Sprung-Loaded Former for Capsule Filter Assembly
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Solution Overview
Problem
Existing methods for assembling filter elements within cup-shaped beverage capsules are complex, requiring multiple mandrels and unsuitable for capsules where the filter element does not extend to the base, and can cause tearing of the filter material due to high loading.
Innovation Solution
A combined weld-head and former with a sprung-loaded former that deforms and bonds the filter element to the capsule body in a single operation, using a weld-head to shape and attach the filter element, reducing the peak force applied and avoiding material tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multi-stage assembly method with three separate mandrels is used to form and insert the filter element, then the filter element can be properly shaped and bonded, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple mandrels into a single integrated mandrel structure that performs the functions of the first mandrel (insertion), second mandrel (shaping), and welding mandrel (bonding) simultaneously. This single integrated mandrel reduces device complexity while maintaining the manufacturing precision required for proper filter element formation and bonding to the capsule body.
Solution Approach 2:
The single integrated mandrel is designed with multi-functional capabilities to perform insertion, shaping, and bonding operations in one assembly step. This universal tool eliminates the need for multiple specialized mandrels, simplifying the assembly process while ensuring proper filter element formation through its designed geometry and bonding features.
2Manufacturing precision
If a rigid former is used to drive the filter element into the capsule body, then the filter element can be properly inserted and shaped, but the filter material may tear due to high loading forces
Solution Approach 1:
The patent changes the mechanical parameters of the former by making it sprung-loaded rather than rigid. This allows the former to apply controlled, progressive force during insertion while accommodating variations in filter material properties. The spring mechanism adjusts the loading parameters to prevent tearing while maintaining sufficient force for proper insertion and shaping of the filter element.
Solution Approach 2:
The sprung-loaded former provides beforehand cushioning by using the spring mechanism to absorb and regulate peak forces during the insertion process. This cushioning effect prevents sudden high loading that could tear the filter material, while still delivering the necessary force to properly insert and shape the filter element within the capsule body.
3Manufacturing precision
If the filter element is assembled to extend to the base of the capsule body, then the filtration coverage is maximized, but the assembly process becomes unsuitable for capsules where the filter should not reach the base
Solution Approach 1:
The patent introduces dynamics to the formerly rigid assembly system through the sprung-loaded former. This allows the assembly process to adapt to different capsule designs and filter element configurations. The spring mechanism enables controlled insertion depth and force application, making the process suitable for both capsules where the filter extends to the base and those where it does not, thereby increasing design flexibility while maintaining positioning precision.
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 method simplifies the assembly process, reduces the risk of filter material tearing, and allows for the assembly of filter elements that do not extend to the base of the capsule, while maintaining the integrity of the filter element during bonding.
Implementation Method 1
a sprung-loaded former of the combined weld-head and former to form a cup-shaped filter element
Implementation Method 2
using a weld-head of the combined weld-head and former to bond the cup-shaped filter element to the cup-shaped capsule body
Data Source
AI summary
The present invention provides a method of assembling a filter element (8) with a cup-shaped capsule body (2) using a combined weld-head (70) and former (80), comprising the steps of positioning the filter element (8) at or near a mouth of the cup-shaped capsule body (2), moving the combined weld-head (70) and former (80) so as to contact and drive the filter element (8) into the cup-shaped capsule body (2), wherein, the filter element (8) is deformed by a sprung-loaded former (80) of the combined weld-head (70) and former (80) to form a cup-shaped filter element (56), and using a weld-head (70) of the combined weld-head (70) and former (80) to bond the cup-shaped filter element (56) to the cup-shaped capsule body (2). The present invention further provides a method of making a beverage capsule and a beverage capsule produced using this method.