Pleated Capsule Body Welding with Reinforcing Element
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Solution Overview
Problem
The manufacturing of capsules with pleated capsule bodies requires multiple complex operations and additional reinforcing elements for stability, leading to precision issues and material waste due to the need for partial insertion and welding within an impermeable shell, which complicates the process and increases the risk of filter tears.
Innovation Solution
A method where the pleated capsule body and reinforcing element are inserted and welded in a single station, allowing for separate formation and coupling processes, enabling easier insertion and welding with a fixed geometry welder, and incorporating a differential diameter design to facilitate the process, thus reducing operations and improving quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the pleated capsule body is formed and partially inserted in the impermeable shell in a first station, then the capsule body can be formed with increased filtering surface, but the capsule body tends to slip out due to elasticity and conicity, harming precision and requiring complex variable geometry welder
Solution Approach 1:
The pleated capsule body is pre-formed in a first station with increased filtering surface area through pleating, then transported to a second station for complete insertion and welding. This preliminary formation allows the filtering surface to be maximized before the final assembly operation, resolving the contradiction between increased filtering surface and insertion precision.
2Stability of the object's composition
If the pleated capsule body is totally inserted and welded in a second station, then the capsule gains structural stability, but multiple complex operations are required leading to increased device complexity
Solution Approach 1:
The manufacturing process is segmented into two distinct stations: a first station for forming the pleated capsule body with increased filtering surface, and a second station for complete insertion and welding to the impermeable shell. This segmentation allows each station to perform its specific function optimally, achieving capsule stability while managing device complexity through functional separation.
3Adaptability or versatility
If variable geometry welder is used to accommodate the conicity of the filter, then the filter can be welded at different positions, but the welding process becomes particularly complex with division into multiple steps
Solution Approach 1:
The pleated capsule body is pre-formed with its conical shape and increased filtering surface in the first station before being transported to the second station for welding. This preliminary action allows the variable geometry welder to work with a pre-positioned component, reducing the need for complex multi-step welding processes while maintaining adaptability to the conical filter geometry.
4Ease of manufacture
If the pleated capsule body is transported partially inserted in the impermeable shell, then the capsule can be assembled, but the filter may tear during subsequent operations due to narrow diameter and low conicity
Solution Approach 1:
The manufacturing process is divided into two stations: the first station forms the pleated capsule body with adequate conicity and increased filtering surface, then transports it to the second station for complete insertion. This segmentation ensures the filter maintains its structural integrity during transport and assembly, preventing tears while enabling capsule assembly.
Solution Approach 2:
The pleated capsule body is pre-formed with adequate conicity and structural strength in the first station before insertion into the impermeable shell. This preliminary strengthening prevents filter tears during subsequent operations while maintaining ease of manufacture through the two-station process.
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 manufacturing process, reduces material waste, enhances the stability and quality of the capsules, and allows for easier detection and removal of defects before final assembly, improving the overall efficiency and precision of capsule production.
Implementation Method 1
the welder is configured so as to weld the pleated capsule body to the reinforcing element
Data Source
AI summary
The present invention describes a method and a machine for the formation of a capsule (100) for producing beverages in which the capsule (100) comprises a pleated capsule body (101) and a reinforcing element (102). The method comprises the following steps: a step of forming the pleated capsule body (101) of the capsule (100) in a first station (110); a step of supplying the reinforcing element (102) in a second station (111) different from the first station (110); a step of transporting the pleated capsule body (101) from the first station (110) to the second station (111); a step of insertion in the second station of the pleated capsule body (101) in the reinforcing element (102); a step of coupling between the pleated capsule body (101) and the reinforcing element (102) in the second station (111).