Simultaneous Capsule Body and Filter Forming Mold
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Solution Overview
Problem
The existing methods for producing beverage capsules with integrated filters are complex, laborious, and costly, requiring separate stations for forming the capsule body and filtering element, which leads to increased production complexity and rejects due to the fragility and instability of the filtering elements.
Innovation Solution
A forming mold that simultaneously shapes both the capsule body and filtering element from thermoformable plastic and filtering material, using a single mold with integrated stretching elements and preheating, allowing for simultaneous deformation and welding of both materials, reducing the need for separate stations and minimizing production rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate stations are used for forming capsule body and filtering element, then each component can be formed with dedicated tools, but the production process becomes complex and laborious
Solution Approach 1:
The patent combines the forming of the capsule body and the filtering element into a single simultaneous operation using one mold. The mold includes a first cavity for the capsule body and a second cavity for the filtering element, both formed in one operation from a single thermoformable sheet, eliminating the need for separate forming stations and reducing process complexity while maintaining precision through integrated tooling design.
Solution Approach 2:
The single mold serves multiple functions by simultaneously forming both the capsule body and the filtering element. The mold structure incorporates both the first cavity for the capsule and the second cavity for the filter, allowing one tool to perform what previously required two separate tools, thereby simplifying the production apparatus while maintaining manufacturing precision.
2Manufacturing precision
If separate stations are used for forming capsule body and filtering element, then each component can be formed independently, but production time increases
Solution Approach 1:
The patent merges the forming operations into a single simultaneous operation where the capsule body and filtering element are formed at the same time in one mold. This eliminates sequential processing steps and reduces production time while maintaining precision through the integrated cavity design that ensures both components are formed with the required accuracy in one operation.
Solution Approach 2:
The forming process continues without interruption as both the capsule body and filtering element are formed simultaneously in the same operation. The continuous action of the mold closing and material deformation occurs in one uninterrupted motion, eliminating the time losses associated with separating, moving, and repositioning components that would occur with sequential forming operations.
3Manufacturing precision
If filtering element is formed separately and then assembled, then the filtering element can be pre-formed with precise geometry, but the assembling station becomes complex and expensive
Solution Approach 1:
The patent eliminates the assembling station by forming the filtering element directly within the mold cavity as part of the simultaneous forming operation. The second cavity in the mold shapes the filtering element in its final configuration, and the welding of the filter to the capsule body occurs automatically during the forming process, removing the need for a separate complex assembling station while maintaining precise filter geometry.
Solution Approach 2:
The filtering element is pre-formed within the mold cavity in its final geometric configuration before the capsule body is completely formed. The second cavity shapes the filter in advance, and the welding operation is performed automatically as part of the forming cycle, eliminating the need for a separate assembling station and reducing overall process complexity.
4Measurement precision
If filtering element is handled separately during assembly, then the filtering element can be positioned precisely, but the fragile and unstable filtering element is more prone to damage and deformation
Solution Approach 1:
The patent combines the positioning and forming operations into a single simultaneous operation where the filtering element is formed directly in its final position within the mold cavity. This eliminates the need for separate handling and positioning operations that would subject the fragile filtering element to damage and deformation, while maintaining precise positioning through the integrated mold cavity design.
Solution Approach 2:
The filtering element is pre-formed and positioned within the mold cavity in its final configuration before any assembly operations. The second cavity shapes the filter in advance in its precise final position, and the welding to the capsule body occurs automatically during the forming cycle, eliminating subsequent handling operations that could damage the fragile filtering element and ensuring both precise positioning and reliability.
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 simplifies the production process, reduces production time and costs, and minimizes rejects by integrating the formation of capsule bodies and filtering elements in a single mold, ensuring precise alignment and reducing the risk of damage to the filtering elements.
Implementation Method 1
In the heating station the sheet material is prepared for the subsequent forming operation i.e. it is heated until it reaches a predetermined softening temperature, in order to increase plasticity and deformability thereof
Implementation Method 2
The forming station comprises one forming mold wherein one or more punches push the sheet inside respective cavities of a die in such a way as to make the casings
Implementation Method 3
The filtering elements are introduced in their respective casings of the capsule and fixed thereto by welding in the packaging machine
Data Source
AI summary
A method for making a capsule provided with a body containing a filtering element suitable for receiving a product for preparing a beverage, including: supplying a first film of thermoplastic material and a second film of filtering material to a forming mold according to a supplying direction, superimposing the second film on the first film, the forming mold including a lower half mold in which a plurality of cavities is obtained and an upper half mold provided with a plurality of stretching elements, one for each cavity, which are movable in one direction that is perpendicular to the supplying direction; pre-heating to a softening temperature the first film of thermoplastic material, by a pre-heating device arranged upstream of the forming mold; closing the forming mold bringing the lower half mold and the upper half mold towards one another until they clamp between one another the first film of thermoplastic material and the second film of filtering material; simultaneously forming in the cavities the bodies of the capsules and the respective filtering elements, using the stretching elements. An apparatus for making a capsule provided with a body containing a filtering element suitable for receiving a product for preparing a beverage, including: one forming mold including a lower half mold wherein a plurality of cavities is obtained and an upper half mold provided with a plurality of stretching elements, one for each cavity, movable in one direction, a supplying means that is movable in one advancement direction that is perpendicular to the direction, to supply simultaneously to the forming mold and to keep taut a first film of thermoplastic material and a second film of filtering material, a pre-heating device for pre-heating at least the first film of thermoplastic material before it is supplied to the forming mold.