Biodegradable Capsule Preheating Apparatus with Airflow Disrupters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing beverage capsules from biodegradable materials are not suitable due to the low heat resistance of these materials, which causes them to melt or degrade during the shaping process, especially at the high speeds required in production.
Innovation Solution
A preheating apparatus that uses a housing with airflow passages to uniformly heat the material, providing a substantially uniform temperature distribution across the defined areas, allowing for quick and efficient heating of biodegradable materials without melting, using heated air streams and airflow disrupters to ensure consistent temperature across the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heated air is applied to shape biodegradable material quickly, then productivity is improved, but the material melts or degrades due to excessive heat
Solution Approach 1:
The patent applies different temperature zones to different areas of the material. The airflow passages deliver heated air at controlled temperatures to specific defined areas, allowing localized heating that is sufficient for shaping without exceeding the material's thermal tolerance and causing degradation.
Solution Approach 2:
The material is preheated to a controlled temperature before the shaping process begins. This preliminary heating prepares the biodegradable material for forming without subjecting it to excessive heat, enabling subsequent shaping while maintaining material integrity.
2Manufacturing precision
If uniform temperature distribution is achieved across the material, then manufacturing precision is improved, but device complexity increases due to airflow disrupters
Solution Approach 1:
Airflow disrupters are introduced as intermediary elements within the airflow passages. These disrupters modify the heated air flow to eliminate temperature gradients and ensure uniform heat distribution across the material surface, achieving precise temperature control.
3Temperature
If heated air is applied to biodegradable material, then the material can be shaped, but the material melts due to low heat resistance
Solution Approach 1:
The patent carefully controls the temperature parameter of the heated air applied to the biodegradable material. By maintaining the temperature within a specific range (above glass transition but below melting point), the material becomes sufficiently pliable for shaping while retaining its structural integrity and preventing melting.
4Productivity
If high speed production is maintained, then productivity is improved, but the material degrades due to insufficient cooling time
Solution Approach 1:
The heating and shaping processes are conducted in continuous sequence without interruption. The material flows continuously through the heating zones and shaping zones, maintaining optimal temperature throughout the process and eliminating idle time that would cause cooling and potential quality issues, thereby enabling high-speed production while preserving material integrity.
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
Enables the production of beverage capsules from biodegradable materials by heating them to the required temperature range (75° C to 140° C) in a short time (less than 1 second) without degrading the material, ensuring consistent quality and environmental sustainability.
Implementation Method 1
a plurality of spaced apart airflow passages for receiving a supply of heated air... an outlet for discharging the heated air to a defined area on the material
Implementation Method 2
an airflow disrupter supported within the airflow passage and being configured to disrupt the airflow through the passage to provide a substantially uniform temperature distribution across the outlet
Data Source
AI summary
The present invention related to an apparatus and method for the manufacturing of beverage capsules. The apparatus can preheat the material used to form the beverage material during the manufacturing process. The material and apparatus are particularly suitable for use in producing single serve beverage capsules from biodegradable materials.