Double Chamber Filter Bag Formation Unit
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Solution Overview
Problem
The existing methods for producing double chamber filter bags, such as teabags, face inefficiencies due to misalignment caused by friction with fixed guiding buffers, leading to discarded products and reduced production rates.
Innovation Solution
A formation unit that includes a rotating cylinder with a blade for cutting and a folding group with movable elements to create a W-shaped fold, followed by a rotating wheel with radial grippers that refold the filter paper into double-chamber bags without the need for fixed buffers, ensuring centered and firm handling of the filter paper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed guiding buffers are used to guide the filter paper during folding, then the folding process can be completed, but friction between the paper and buffers causes misalignment and positioning errors
Solution Approach 1:
The patent removes the fixed guiding buffers from the system entirely. Instead of having stationary buffers that cause friction, the invention uses a rotating wheel with radial grippers that actively grasp and guide the portions through the folding process without sliding contact, thereby eliminating the source of misalignment
Solution Approach 2:
The invention transitions from static fixed buffers to a dynamic rotating wheel with movable radial grippers. The wheel rotates to present grippers to the portions, and the grippers move radially to grasp and release portions at different positions, providing adaptive guidance without friction-based misalignment
2Productivity
If the filter paper slides against fixed buffers during folding, then the folding can proceed, but friction causes portions to enter grippers in incorrect positions leading to production defects
Solution Approach 1:
The radial grippers act as intermediaries between the portions and the rotating wheel. Instead of portions sliding directly against fixed buffers, the grippers grasp the portions and actively guide them through the folding process, ensuring precise positioning while eliminating friction-based errors
Solution Approach 2:
The rotating wheel with radial grippers provides a controlled, repeatable positioning mechanism. Each gripper follows a predetermined path during wheel rotation, ensuring that portions are consistently positioned at the correct location for folding and subsequent processing, reducing defects
3Ease of manufacture
If conventional folding elements and fixed buffers are used, then the double chamber bag formation can be completed, but misalignment requires subsequent discards reducing efficiency
Solution Approach 1:
The radial grippers perform preliminary positioning and centering of the portions before they enter the folding process. By grasping the portions at the correct position on the rotating wheel and maintaining that positioning throughout the folding operation, the system ensures proper alignment is achieved in advance, preventing the need for later discards
Data Source
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AI summary
A method for the formation of filter bags (1) for infusion material, which comprises the phases of cutting a tubular wrapping (4) containing doses (2) of said infusion material, into relative portions (P), effecting the W-shaped folding of an edge (10) of each of said portions (P) and effecting the refolding into two substantially equal parts (Pi, P2) of the portion (P) itself, each of said parts (PI, P2) containing a relative dose (2), in order to form, by means of gripper operating means (14), a double chamber bag (1), the method comprises the further phase of firmly holding both said wrapping (4) before said cutting, and said portion (P) during the subsequent W-folding and refolding phases, the holding being effected by holding means (Z) for holding the wrapping (4) before cutting and for holding at least the relative portion (P) during the W-folding of the edge (10) and during the refolding of said parts (PI, P2) of the portion (P) itself, in a stable position.