Expanding Collet Sealing for Precise Brew Cup Filter Placement
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Solution Overview
Problem
Existing systems for placing and sealing cup-shaped filters into brew cups face challenges with precision alignment and consistent sealing, leading to aberrations such as failed welds, media spills, and inconsistent beverage handling due to the flimsy nature of filter materials and the need for precise equipment.
Innovation Solution
The use of expanding collets for precise filter placement and sealing, where a first collet positions the filter and a second collet provides redundancy to ensure a full seal, increasing the weld area by four times compared to prior systems, eliminating the need for precise locating devices and reducing aberrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single push-down welding action is used to position and seal the filter, then the process is simple and fast, but the filter placement precision is poor leading to failed welds and seals
Solution Approach 1:
The patent divides the filter placement and sealing process into two separate stages: first positioning the filter to the correct height using a tamper, then sealing it using an expanding collet. This segmentation allows each stage to be optimized independently, achieving precise filter placement without requiring complex locating devices.
Solution Approach 2:
The patent employs an expanding collet that dynamically adjusts its diameter during the sealing process. The collet expands from a smaller diameter to engage and hold the filter at the correct position, then continues expanding to create the seal. This dynamic adjustment eliminates the need for precise pre-positioning equipment.
2Reliability
If precise locating devices and linear rails are used to align the welding head, then seal consistency is improved, but the equipment complexity and cost increase significantly
Solution Approach 1:
The expanding collet performs multiple functions automatically: it locates the filter by engaging its rim, positions the filter at the correct height through controlled expansion, and creates the seal all in one operation. This self-service capability eliminates the need for separate locating devices and complex alignment equipment.
Solution Approach 2:
The patent changes the diameter parameter of the collet during operation. By controlling the expansion rate and final diameter, the system achieves precise filter positioning and sealing without requiring the welding head to be precisely located beforehand. The dynamic parameter change compensates for any initial misalignment.
3Ease of manufacture
If the filter material is thin and flimsy, then the filter is flexible and easy to manufacture, but consistent control over placement and sealing becomes difficult
Solution Approach 1:
The tamper performs preliminary action by positioning the filter to the correct height above the cup before the sealing operation begins. This preliminary positioning ensures that when the expanding collet engages the filter, it is already at the optimal position, making the subsequent sealing process reliable even with thin, flimsy material.
Solution Approach 2:
The expanding collet acts as an intermediary between the filter and the sealing mechanism. It engages the filter rim, provides mechanical support during positioning, and distributes the sealing force evenly around the filter circumference. This intermediary role prevents deformation of the thin filter material while achieving precise placement and sealing.
4Reliability
If a larger sealing area is used to improve weld quality, then seal reliability increases, but the equipment size and complexity increase
Solution Approach 1:
The expanding collet dynamically increases its sealing area during operation. It starts with a smaller diameter to engage the filter, then expands to engage the cup flange and create a wide sealing surface. This dynamic area expansion achieves high weld quality without requiring a large stationary sealing device.
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 method ensures accurate and consistent filter placement and sealing, reducing failures and improving the quality of the weld, resulting in reliable beverage handling and dispensing systems.
Implementation Method 1
An expanding weld collet is inserted into the filter and prevents failures caused by the prior combined push-down and welding action
Implementation Method 2
The heated sealing cone both positions and welds the filter by pressing down toward the cup as it seats or places the filter therein
Data Source
AI summary
A filter setting and sealing apparatus includes a wobble plate (16) mounted to press a filter edge (18) into a plane defined by the top rim (20) of a brew cup (12). A sealer (30) defined by expandable sealer jaws (32-39) is moveable into the filter (10). The jaws (32-39) are actuated for radial outward expansion to seal the filter (10) to the cup (12) proximate the filter rim (18) and cup edge (20). A second sealer (70) is used to seal any gaps remaining in the seal after initial sealing. Methods are disclosed.