Filtering Element Joining for Beverage Capsule Manufacturing

Solution Overview

Problem

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

Innovation Solution

A method and machine that position a strip of filtering material above rigid bodies, join it to the rims, and subsequently form the filtering element to define a chamber, with cutting occurring after joining, allowing for simpler and more precise operation on plane surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the filtering material is shaped before joining to the rigid body, then the filtering element can be formed, but the positioning accuracy and joining difficulty increase

Engineering Contradiction:

Improvefiltering element shapeVSAvoidpositioning accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The filtering material is positioned and joined to the rigid body in its flat strip state before forming. This preliminary joining action on plane surfaces ensures accurate positioning, and only after joining is the filtering material formed into the final filtering element shape, eliminating positioning difficulties associated with shaping beforehand

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional sequence is inverted: instead of shaping the filtering material first and then joining it, the patent joins the flat filtering material strip to the rigid body first, and then forms it into the filtering element. This reverse sequence simplifies positioning and joining operations

Inventive Principle:

Principle #13The other way round (Inversion)

2Shape

If the filtering material is shaped before joining, then the filtering element is formed, but the device complexity increases

Engineering Contradiction:

Improvefiltering element shapeVSAvoidshaping and joining steps

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The filtering material is positioned and joined to the rigid body in its flat strip state before forming. This preliminary joining action on plane surfaces ensures accurate positioning, and only after joining is the filtering material formed into the final filtering element shape, eliminating positioning difficulties associated with shaping beforehand

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional sequence is inverted: instead of shaping the filtering material first and then joining it, the patent joins the flat filtering material strip to the rigid body first, and then forms it into the filtering element. This reverse sequence simplifies positioning and joining operations

Inventive Principle:

Principle #13The other way round (Inversion)

3Length of moving object

If cutting is performed before joining, then the filtering material can be sized, but the cutting difficulty increases

Engineering Contradiction:

Improvefiltering material sizeVSAvoidcutting ease

Core Design Contradiction:

Length of moving objectVSEase of manufacture

Solution Approach 1:

The filtering material is positioned and joined to the rigid body in its flat strip state before forming. This preliminary joining action on plane surfaces ensures accurate positioning, and only after joining is the filtering material formed into the final filtering element shape, eliminating positioning difficulties associated with shaping beforehand

Inventive Principle:

Principle #10Preliminary action

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 the positioning and joining of the filtering element, enabling easier cutting and achieving high-quality intermediate components with improved productivity and precision.

Implementation Method 1

a heating element arranged downstream of the positioning means and upstream of the joining station, configured to heat the first strip of filtering material

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a joining station arranged downstream of the heating element, configured to join the first strip of filtering material to the rigid bodies

Methodology Applied

Scientific EffectThermal sealing: Welding

Data Source

PatentUS10464700B2Method and machine for making intermediate component of single use capsules for beverages

Publication Date: 2019.11.05 GIMA TT SPA

AI summary

A method for making an intermediate component (11) of 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) for a dose of product. A machine for making intermediate components of single use capsules (1) for extraction or infusion beverages includes: a feeding system (40); a transport system (50); a joining station (60); and a forming station (70).