Single-Dose Capsule Powder Dosing With Synchronized Transfer Plates
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Solution Overview
Problem
Existing methods for producing single-dose capsules with powdered products face issues such as non-uniform stratification and contamination of compartments due to powder dispersion, particularly with low granularity powders, leading to sealing problems and reduced production capacity.
Innovation Solution
A dosing apparatus and method involving pre-dosing plates synchronized with molds to transfer pre-defined quantities of powdered substances without relative motion, using a system of hoppers, release valves, and synchronized carousels to ensure uniform distribution and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gravity dosing system with fixed nozzle is used, then production capacity is maintained, but powder dispersion causes contamination and non-uniform stratification
Solution Approach 1:
A dosing plate is introduced as an intermediary carrier between the gravity dosing system and the mold. The dosing plate receives pre-dosed powder from the gravity system, then transfers it to the mold through controlled movement, preventing direct dispersion into the environment while ensuring uniform distribution in the target location.
Solution Approach 2:
The powder is pre-dosed onto the dosing plate before the mold arrives at the dosing position. This preliminary action allows the powder to be contained and organized on the dosing plate, preventing dispersion during the dosing process and ensuring uniform stratification when transferred to the mold.
2Manufacturing precision
If synchronized movement of dosing plate and mold is implemented, then powder distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The dosing plate is integrated with the mold carrier system, combining the dosing function with the existing mold transport mechanism. This merging reduces the need for separate synchronization systems, as the dosing plate and mold move together as a coordinated unit within the same mechanical framework.
3Productivity
If faster movement of molds and plates is allowed, then productivity increases, but powder dispersion and leakage risks increase
Solution Approach 1:
The dosing plate is positioned and synchronized with the mold before the dosing operation commences. This preliminary positioning ensures that even at higher speeds, the powder is transferred in a controlled manner without dispersion, maintaining both productivity and sealing quality.
Solution Approach 2:
The dosing plate acts as a controlled intermediary that contains the powder during high-speed movement. By keeping the powder confined on the dosing plate until the moment of transfer, the system can operate at higher speeds without risking dispersion or contamination that would compromise sealing quality.
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 solution ensures uniform powder distribution and prevents contamination, enhancing production efficiency and quality by allowing faster movement of molds and plates, reducing leakage risks, and accommodating various compartment geometries.
Implementation Method 1
a heated roller (31) arranged at said forming unit to heat a PVA film (61) before being placed on said molds
Implementation Method 2
The PVA film is then deformed onto cavities or molds having the shape of the compartments to be filled with the products required to obtain the required capsule
Implementation Method 3
a pressure roller (52), arranged at said forming unit downstream of said dosing unit, to close said molds filled by the dosing plates
Data Source
AI summary
A dosing apparatus for dosing powdered substances for producing single-dose capsules, having at least one compartment in which at least one powdered substance is present, including a forming unit having one or more molds movable in an advancement direction, and a dosing unit including at least one dosing plate having one or more chambers, in each of which a quantity of at least one of the powdered substances can be inserted, to be subsequently transferred from at least one of the chambers to a respective mold.