Cosmetic Capsule Manufacturing via Coating and Solidification
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Solution Overview
Problem
Existing methods for manufacturing cosmetic capsules are inefficient and lack adaptability, making it difficult to produce a large variety of capsules with different contents quickly and easily, especially for small-scale distribution and customization.
Innovation Solution
A process involving a support coated with a viscous material, shaped, and solidified to form capsule walls, with a cosmetic product filled and sealed within, using a system with a reservoir, shaping module, and cutting device to create cylindrical capsules efficiently and reliably.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional capsule manufacturing methods are used, then production efficiency is low, but the process is simple to implement
Solution Approach 1:
The patent combines multiple manufacturing operations (coating, shaping, solidification, filling, and cutting) into a single integrated continuous process. The support moves sequentially through a coating reservoir, shaping module, and cutting device, enabling all operations to occur in one streamlined workflow rather than separate discrete steps, thereby dramatically increasing production efficiency while maintaining manageable system complexity through modular integration.
Solution Approach 2:
The manufacturing process operates continuously with the support moving constantly through each stage without interruption. The coating, shaping, solidification, filling, and cutting operations occur in an unbroken sequence, eliminating idle time between steps and maximizing productivity. This continuous action is maintained through coordinated movement of the support through all modules simultaneously.
2Adaptability or versatility
If capsules are designed with varied contents for customization, then adaptability increases, but manufacturing complexity increases
Solution Approach 1:
The manufacturing system is divided into distinct functional modules: a coating reservoir for applying viscous material, a shaping module for forming capsule walls, a filling section for inserting cosmetic products, and a cutting device for sealing. This segmentation allows each module to be independently configured and adjusted for different capsule types and contents, providing high adaptability without requiring complete process redesign for each variation.
Solution Approach 2:
The system incorporates adjustable parameters including support speed, coating thickness, shaping module configuration, and cutting positions that can be dynamically modified to produce different capsule specifications. This dynamic adjustability enables the same manufacturing line to efficiently produce varied capsule contents and dimensions without increasing fundamental process complexity.
3Productivity
If rapid production is implemented, then productivity increases, but risk of defects like air bubbles increases
Solution Approach 1:
The support is coated with viscous material and shaped into capsule walls before the cosmetic product is inserted. This preliminary formation of the capsule structure creates a defined internal space that guides product insertion and prevents air entrapment. The pre-formed geometry ensures that filling occurs in a controlled manner even at high production speeds, maintaining quality without sacrificing productivity.
Solution Approach 2:
The patent replaces complex mechanical filling mechanisms with a simpler gravity-assisted or pressure-driven filling process where the cosmetic product is introduced into the pre-formed capsule space. This substitution reduces mechanical complexity and potential failure points while maintaining reliable filling at high speeds, as the product naturally settles into the defined internal space without requiring complex positioning mechanisms.
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
Enables rapid production of customizable cosmetic capsules with varied contents, ensuring no air bubbles and easy sealing, suitable for small-scale distribution, with high production rates and adaptability to different materials and products.
Implementation Method 1
The material is kept in the viscous state in the first reservoir by heating
Implementation Method 2
is solidified in the shaping module by cooling
Implementation Method 3
The material is kept in the viscous state in the first reservoir by heating, and is solidified in the shaping module by cooling
Data Source
AI summary
Process for manufacturing a plurality of capsules containing a cosmetic product, the process including the following steps: —displacement of a support (32) through a first reservoir (44) containing a viscous material (52) designed to form the side wall, and coating of the support with a layer (56) of the viscous material; —displacement of the support through a shaping module (28) and solidification of the layer of material; —withdrawal of the support outside the shaping module, freeing an internal slot (74) defined by the layer of solidified material; —entry of at least one cosmetic product (11) from a second reservoir (80) into the internal slot; and —cut out the layer using a cutting device (68) to form the side walls of at least one capsule, and sealing of the internal spaces of capsules containing the cosmetic product by seals.