Capsule Packaging Synchronization Using Carrier Blocks
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Solution Overview
Problem
Current packaging machines for infusion products face challenges in maintaining the precise positioning of capsules within overwrapping film, leading to inertial instability and reduced productivity, which affects the quality of the final product due to high-speed differences between capsule and film movement.
Innovation Solution
A machine with synchronized control units and specialized mechanisms, including L-shaped levers and suction cups, ensures precise feeding and stabilization of capsules onto carrier blocks, followed by controlled movement and sealing within a controlled atmosphere to maintain capsule stability during overwrapping and sealing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If capsules are released onto the overwrapping film freely without holding them in place, then the machine structure is simpler, but the capsule positioning precision deteriorates due to inertial instability
Solution Approach 1:
The patent introduces carrier blocks as intermediary devices to hold capsules during the overwrapping process. The carrier blocks serve as a mediator between the capsule feeding mechanism and the overwrapping film, ensuring precise capsule positioning while simplifying the overall machine structure. This resolves the contradiction by providing a simple yet effective positioning solution without complex mechanisms.
Solution Approach 2:
The patent implements preliminary action by pre-positioning capsules on carrier blocks before they are subjected to the overwrapping process. The capsules are held in place on the carrier blocks prior to contact with the overwrapping film, ensuring correct positioning is established in advance. This prevents inertial instability and positioning errors during the high-speed overwrapping operation.
2Productivity
If the overwrapping film is fed forward at high speed, then productivity is improved, but capsule stability deteriorates due to speed differences between capsule and film
Solution Approach 1:
The carrier blocks act as an intermediary that synchronizes the movement of capsules with the high-speed overwrapping film. By holding capsules on the carrier blocks during the overwrapping process, the system maintains capsule stability even while the film moves at high speed. This resolves the contradiction by enabling high productivity without sacrificing capsule stability.
Solution Approach 2:
The patent employs dynamic synchronization where the carrier blocks move in coordination with the overwrapping film speed. The system adjusts the motion of carrier blocks to match the high-speed film feeding, ensuring capsules remain stable relative to the film throughout the overwrapping process. This dynamic adjustment enables high productivity while maintaining capsule stability.
3Device complexity
If capsules are placed on the overwrapping film without holding mechanisms, then the device complexity is reduced, but the end product quality deteriorates due to capsule displacement
Solution Approach 1:
The carrier blocks serve as a simple intermediary holding mechanism that ensures capsule positioning without adding significant complexity to the device. The carrier blocks provide reliable capsule holding during the critical overwrapping phase, preventing displacement and ensuring high end product quality. This resolves the contradiction by providing an effective holding solution with minimal added complexity.
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 enhances productivity while ensuring high-quality capsules by maintaining precise capsule positioning and stability throughout the packaging process, reducing the risk of displacement and improving end product quality.
Implementation Method 1
a holding means, in particular a suction cup, for holding the capsule in place on the carrier block
Data Source
Figure 1
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Figure 5
AI summary
A machine for packing infusion products into capsules (2) comprises a plurality of stations along a feed line (L), including a coupling and sealing station (27) for coupling an overwrapping film (F1) and the capsules (2) after the latter have been sealed and for sealing the overwrapping film (Fl) around a respective capsule (2) to form an individual pack (C); the coupling and sealing station (27) comprises a frame (40) for continuously forming the second, overwrapping film (F1) into the shape of a tube, a pusher device (41) for pushing the capsule (2) along a sliding feed table (39) and designed to position the capsule (2) at a predetermined point, and means (43) for guiding and retaining the capsule (2) feeding out of the frame (40), to allow coordinated feeding of the capsule (2) and of the overwrapping film (F1) in such a manner as to keep the capsule (2) and the tube of overwrapping film (F1) in a stable position relative to each other.