Single-Use Beverage Capsule Forming and Joining Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing single-use beverage capsules lack precision and efficiency in forming and joining capsule components, leading to suboptimal productivity and potential defects during the manufacturing process.
Innovation Solution
A method involving positioning a flat piece of filter paper over a cup-shaped rigid body, joining it along the rim, and forming it into a containment chamber through plastic deformation, followed by filling and closing the capsule with a sheet lid, utilizing a machine with coordinated cutting, joining, and thermoforming units to enhance precision and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to form and join capsule components, then the manufacturing process is simpler, but the precision and reliability of component positioning and joining deteriorate
Solution Approach 1:
The filter paper is positioned and joined to the rigid body before the forming operation. This preliminary positioning ensures precise alignment of the filtering chamber relative to the external body before deformation occurs, resolving the precision issue while maintaining process simplicity
Solution Approach 2:
The manufacturing process is divided into distinct sequential steps: positioning flat filter paper, joining along the rim, then forming into the containment chamber. This segmentation allows each operation to be optimized independently, achieving high precision without excessive overall complexity
2Productivity
If traditional capsule production methods are used, then the equipment is simpler, but the productivity and production speed deteriorate
Solution Approach 1:
The machine integrates cutting, joining, and thermoforming operations into a single coordinated system that processes capsules sequentially. This merging of operations into one machine eliminates the need for multiple separate equipment, increasing productivity while controlling overall device complexity
Solution Approach 2:
The machine performs cutting, joining, and forming operations in continuous sequence without interruption for each capsule. This continuous production flow maximizes productivity by eliminating idle time between operations, justified by the integrated machine design
3Reliability
If flat filter paper is positioned and joined before forming, then the relative positioning precision and joining security improve, but the process steps increase
Solution Approach 1:
The filter paper is joined to the rigid body in a flat state before forming occurs. This preliminary joining ensures secure attachment and precise relative positioning are established before the forming operation, improving reliability while the sequential integration keeps process complexity manageable
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
The method and machine achieve precise positioning and secure joining of internal and external components, significantly improving productivity and reducing the risk of defects, resulting in a faster and more efficient production of high-quality single-use beverage capsules.
Implementation Method 1
forming the piece of filter paper towards the interior of the rigid body and by means of plastic deformation of the piece of filter paper so as to define a containment chamber
Implementation Method 2
joining the flat piece of filter paper along at least the rim of the rigid body
Data Source
AI summary
A method for producing a single-use capsule (1) for extraction beverages comprises the steps of: positioning a flat piece (8) of filter paper over a cup-shaped rigid body (2); joining the flat piece (8) of filter paper along at least the rim (7) of the rigid body (2); forming the piece (8) of filter paper towards the interior of the rigid body (2) and by means of plastic deformation of the piece (8) of filter paper so as to define a containment chamber (5); filling of the containment chamber (5) with a dose (D) of product; closing of the chamber (5) and of the external rigid body (2) with a sheet lid (6). This invention also relates to a machine (100) which implements said method.