry is going through a period of unpopularity due to environmentalist currents that have denounced the plastic industry's production as a major factor of pollution.
With the Continuous Sealing Machine of two plastic films, we will achieve ecological productions that will allow us all to contribute to the care of the environment.
This way we all take care of the planet, and the plastics industry will experience a resurgence.
If the trend is heeded, it will revitalize the plastics industry and improve its image. PATENT ANTECEDENT 10162208, MULTI-COMPARTMENT PLASTIC GUSSET BAGS
The two plastic film continuous sealing machine differs from the two compartment bag as a patent, both are patents of invention with the difference that one refers to a product and a method for its manufacture and the patent two plastic film continuous sealing machine refers to an invention for the industry, the sections of the industry are not affected with the introduction of the machine, no adaptations are required, it works with the sections in an independent section, the product of the patent two-compartment bags is for the use of people to carry products to their homes, in one compartment food and in the other compartment toiletries, subsequently to be used as a deposit, in one compartment recyclable waste and in the other non-recyclable waste, the two-compartment bag as a product is a patent that exceeds the state of the art where there are plastic bags that do not allow the classification of products or in its second use the separation of waste, the patent machine is in the industrial context has industrial characteristics, we refer to speeds, accuracy, film tension, sealing temperature, position correction, cold behavior, all industrial characteristics and we do not refer to the manufacture of a product but to the manufacture of rolls within an industrial process where there are sections, some upstream and others downstream, we guarantee performance characteristics, high speeds, performance, all industrial characteristics, it is not an improved method it is a new patent with industrial orientation that goes beyond the state of the art to become part of the industry.
The general objective of this invention is to provide means for a modernization of the plastics industry.
The two-film continuous plastic film sealing machine is a high-performance machine that performs the production of two-compartment tubulars with bellows.
It performs the continuous sealing of two films, a tubular with bellows and a plastic film, folds the bellows of the new compartment and as a result, two-compartment tubulars are obtained, both compartments with bellows.
It is a machine on a main structure consisting of: unwinders, rocker arms, edge aligners, puller roll systems, anti-static bars, special device, motors with coupled gearbox, automatic brakes, electromagnetic clutches, continuous sealers, bellows former, sealer camshaft, front puller roll pitch motor, winding bars, sheet positioning system.
The Continuous Sealing Machine of two plastic films is part of the plastic industry machines along with extruders, printers, sealers, trimming machines, raw material mixers and cliché assembly machines.
Description will now be given with reference to the attached
The Continuous Sealing Machine for two plastic films seals a plastic film and a tubular film with bellows on both sides. On the upper unwinder (1) the film reel is placed on the film reel and on the lower unwinder (2) the tubular film reel with bellows is placed on the lower unwinder (2). The foil film is fed through a puller roller system (7) and the tubular film with bellows through a second puller roller system (8). To avoid negative factors during sealing, the unwinders have been decoupled from the main structure, since the unwinders use an edge aligning system that produces transversal movements on the unwinding bars to correct the alignment of the films, both unwinders have this system that produces vibrations. In the main structure of the machine (33) there is a special device (37) that gives an arc shape to a film by placing its edges on the edges of the tubular with bellows. The device has three segments, the first segment (12) gives the sheet the shape of an arc. The second segment (15) is a stainless-steel arched tunnel with flat flaps and sealing windows with continuous sealers (16) and (17) for sealing the films. Finally, the third element forms the bellows of the new compartment. The films advance, the laminated film above the device and the tubular film with bellows below the device. At the front of the main structure of the machine is located a system of front puller rollers (22), this system of puller rollers keeps the tension of the films constant for a good performance during the sealing and the forming of the bellows of the new compartment. At the end of the structure are located the constant tension winders with clutch (32). Clutch winders tend to overheat, so two winders are used, one working while the other rests to ensure machine availability and performance.
In
In
In
In
In
This general description helps us to locate the parts in the structure of the machine, in the chapter Machine Parts explains in detail its operation.
In the plastics industry there are three sections: extrusion, printing and sealing.
The continuous sealing machine for two plastic films performs the joining of a tubular with bellows and a plastic film.
The two rolls are produced in the extrusion section, in the printing section one of the two rolls is printed.
The continuous sealing machine for two plastic films joins the two films—the tubular and the film—and as a result provides us with a double tubular, both compartments with bellows.
Industrial performance Accuracy High Speed
Availability: 24 hours as it has two constant tension winding motors with electromagnetic clutches.
Speed: from to 180 meters 220 per minute.
