Capsule Manufacturing Machine for Smoking Articles
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Solution Overview
Problem
Existing manufacturing machines for producing capsules for smoking articles with liquid contents face challenges in achieving satisfactory productivity and maintaining welding quality due to the small dimensions of the components involved, particularly in the cutting and welding steps.
Innovation Solution
A manufacturing machine with a closed-loop feeding system that includes a conveyor, a coupling station with a transfer drum and pneumatic suction system for precise handling and cutting of covering elements, and a welding station with ultrasound welders for uniform welding of covering elements to cup-shaped bodies, ensuring efficient and high-quality assembly of capsules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cutting and welding stations are used for small capsule components, then the manufacturing process can be completed, but productivity is insufficient and welding quality is compromised
Solution Approach 1:
The machine is divided into specialized stations (moulding, control, filling, cutting, welding) that operate in sequence along a closed-loop conveyor path. Each station handles specific operations with dedicated equipment optimized for that function, allowing parallel processing and maintaining precision while increasing overall productivity.
Solution Approach 2:
The patent replaces manual or simple mechanical handling with an automated closed-loop conveyor system that mechanically transports components through the production sequence. This substitution enables consistent positioning and handling of small components, improving both productivity and welding quality through automated precision.
2Volume of moving object
If the size of capsules is reduced to approximately one centimetre, then the capsules are suitable for smoking articles, but handling and assembly become extremely difficult
Solution Approach 1:
The closed-loop conveyor system acts as an intermediary that facilitates the handling of small capsule components. The conveyor provides a controlled mechanism for transporting, positioning, and presenting the tiny covering elements to welding stations, making operations that would be difficult manually become automated and precise.
Solution Approach 2:
This principle does not apply to this patent as there are no oxidation processes involved in the capsule manufacturing method described.
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 machine effectively handles small components, enhancing productivity while maintaining the quality of the welding process, ensuring efficient assembly and preventing issues like incorrect liquid discharge from the capsules.
Implementation Method 1
a welding station (S6) for welding the covering elements (7) to the respective cup-shaped bodies (2)... with a plurality of ultrasound welders (43)
Data Source
Figure 1a~2
Figure 3
Figure 4
AI summary
A method and a manufacturing machine (10) for the production of capsules (1) for smoking articles, designed to contain a liquid to be used in the cooling of the smoke and comprising a cup-shaped body (2) and a covering element (7); the manufacturing machine (10) is provided with a feeding system (11) that feeds the semi-finished capsules (1) along a forming path; a number of operating stations (S4, S5, S6) arranged along the forming path and comprising a coupling station (S5) for coupling the covering elements (7) to the cup-shaped bodies (2) and a welding station (S6) for welding the covering elements (7) to the cup-shaped bodies (2) arranged downstream of the coupling station (S5); and wherein the coupling station (S5) comprises a transfer drum (14), which rotates around a rotation axis (R) with an intermittent motion and above which a strip (16) of plastic material is fed and which transfers the covering elements (7) to the feeding system (11); and wherein the covering elements (7) are transferred into respective pockets (12) of the feeding system (11) and each of said pockets (12) contains a respective cup-shaped body (2) and, in the inner surface (13) of each pocket (12) an annular abutment (35) is provided to define a seat for the covering element (7) above the respective cup-shaped body (2).