Filter-Bag Forming Machine with Dual-Needle Knotting Station
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Solution Overview
Problem
Existing machines for forming filter-bags for infusion products, such as tea and coffee, use metal staples for closure, which are harmful and pollutant, and are inadequate for creating knots with natural fiber strings.
Innovation Solution
A machine with a forming and joining station equipped with two needles and auxiliary strings to pierce and knot the filter-bag and tag, allowing for simultaneous and secure knot formation without metal staples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal staples are used for filter-bag closure, then the filter-bag can be reliably closed and maintained in prior art machines, but the filter-bag quality deteriorates due to environmental harm and pollution during infusion
Solution Approach 1:
The invention extracts and removes the harmful metal staple component from the filter-bag closure system. By replacing metal staples with knots formed from natural fiber strings, the harmful metallic elements are completely extracted from the product, eliminating environmental pollution and harmful effects during infusion while maintaining closure functionality.
Solution Approach 2:
The invention changes the material parameter of the closure element from metal to natural fiber. This parameter change transforms the closure mechanism from metal staple-based to knot-based using natural fibers, which fundamentally alters the environmental compatibility and safety characteristics of the filter-bag closure system.
2Object-affected harmful factors
If knots are formed with string made of natural fibres, then environmental harm is eliminated, but the prior art machines are inadequate for making these knots
Solution Approach 1:
The invention replaces the mechanical staple-punching system with a knot-tying mechanism. The new system uses piercing elements to create holes through which string is passed, followed by knot formation mechanisms that tie secure knots using natural fiber strings, substituting the entire mechanical closure approach to enable eco-friendly knot-based closure.
Solution Approach 2:
The invention introduces auxiliary strings as intermediary elements in the knot formation process. These auxiliary strings facilitate the tying of secure knots by providing the necessary length and manipulation capability, acting as mediators between the piercing elements and the final knot structure, enabling reliable natural fiber closure.
3Device complexity
If a single station is used for joining string to tag and closing filter-bag, then device complexity is reduced, but manufacturing precision deteriorates due to simultaneous operations
Solution Approach 1:
The invention segments the single station into two distinct joining zones: a first joining zone for attaching the string to the tag, and a second joining zone for closing the filter-bag. This spatial segmentation allows each zone to be optimized for its specific function, maintaining high manufacturing precision while consolidating operations into one station structure.
Solution Approach 2:
The invention transitions from sequential operations to simultaneous operations by utilizing different spatial zones within the same station. The first and second joining zones operate concurrently at different locations, effectively adding a spatial dimension to the operation timeline, which maintains precision while reducing overall cycle time and device complexity.
Data Source
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AI summary
Described is a machine (100) for forming filter-bags (1) for infusion products, comprising a station (15) for forming and joining a first portion of string (16) to a tag (17), and for positioning and joining a second portion of the string (16) to top edges (12) of a length (10) of filter material; the forming and joining station (15) comprising a unit (22) provided with two separate needles (23, 24); movement means (27) configured to move the needles (23, 24) to pierce the tag (17) in at least two points and, respectively, the top edges (12) and a fold (14) of the length (10) of filter material; a carousel (28) at least for moving and positioning at least the second portion of string (16) from a first joining zone (18) to a second joining zone (21 ); a first unit (29) having first gripping means (30) configured for forming, in phase coordination with the first needle (23), at least a first knot (19) with a portion of a first auxiliary string (25) and joining the tag (17) to the first portion of string (16); a second unit (31) having second gripping means (32) configured for forming, in phase coordination with the second needle (24), a second knot (20) with a portion of a second auxiliary string (26) for joining the length (10) of filter material to the second portion of string (16).