Output: Production capacity is determined by machine speed and packaging specifications. A 120 kg roll, at 180 meters per minute: 13.32 minutes. A 120 kg roll, at 220 meters×minute: 10.9 minutes.
Quality monitoring: film detection during the sealing process, sealer temperature measurement, edge alignment system, film positioning rollers. These machine features ensure film sealing or stop the machine and alert the operator.
Antistatic bars
Edge alignment system on unwinder bars
Sealer camshaft
Pitch motor of the front puller rollers
Automatic brakes
Electromagnetic clutches
Film positioning servomotors
Film detection sensors
Safety guards, wheel damping, machine anchors, emergency stops, electrical safety, low noise and low vibration systems, finishes, painting, notices, warnings.
Manuals and spare parts box.
Machine structure (33)
It consists of two parts. The structure of the unwinders decoupled from the main structure and the main structure with the supports for the parts.
The unwinder bars are steel bars, with a toothed wheel at one end for coupling to the magnetic brakes. They have cast iron stops with a safety pin with thread that adjusts to fix the rolls to the bar. The unwinder has at its other end a bushing divided in two with a safety lock to hold the bar.
Constant Tension Unwinders (1) and (2) with Rocker-Controlled Brakes
The unwinders will be decoupled from the main structure so that vibration will not affect the sealers or subsequent stages, sheet positioning rollers, bellows former.
The foil coil is placed on the constant tension unwinder with a rocker arm-controlled brake located at the top. The bellows tubular reel is placed on the constant tension unwinder with brake located at the bottom. The rocker arm (3) and (4) ensure a constant tension on the films in such a way that if the tension decreases, the brake on the spool is activated and if the tension increases, the spool is released from the brake and thus the rocker arm continuously regulates the tension.
For continuous operation, an edge aligner is used to move the bar on which the film reel or roll is placed.
The moving bed has a roller at the height of the rollers of the upper plane of the rocker arm, which moves with the bed. Just before this roller are located the edge-aligning sensors, on the structure where the moving bed is located. The sensors do not move with the bed.
The sensor uses a reference to move the bed to the right or left to perform the alignment correction to ensure that the edges of the film and tubular match exactly at the time of sealing. The edge aligning sensors are placed on the same side on both films. The edge alignment correction is done on a bed that supports the unwinding bars through transversal movements towards the required side by means of a double rotation motor and an auger attached to the bed to permanently center both films.
Both films pass independently through feed rollers. These rollers have a vulcanized rubber coating on the outside to continuously pull the films.
Sprocket Mechanism (9) and (10) and Chain with Motor (11)
The films must maintain a constant linear speed which must be equal on both to ensure sealing, to ensure this both feed roller systems will be linked together by means of a sprocket and chain mechanism and traction will be provided by a single motor with independent speed control.
The electrode bars or antistatic bars are located at the entrance of the films.
The antistatic bars incorporate an inductive coupling that achieves static neutralization.
Operating voltage: V7000.
Stainless steel emitters on insulating material.
Antistatic bars eliminate static electricity from materials by producing positive and negative ions that neutralize those of the material to be de-ionized.
Static-free material is deployed on the surface of the special device.
Special device (37)
It is a device specially designed to condition the films so that their edges match at the time of sealing and for the behavior of the cold film for bellows folding. Its location is from the top entry puller rolls to the front puller rolls.
It is made up of:
First segment of the special device is the element that shapes a sheet or input element of the device (12).
Second segment of the special device is a stainless steel arched tunnel with flat ailerons and sealing windows or central element of the device (15).
The third segment of the special device is the element where the bellows of the new compartment or bellows former are formed.
The first element of the device receives the sheet from the feeding rollers of the machine and places it on the tunnel. It receives the flat sheet, at the same level as the tubular, and brings it up to the height of the tunnel. The purpose of this segment of the device is to take the flat sheet as wide as it is and guide it while making it take the shape of an arc so that in this transition the edges of the sheet are brought closer to the edges of the tubular. When reaching the height of the tunnel at the lower ends of the tunnel, the edges of the sheet coincide with those of the tubular.
Stainless Steel Arched Tunnel with Flat Ailerons and Sealing Windows (15)
The second element of the device has the shape of a tunnel on which the sheet is placed. Below this tunnel is the tubular with bellows, both moving at the same speed. The purpose of this segment of the device is to seal the two films on both sides in the sealing windows.
