Capsule Manufacturing Machine Ultrasonic Welding Loop
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Solution Overview
Problem
Existing manufacturing machines for producing capsules for smoking articles with small dimensions face challenges in achieving satisfactory productivity and maintaining welding quality due to the delicacy of the cutting and welding steps involved in covering element attachment.
Innovation Solution
A manufacturing machine with a closed-loop feeding system, including a welding station using ultrasound welders and a cutting station with rotating cutting heads, allows for precise handling and efficient welding of small components, ensuring high productivity and quality without compromising the attachment of covering elements to cup-shaped bodies.
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 patent divides the manufacturing process into distinct modular stations: a forming station for cup-shaped bodies, a separate welding station with multiple ultrasound welders for attaching covering elements, and a cutting station with rotating cutting heads. This segmentation allows each station to be optimized independently, with the welding station specifically designed with multiple welders to handle multiple capsules simultaneously, thereby increasing productivity without compromising welding quality
Solution Approach 2:
The patent replaces traditional mechanical cutting and welding methods with ultrasonic welding technology. The ultrasound welders use high-frequency mechanical vibrations to weld the covering elements to the cup-shaped bodies, providing precise control and consistent welding quality. This substitution eliminates the delicacy issues associated with traditional mechanical methods for small components
2Manufacturing precision
If traditional handling methods are used for small capsule components, then the process is simpler, but handling precision and component protection are insufficient
Solution Approach 1:
The patent introduces specialized handling mechanisms as intermediaries between stations. Transfer mechanisms with gentle gripping systems move cup-shaped bodies from the forming station to the welding station, and then to the cutting station. These intermediary handling systems are designed specifically for small components, providing precise positioning and gentle handling to prevent damage, while the modular station design keeps overall system complexity manageable
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 and maintaining the quality of the welding process, ensuring efficient production of capsules while preventing defects in the attachment of covering elements.
Implementation Method 1
a welding station (S5) to weld a strip (14) of plastic material to the cup-shaped bodies (2)... with a plurality of striker heads (17), each provided with a welder (31), for example a sonotrode, cooperating with a respective striker element (20) for lifting the cup-shaped bodies (2) towards the striker head (17)
Data Source
Figure 1a~2
Figure 3
Figure 4~4a
AI summary
A method and a manufacturing machine (10) for the production of capsules (1) for smoking articles, in particular for filters, designed to contain a liquid to be used in the cooling of smoke; wherein each capsule (1) comprises a cup-shaped body (2) and a covering element (7); the manufacturing machine (10) comprises a welding station (S5) for welding a strip (14) of plastic material to a plurality of cup-shaped bodies (2); a cutting station (S6) for cutting the strip (14) of plastic material welded to the cup-shaped bodies (2) so as to obtain the covering elements (7), wherein the cutting station (S6) is arranged downstream of the welding station (S5); and a dragging device (22) for the strip (14) of plastic material that is interposed between the welding station (S5) and the cutting station (S6) and adapted to obtain a loop (23) of plastic material which allows the two groups of semifinished capsules (1) to be independent.