Capsule Packaging Machine Punch and Die Cutting System
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Solution Overview
Problem
Existing packaging machines for making capsules with aromatic substances generate excessive material waste due to cutting covers and bottom linings, as they are cut larger than needed and spaced according to container construction requirements, leading to inefficiencies.
Innovation Solution
A packaging machine that uses a 'punch and die' cutting system to cut disc-shaped elements from a continuous web, allowing for precise and clean cuts, and transfers these elements to a separate associating station for application, where they are sealed to the containers without being cut to excess size, reducing waste and optimizing material use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If actuator means with knives are used to cut covers from continuous web at same spacing as containers, then covers can be applied to each container, but large amounts of material waste offcuts are generated
Solution Approach 1:
The patent introduces a movable carriage that can dynamically adjust its position along the container feed path, allowing the cutting station to be positioned at optimal locations rather than being fixed at container spacing intervals. This dynamic positioning enables cutting covers to be applied precisely when needed without generating excess waste from fixed-spacing cutting.
Solution Approach 2:
The patent separates the cutting function from the container feed spacing by introducing an independent carriage system. The carriage can carry multiple cutters and position them independently of the container spacing, allowing covers to be cut from the web at precise locations without being constrained by container intervals, thereby reducing waste.
2Ease of operation
If covers are cut to size much larger than container mouth, then same actuator element can cut, position and seal the cover, but much more material is used than necessary
Solution Approach 1:
The patent implements a preliminary cutting action where covers are cut to the exact required size from the continuous web before being applied to containers. The movable carriage positions cutters to cut covers precisely to the dimensions needed for the container mouth, eliminating the need to cut excessive material and then waste it.
Solution Approach 2:
The patent replaces the single actuator system that required oversized covers with a movable carriage carrying precision cutters. This mechanical substitution enables precise cutting to exact dimensions, eliminating the need for oversized covers and the associated material waste.
3Reliability
If actuator means are spaced at same spacing as containers, then constructional requirements are met, but large amounts of waste offcuts are formed from webs
Solution Approach 1:
The patent introduces a dynamically movable carriage that can adjust its position along the container feed path independently of the fixed container spacing. This allows the cutting operation to be positioned optimally to minimize web waste while maintaining the required constructional spacing between containers.
Solution Approach 2:
The movable carriage acts as an intermediary between the fixed container spacing system and the continuous web cutting system. It mediates by carrying cutters that can be positioned independently, allowing precise cutting without being constrained by container spacing, thus reducing waste offcuts.
Data Source
AI summary
A packaging machine for making capsules of the type including a container having an inlet opening and a bottom and at least one substantially disc-shaped element associated with the container, including a movement system by which the containers are directed along a predetermined path in a feed direction; a movement means by which a continuous web for defining the disc-shaped elements is moved along a second predetermined path; a cutoff station where the disc-shaped elements are cut from the continuous web and which is positioned along the second predetermined path and an associating station where the disc-shaped elements are associated with the containers and which is positioned along the predetermined path; the associating station is distinct from the cutoff station and the machine includes a transfer system by which the disc-shaped elements are transferred from the cutoff station to the associating station.