Thermoformable Filtering Material Joining for Beverage Capsules

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Solution Overview

Problem

Existing methods for manufacturing single-use capsules for beverages are complex and inefficient, particularly in joining the filtering material to the rigid body, leading to difficulties in precise positioning and cutting.

Innovation Solution

A method involving positioning a strip of thermoformable filtering material above rigid bodies, joining it to the rims, forming the filtering element, filling the chamber, and subsequently cutting the material, which simplifies the process by allowing easier cutting and precise positioning on plane surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the filtering material is shaped before joining to the rigid body, then the filtering element can be formed, but the positioning and joining becomes complicated and imprecise

Engineering Contradiction:

Improvepositioning precision of filtering elementVSAvoidcomplexity of shaping and joining steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The filtering material is positioned and joined to the rigid body in its planar state before forming the chamber. This preliminary joining action on flat surfaces enables precise positioning and simplifies the joining process, avoiding the complexity of shaping and joining curved surfaces simultaneously.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing process is segmented into distinct sequential steps: first joining the filtering material to the rigid body while both are in planar state, then subsequently forming the chamber. This segmentation allows each step to be optimized independently, achieving both precision and simplicity.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If the filtering material is cut before joining, then cutting can be performed, but the filtering material cannot be properly positioned and joined to the rigid body

Engineering Contradiction:

Improveease of cutting filtering materialVSAvoidpositioning accuracy of filtering element

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The filtering material is joined to the rigid body before cutting. This preliminary joining provides a reference edge from the rigid body that guides accurate cutting, ensuring both ease of manufacture and positioning accuracy.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If existing methods are used to join shaped filtering material to rigid body, then capsules can be produced, but the process is complicated and productivity is reduced

Engineering Contradiction:

Improvecapsule production rateVSAvoidcomplexity of joining process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The filtering material is joined to the rigid body before forming the chamber, eliminating the need for complex simultaneous shaping and joining operations. This simplifies the process and increases productivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional sequence is inverted: instead of shaping then joining, the method joins in planar state then forms the chamber. This inversion simplifies the joining process and eliminates complex positioning requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

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 simplifies and streamlines the production of single-use capsules, enhancing productivity and precision in forming and cutting the filtering material, resulting in high-quality capsules with improved perimetral joining.

Implementation Method 1

The machine (100) includes a joining station (60) adapted to join the first strip (S1) to the rigid bodies (2) in form of a second strip (S2)... by heating and pressing the first strip (S1) and the second strip (S2)

Methodology Applied

Scientific EffectHeating and pressing:

Implementation Method 2

a forming station (70) adapted to form the first strip (S1) of filtering material to achieve a filtering element (8) that defines a chamber (5)

Methodology Applied

Scientific EffectHeating and pressing:

Data Source

PatentUS10315791B2Method and machine for making single use capsules for beverages

Publication Date: 2019.06.11 GIMA TT SPA

AI summary

A method for making a single use capsule (1) for extraction or infusion beverages includes the step of: arranging a first strip (S1) of thermoformable filtering material above rigid bodies (2); joining the first strip (S1) of thermoformable filtering material to the rigid bodies (2) at respective rims (7); forming the first strip (S1) of thermoformable filtering material to achieve a filter (8) that defines a chamber (5); filling the chamber (5) with a dose (D) of product; closing the chamber (5) and the rigid body (2) with a closing lid (6). A machine for making single use capsules (1) for extraction beverages includes: a feeding system (40); a transport system (50); a joining station (60); a forming station (70); a filling station (80); and a closing station (90).