Now the sheet must descend to the same level as the tubular and coincide with the same width, because now it will have bellows. This part of the device consists of an inner and an outer part. The inner part of the bellows former guarantees the exact shape of the new compartment located over the original tubular and ensures that when the bellows of the new compartment are formed, the pressure on the films does not deform the original tubular. It does this in the following way: inside the new compartment it creates through two metal frames the shape of the expanded compartment necessary for the bellows to be inserted into the new compartment. The outer part of the bellows former uses the outer fittings of the bellows former (20) and (21) by means of which it inserts the bellows into the new compartment.
At the bottom, the bellows former has a rectangular metal frame in contact with the top face of the original tubular, which holds it in place during the process of forming the new bellows where pressure is exerted on it.
From the top of the tunnel to the tunnel exit, the bellows former has a downward trapezoidal metal frame so that the film makes the natural transition from the top of the tunnel to the bottom of the device where the original tubular is located.
On the outside of the film, between the two metal frames, on each side the bellows are inserted through the external fittings of the bellows former which consist of two pieces of wood that push in the material, similar to those used conventionally. These wooden pieces do not produce splinters and have a polished finish.
The sheet positioning rollers located at the lower ends of the arched tunnel rotate outward with independent motors and ensure the sheet position.
To ensure that the new two-compartment film is completely sealed the film positioning rollers (13) and (14) use capacitive film detection sensors and a two-speed motor that performs film correction and positioning displacements.
The capacitive sensors are aligned in threes.
Film detection is performed with capacitive sensors.
Capacitive sensors measure capacitance because the film is an insulating material, the capacitance increases with the film, so capacitive sensors detect the film.
0.4=diameter of each sensor 0.8=width of wheel sealing
The outermost or third sensor detects the film on one side and performs the speed change on the roller on the opposite side. The film positioning roller motors have two speeds, one speed causes the film to extend over the device the other speed causes the film to move to make the positioning correction.
The second speed provides continuous film pulling.
Thus, the Friction Velocity Area ratio equals the correction displacement.
The film is constantly displaced on both sides and sealing is guaranteed.
The continuous sealing system performs the sealing of the films. It performs the function of sealing the edges of the film and the tubular with bellows on both sides. Its main component are the sealing wheels (16) and (17) located in the sealing windows. The continuous sealing system consists of:
Bronze Sealing Wheels (16) and (17) with Heating Elements
Collector and brush system (29) and (30)
Shaft (34) and (35) and support (27) and (28) of the sealing wheels Non-stick Teflon tape
Sealing wheel damping system
Sealing wheel pulleys (18) AND (19)
Sealing wheel camshaft
Sealant bases and tubular guides
Bronze Sealing Wheels (16) and (17) with Resistors
The sealer is a bronze wheel with high relief cross-hatching that provides a safety seal. It rotates on a shaft (34) and (35), the resistors are cylindrical and are located in the center or core of the wheel where the holes for the resistors have been drilled.
The temperature is adjustable and is controlled through the reading of a thermocouple housed in the center of the wheel by means of an electric thermostat. There are two thermocouples, one in each wheel and two thermostats to control the temperature of each wheel. If the temperature rises in the wheels the thermostat de-energizes the resistors and if it falls it energizes turning on the resistors, with some temperature curves it manages to maintain the constant sealing temperature.
Power is provided by a collector and brush system. The commutator rotates with the wheels and has conductive tracks that transmit electricity. The carbon brushes remain static and transmit the electricity to the collector tracks.
A shaft (34) and (35) is used as a support for the sealing wheels, which holds the sealing wheel (16) and (17) and rotates with the sealing wheel. It has three main parts. The first one is to hold the sealing wheel, the second part carries inside it the wires of the resistors that are connected to the collector that rotates together with the shaft. The third part is to support the sealing wheel pulley (18) and (19) from where the wheels receive the traction. The shaft is attached to a support (20) and (21) with bearing which functions as a support for the parts. The support is an arm that has a pivot point, its second function is to raise the wheels by action of the camshaft.
The sealing wheels use non-stick Teflon tape to achieve the controlled parameters of temperature, pressure, sealing time, during the operation of the sealers. The Teflon tape is non-stick and thus does not allow the films to stick to the sealers, thus achieving stable parameters and continuous work.
The sealing wheels use compression springs to ensure contact with the films at high speeds. The springs are located in the arm or support of the sealing wheels and act in both positions of the wheel, in contact with the films and in an elevated position.
