Filter Insert Embossing After Folding to Prevent Paper Damage
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Solution Overview
Problem
Existing methods for producing filter inserts, such as coffee and tea filters, face issues like space requirements for embossing devices, one-sided visibility of markings, material weakening, and increased risk of damage during processing, due to embossing before folding.
Innovation Solution
A method involving continuous folding of filter paper webs into double layers, followed by embossing with a male and elastic counter-plate to apply markings on both sides without connecting the layers, reducing stress and damage, and using a single pair of embossing rollers for both connecting seams and non-connecting identifications in a compact process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If embossing is performed before folding the filter paper web, then the marking can be applied to the filter insert, but the material is locally weakened and damaged easily during further processing
Solution Approach 1:
The filter paper web is folded into a double layer before embossing the marking. This preliminary folding action creates a thicker, more robust structure that can withstand the embossing process without local weakening or damage, resolving the contradiction between ease of marking application and material integrity
Solution Approach 2:
The conventional sequence is inverted: instead of embossing before folding, the patent performs folding first and then embossing the marking on the double-layered web. This reversal of the process sequence eliminates material damage while maintaining marking capability
2Device complexity
If embossing is performed before folding, then the marking process is simplified, but the embossed marking can only be seen on one side and must be correctly positioned for reading
Solution Approach 1:
Folding the filter paper web into a double layer before embossing allows the marking to be applied to both sides simultaneously. The double-layer structure ensures that when the filter insert is used, the marking is visible from both the inside and outside, eliminating the need for correct positioning and improving ease of operation
Solution Approach 2:
By performing embossing on a double-layered web (adding the dimension of layering), the marking becomes visible from both sides of the filter insert, transforming a one-sided marking problem into a two-sided solution without increasing device complexity
3Area of stationary object
If embossing is performed on a single-layer filter paper web, then the process requires less installation space, but the filter paper web is heavily stressed and damaged easily
Solution Approach 1:
The filter paper web is folded into a double layer before embossing, creating a more durable structure that resists damage during the marking process. This preliminary folding maintains compact installation space while significantly improving filter paper durability through the double-layer reinforcement
4Strength
If embossing connects the two filter paper layers, then the marking is securely attached, but the filter inserts cannot be properly separated from the web
Solution Approach 1:
The embossing process is designed to create localized markings without forming connecting bonds between layers. By controlling the embossing parameters and tooling, the marking is securely attached to each layer independently while maintaining the ability to separate filter inserts from the web without damage
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 approach allows for efficient, compact production with reduced material stress, easy identification on both sides, and minimized risk of damage, while maintaining the embossed markings' integrity and reducing the need for additional additives.
Implementation Method 1
an elastic counter-plate is provided, viewed from the filter paper web side, having a male stamp for embossing the identification, by which the two layers of the filter paper web are not connected to one another
Data Source
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AI summary
Described and illustrated is a method and a device for producing filter inserts (1), in particular filter inserts (1) for preparing a coffee or tea filtrate, comprising the continuous folding (A) of a filter paper web (2) to form a double layer (3), the partially connecting (B) the double layer (3) to form a multiplicity of connected filter inserts (1) by at least one embossed seam (4) and separating (D) the connected filter inserts (1) from the filter paper web (2). The object of the present invention is to specify a method for producing filter inserts (1) in which the problems known from the prior art are avoided, at least in part, and damage to the filter paper web (2) is reliably prevented. The aforementioned object is achieved according to the invention in a method of the type mentioned in that the filter inserts (1) are provided with a marking (5) after folding (A).