Paper Sealing Ring Assembly for Reliable Capsule Flange Sealing
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Solution Overview
Problem
Existing capsule manufacturing methods face challenges in ensuring a reliable seal between the capsule flange and the dispensing machine, leading to potential product leakage and increased production costs due to the use of complex and costly sealing elements made of elastomeric materials.
Innovation Solution
An apparatus and method for making capsules using a paper-based sealing ring system, where the sealing rings are formed by etching pre-cutting lines on a sheet, allowing them to be anchored to the sheet and then coupled to the capsule flange, followed by a heat sealing process to ensure a secure fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing element made of elastomeric material is applied to the capsule flange, then the seal reliability is improved, but the production cost and device complexity increase
Solution Approach 1:
The patent replaces expensive, complex elastomeric sealing elements with a simple paper-based sealing ring that is integrated into the capsule structure. The sealing ring is made from the same paper material as the capsule body, eliminating the need for separate elastomeric components and reducing both material cost and manufacturing complexity while maintaining adequate sealing performance for single-use capsules
Solution Approach 2:
The sealing function is merged with the capsule body structure by integrating the sealing ring directly into the paper material of the capsule. Instead of adding a separate sealing element, the patent creates a sealing ring as an integral part of the capsule body through die-cutting or laser cutting, combining the structural and sealing functions into a single component
2Reliability
If a sealing element made of elastomeric material is applied to the capsule flange, then the seal reliability is improved, but the production cost increases
Solution Approach 1:
The patent uses inexpensive paper material for the sealing ring instead of costly elastomeric materials. Since capsules are single-use items, the disposable nature of paper is acceptable, and it provides sufficient sealing performance for the intended application while dramatically reducing material costs
Solution Approach 2:
The patent changes the material parameter from elastomeric to paper-based, and modifies the geometric parameters of the sealing ring (thickness, diameter, profile) to optimize sealing performance. The sealing ring is designed with specific dimensional parameters that allow it to deform adequately under capsule filling pressure to create an effective seal against the cup wall
3Device complexity
If the flange thickness is reduced to a few tenths of a millimetre, then the capsule structure is simplified, but the seal quality deteriorates
Solution Approach 1:
The patent applies local quality by creating a sealing ring with specific localized properties (thickness, density, profile) at the sealing surface, while the rest of the capsule maintains uniform thin-wall construction. The sealing ring is die-cut or laser-cut from the capsule body with optimized local geometry that enhances sealing capability without increasing overall flange thickness
Solution Approach 2:
The sealing ring is pre-formed during capsule manufacturing by die-cutting or laser cutting the paper material before capsule assembly. This preliminary shaping creates the optimal sealing profile in advance, ensuring that the thin flange structure achieves adequate sealing performance without requiring post-manufacturing modifications or additional components
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 apparatus achieves a reliable seal with reduced production costs, maintaining cleanliness, safety, and efficiency while using environmentally-friendly materials.
Implementation Method 1
a station (ST5) for etching said sheet (12) with etching means (9) designed to etch the sheet (12) creating pre-cutting lines (33) along edges of the sealing rings (10)
Implementation Method 2
a suction device (46) configured to detach the sealing rings (10) from the sheet (12)
Implementation Method 3
a sealing station (ST4) for sealing said rings (10) to the respective capsule bodies (8)
Data Source
AI summary
An apparatus for making capsules, includes: a receiving station for receiving capsule bodies having bottom and side walls defining a filling cavity with an opening opposite the bottom and a flange surrounding the opening. A forming station for making sealing rings includes a device for feeding a sheet from a reel. A coupling station couples each ring to a capsule body at the respective flange. A welding station welds the rings to respective capsule bodies. Groups of receiving seats receive the capsule bodies. An etching device etches pre-cutting lines along the edges of the rings, so that a central portion of the rings is detached from the etched sheet. Detaching elements detach from the sheet the rings that had been etched onto the sheet and bring them into contact with the flange at the coupling station. The etching device operates remotely and separately from the coupling station.