Beaker-Shaped Filter Manufacturing and Insertion Apparatus
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Solution Overview
Problem
Existing apparatuses and methods for manufacturing and inserting beaker-shaped filters into single dose capsules for beverages are complex, require significant space, and have low throughput due to the need for complicated handling and feeding mechanisms.
Innovation Solution
An apparatus comprising a punching and forming device for creating beaker-shaped filters, separate transport devices that are movable with respect to each other for efficient filter placement into capsules, allowing for higher throughput and compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single device is used for punching, forming and inserting filters along a single work axis, then the device construction is simplified, but the throughput is reduced and the device requires considerable space
Solution Approach 1:
The apparatus is divided into separate functional devices: a punching and forming device for creating filters, and a separate insertion device for placing filters into capsules. These devices work in parallel along the work flow direction, allowing simultaneous filter production and insertion operations, thereby increasing throughput without requiring a single complex multi-functional device.
2Manufacturing precision
If complicated handling and feeding mechanisms are used to feed filters to capsules, then the filter insertion precision is improved, but the device requires significant space and has low throughput
Solution Approach 1:
The filter feeding and positioning function is extracted from the insertion device and integrated into the punching and forming device. The formed filters are directly transferred from the punching and forming device to the insertion device through a simplified transport mechanism, eliminating the need for complex intermediate handling and feeding mechanisms while maintaining insertion precision.
3Productivity
If separate devices for punching and forming and for inserting are used, then the throughput is increased, but the device construction becomes more complex
Solution Approach 1:
The punching and forming operations are merged into a single integrated device that produces formed filters ready for insertion. This combined device works in parallel with the insertion device, allowing simultaneous filter production and insertion. The merging of punching and forming functions reduces the number of separate devices needed while maintaining high throughput.
4Adaptability or versatility
If filters are fed from a filter forming station to the insertion line, then the filter formation and insertion can be separated, but the plant footprint increases and complicated handling means are required
Solution Approach 1:
The apparatus arranges the punching and forming device and insertion device along the work flow direction rather than perpendicular to it. This dimensional reorganization allows the formed filters to be directly transported from the punching and forming device to the insertion device in a compact linear arrangement, reducing the plant footprint while maintaining process flexibility.
Data Source
AI summary
An apparatus for manufacturing filters and inserting the filters into single dose capsules for preparing beverages comprises a punching and forming device for punching material portions from a sheet material and forming the material portions to assume the form of a beaker-shaped filters, an insertion device arranged in a distance of the punching and forming device along a work flow direction for inserting the formed filters into the capsules, a first transport device (175, 176) for accepting a plurality of formed filters from the punching and forming device and transporting the accepted filters to the insertion device, a second transport device (177) for accepting a plurality of formed filters from the punching and forming device and transporting the accepted filters to the insertion device. The first transport device (175, 176) and the second transport device (177) are movable with respect to each other.