The speed of the sealing wheels must be identical to that of the film or the film will tear on contact with the wheels at high temperatures. This is achieved by using pulleys that receive traction from the feed rollers. The pulleys should be of the same dimension on the wheels and on the feeder rolls, two pulleys one on each wheel and two pulleys on one of the feeder rolls, one on each side, connected with elastic belts of circular cross section.
It has two positions.
The raised position raises the sealing wheel.
When the cam is in the second position the wheel contacts the films.
As bases for the sealing of the films, flat rectangular pieces are used, one on each side of the films, which are placed between the folds of the bellows of the original tubular. In addition to providing support for the sealants, this prevents the upper fold from sealing with the lower fold of the bellows of the tubular, which would spoil this compartment. It also serves as a guide to ensure the correct position of the original tubular. These pieces are made of aluminum of a suitable thickness and with rounded edges to avoid heating and to improve the displacement conditions of the tubular film.
At the exit of the special device the front puller roller system advances at the same speed as the infeed rollers and maintains the tension of the two-compartment film in both compartments with bellows.
The front puller roller system advances at the same speed as the infeed rollers and maintains film tension.
If this does not happen, the films suffer a shift to the right or to the left, making the seal on one side defective.
The stepper motor allows the front puller roller system to advance in degrees while maintaining the speed of the films and performs the tension correction.
If the voltage decreases, the current also decreases in the motor power supply.
To perform the voltage correction, the stepper motor is advanced a few degrees. Increasing the voltage increases the current intensity, making the respective correction.
Two Constant Tension Winders with Clutch (32)
When one motor is working, the other rests.
For working 24 hours
365 days per year
The electromagnetic clutch couples the motor to the load.
While the field assembly is fixed and prevented from turning, the rotor assembly is secured.
When the coil is energized the armature positively connects the motor to the load.
Thus, boosting the load at high medium and low speed.
Today's plastics industry manufactures two-track rolls, so in extrusion, printing and sealing areas, more efficient production is achieved. Productivity is very important, so machines have improved their efficiency with two-track production.
The Continuous Two-Track Film Sealing Machine described below is no exception. With two-track productions it achieves unsurpassed for their performance in terms of accuracy, speeds, availability and throughput.
The two-track Continuous Film Sealing Machine uses two modules, one for blowing the balloons to form the new bellows and one for rewinding to split the film.
The first module divides the tubular with a hot knife and seals it longitudinally, uses an arched support that contributes to the rapid cooling of the films, fills the two tubulars with air with air guns and forms the bellows of the two tubulars.
In the bellows forming tower, the upper puller rollers ensure that air does not escape from the balloons. The upper puller rollers are equipped with shutters that do not allow the balloons to move forward or backward.
Wooden parts insert the bellows. The louvers ensure symmetries.
The second trimming module splits the sheet in two with a cold knife. The positions of the two modules are described below.
The balloon blowing module is located at the rear and the tubular films use guide rollers for their location on the rocker arms.
The foil trimming module is located in front of the blowing module above, it uses guide rollers for its location on the upper rockers.
The two foil films move outward. Likewise, the two tubular films with bellows are centered on each other.
For this purpose, two rotating guide rollers are used, mounted in such a way that they receive the films and project them outwards to obtain the displacement.
Then, the foil and tubular films with bellows enter the rocker arms independently. The work of the rocker arms is very important as the input tension must be equal on both tracks.
Then the independent rocker arms, two for each track, achieve the tensions.
The infeed rollers with their system of sprockets and motorized chain feed the films on both sides.
Then two special function devices, one for each track, position the edges of the foil films on the edges of the tubular films with bellows.
Both special function devices with their sealing wheels, sealer bases and foil positioning rollers.
The front puller rollers with their stepper motor maintain the tension.
Split winders, each side with its electromagnetic clutches and motor make up the two-compartment rolls.
Tubular films with bellows and foil are now printed. Both prints have the print bar used by optical readers in sealing. Our machine has to center both prints. For this ituses the stroboscopic effect that facilitates the operation and a moving roller that moves in the direction of the films on a metal frame, there are four rollers, the two back ones do not move, the front one on top moves centering the prints.
A servomotor is also used to adjust the position of the moving roller. In this case, optical readers are used to locate the tags.
Having described certain embodiments of the invention, it should be understood that the invention is not limited to the above description or the attached exemplary drawings. Rather, the scope of the invention is defined by the claims appearing hereinbelow and includes any equivalents thereof as would be appreciated by one of ordinary skill in the art.
| Number | Date | Country | Kind |
|---|---|---|---|
| NC2019/0004838 | May 2019 | CO | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2020/054303 | 5/7/2020 | WO |
