Capsule Filling Sealing Head Laser Ablation Cleaning
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Solution Overview
Problem
Capsule filling lines require frequent cleaning and maintenance, particularly of thermal sealing heads, which is labor-intensive and causes downtime due to residue buildup from powders and granulates, often damaging the sealing heads and affecting productivity.
Innovation Solution
Implementing an ablation unit, such as a laser, to irradiate and ablate residue off the sealing heads, reducing downtime and damage by intermittently cleaning the sealing heads during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire cleaning brushes are used to remove residue from sealing heads, then residue is removed, but downtime increases and damage to sealing heads occurs
Solution Approach 1:
The patent replaces mechanical wire cleaning brushes with a thermal field (heating element) to remove residue. The heating element softens or melts the residue, allowing it to be removed without mechanical contact, thereby eliminating downtime and preventing damage to the sealing heads.
Solution Approach 2:
The patent changes the physical state of the residue by applying heat, transforming it from a solid adhered state to a softened or melted state that can be easily removed. This parameter change allows residue removal without mechanical force, resolving the contradiction between cleaning effectiveness and sealing head protection.
2Reliability
If wire cleaning brushes are used to clean sealing heads, then residue is removed, but labor intensity increases
Solution Approach 1:
The patent replaces manual mechanical cleaning operations with an automated thermal field system. The heating element is positioned to automatically contact the sealing head surface, softening residue without requiring labor-intensive brush operations, thus reducing labor intensity while maintaining cleaning effectiveness.
Solution Approach 2:
The thermal field system performs self-service cleaning by automatically heating and softening residue on the sealing head during or between operational cycles, eliminating the need for manual intervention and reducing labor intensity while preserving sealing head condition.
3Reliability
If cleaning procedures are performed frequently to remove residue, then sealing head performance is maintained, but productivity decreases
Solution Approach 1:
The patent enables continuous cleaning action by positioning the heating element to operate during or between filling cycles without interrupting production. The thermal field continuously softens residue as it accumulates, maintaining sealing head performance while preventing productivity loss from frequent shutdowns.
Solution Approach 2:
The heating element performs preliminary softening of residue before it becomes difficult to remove, preventing buildup that would require frequent intensive cleaning. This preliminary action maintains sealing head performance continuously without interrupting productivity, as the residue is softened incrementally rather than requiring periodic full cleaning cycles.
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 ablation method effectively removes residue from sealing heads, including intricate features, while maintaining their condition, thus reducing downtime and minimizing damage, particularly effective for thermal sealing heads.
Implementation Method 1
operating an ablation unit to irradiate the sealing head to ablate a residue off the sealing head
Data Source
AI summary
Apparatus and methods of cleaning a sealing head (23) of a capsule filling line, comprising operating an ablation unit (10) to irradiate the sealing head (23) to ablate a residue off the sealing head (23).