Brewing Cup Filter Sealing with Expanding Collets for Weld Alignment
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Solution Overview
Problem
Existing systems for placing and sealing cup-shaped filters into brew cups suffer from precision alignment issues, leading to failed welds and inconsistent seals, resulting in media spills, inaccurate liquid flow, and machine malfunctions due to the flimsy nature of filter materials and reliance on complex alignment devices.
Innovation Solution
The use of expanding weld collets for precise filter placement and sealing, where a first collet positions the filter and a second collet provides redundancy to ensure a full seal, eliminating the need for precise alignment devices and enhancing the weld area by providing 75% coverage, resulting in a four times greater sealing area compared to prior systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single push-down motion is used to position and weld the filter, then the process is simple and fast, but the filter placement precision is poor leading to failed welds
Solution Approach 1:
The single push-down motion is segmented into two distinct operations: first positioning the filter to the correct height above the cup, then welding it in place. This separation allows each operation to be optimized independently, achieving both high speed and high precision.
Solution Approach 2:
The filter is preliminarily positioned at the correct height above the cup before welding occurs. This preliminary positioning ensures proper alignment and spacing, preventing failed welds while maintaining efficient production speed.
2Manufacturing precision
If the welding head is precisely located using linear rails and floating mechanism, then alignment is improved, but the equipment complexity increases significantly
Solution Approach 1:
The complex alignment mechanism (linear rails and floating head) is extracted and replaced with a simpler positioning system that places the filter at the correct height before welding. This eliminates the need for precision alignment apparatus while maintaining welding accuracy.
Solution Approach 2:
Instead of using expensive, complex precision alignment equipment, the invention uses a simpler, more economical positioning approach that achieves the same alignment result without requiring sophisticated machinery.
3Strength
If one side of the filter is pushed lower than the rest during welding, then the filter may be secured, but seal failure occurs
Solution Approach 1:
The filter is preliminarily positioned at the correct height above the cup before welding, ensuring uniform alignment across the entire filter surface. This prevents uneven pushing during welding that would cause seal failures while maintaining secure attachment.
Solution Approach 2:
The attachment process is segmented into positioning and welding stages, allowing the filter to be uniformly positioned before the welding force is applied. This ensures even pressure distribution and consistent sealing around the entire filter perimeter.
4Manufacturing precision
If the filter material is flimsy and difficult to control, then placement consistency is poor, but using stiffer material may compromise filter performance
Solution Approach 1:
The filter is preliminarily positioned at the correct height above the cup before welding, achieving precise placement control without requiring stiff material. This preliminary positioning works effectively with flimsy filter materials, maintaining both placement consistency and material flexibility.
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 method ensures consistent and accurate filter placement and sealing, reducing aberrations and improving the quality of the weld, thereby preventing spills and malfunctions, and enhancing the reliability of beverage handling systems.
Implementation Method 1
An expanding weld collet is inserted into the filter and prevents failures caused by the prior combined push-down and welding action
Implementation Method 2
heat-conductive sealing, providing a wider sealing area and redundancy to ensure consistent and reliable filter-to-cup welds
Data Source
AI summary
A filter setting and sealing apparatus includes a wobble plate mounted to press a filter edge into a plane defined by the top rim of a brew cup. A sealer defined by expandable sealer jaws is moveable into the filter. The jaws are actuated for radial outward expansion to seal the filter to the cup proximate the filter rim and cup edge. A second sealer is used to seal any gaps remaining in the seal after initial sealing. Methods are disclosed.