Filter Bag Wrapping Machine Sealing Station Dynamics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current machines for producing filter bags wrapped in heat-sealed outer envelopes are limited to a production speed of around 450 units per minute due to the constraints of the heat-sealing step, which compromises the quality of the seal and reduces production capacity.
Innovation Solution
A machine with a sealing station featuring a synchronised, stepwise driven carrousel and intermittent drive system that increases the actual sealing time by maintaining contact with the overwrapping sheet for a longer duration, allowing for higher production speeds while maintaining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heat-sealing operation is performed using conventional fixed stations with stepwise carrousel, then the machine structure is simple and easy to manufacture, but the production speed is limited to around 450 units per minute due to insufficient sealing time
Solution Approach 1:
The patent applies dynamics by making the sealing station mobile rather than fixed. The sealing station moves along the feeding direction of the overwrapping sheets, allowing it to maintain continuous contact with the sheets being sealed. This dynamic configuration enables the sealing operation to proceed at higher speeds while maintaining adequate sealing time, resolving the contradiction between productivity and sealing duration.
2Productivity
If the sealing station is made mobile to increase production speed, then productivity improves, but the device complexity increases due to additional drive mechanisms
Solution Approach 1:
The patent merges the sealing station with the carrousel drive system. The sealing station is integrated into the rotating carrousel structure, and the intermittent drive mechanism that rotates the carrousel also drives the sealing station's movement. This combination reduces the need for separate drive mechanisms, thereby limiting the increase in device complexity while still achieving the productivity improvement through mobile sealing.
Solution Approach 2:
The carrousel drive system serves multiple functions: it positions the filter bags, feeds the overwrapping sheets, and drives the mobile sealing station. By making the sealing station mobile and integrating it into the existing carrousel mechanism, the system achieves multi-functionality, reducing overall device complexity while improving productivity.
3Manufacturing precision
If the sealing time is extended to ensure quality seals, then the sealing quality improves, but the production capacity is reduced
Solution Approach 1:
The patent implements continuity of useful action by having the mobile sealing station maintain continuous contact with the overwrapping sheets during the sealing process. As the sealing station moves along with the sheets, the sealing action is continuous rather than intermittent, ensuring consistent sealing quality while maximizing the use of available time for production, thus resolving the contradiction between sealing quality and production capacity.
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 achieves increased production speeds for filter bags wrapped in sealed outer envelopes, exceeding previous limits while ensuring high-quality seals, thus enhancing production capacity without compromising the final product quality.
Implementation Method 1
a seventh station for applying an overwrapping sheet to each filter bag and closing the overwrapping (by heat-sealing) to form an outer envelope
Data Source
AI summary
A machine for making outer envelopes (101) in which a filter bag (103) for an infusion product is wrapped in an overwrapping (S) comprises: stations for making the filter bags (103), means (106) for moving the filter bag (103) towards a station (107) for wrapping a sheet (S) of overwrapping material around the filter bag (103); and a station (109) for closing longitudinal end edges (S1, S2) and a transversal end edge (S3) of the “U”-wrapped sheet (S) to form an outer envelope (101); the closing station (109) comprises a joining carrousel (110) equipped with a plurality of sealing elements (112) which are movable in rotation with the joining carrousel (110) and designed to receive respective single filter bags (103) with the folded overwrapping sheet (S) and to allow simultaneous closing of the longitudinal edges (S1, S2) and the transversal edge (S3) of the sheet (S).