Vacuum Capsule Sealing Bell Segmentation
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Solution Overview
Problem
Existing apparatuses for packaging capsules under vacuum for beverage extraction machines often result in non-uniform vacuum levels, leading to defective capsules and high energy consumption, which increases operating costs and reduces productivity.
Innovation Solution
An apparatus with a series of bell-shaped members, each capable of independent vacuum generation and sealing, ensures uniform vacuum levels in capsules by allowing precise control of the vacuum process and skipping defective capsules to maintain production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large vacuum bell is used to package multiple capsules simultaneously, then the productivity is improved, but the vacuum uniformity deteriorates and energy consumption increases
Solution Approach 1:
The single large vacuum bell is divided into multiple smaller vacuum bells, each capable of independently packaging individual capsules. This segmentation allows each bell to achieve uniform vacuum levels while maintaining high productivity through parallel operation of multiple bells.
Solution Approach 2:
The vacuum bells are designed to be movable and independently controllable, allowing dynamic adjustment of vacuum levels for each bell based on capsule requirements. This enables precise vacuum control while maintaining high throughput.
2Productivity
If a single large vacuum bell is used to package multiple capsules simultaneously, then the productivity is improved, but the energy consumption increases
Solution Approach 1:
The vacuum system is segmented into multiple independent vacuum bells, each with its own vacuum generation capability. This allows energy to be distributed efficiently across multiple smaller units, reducing total energy consumption while maintaining high productivity through parallel processing.
Solution Approach 2:
Instead of applying vacuum to all capsules simultaneously in one large bell, the system applies vacuum partially to individual capsules in separate bells, allowing optimized energy usage for each packaging operation.
3Use of energy by moving object
If the vacuum bell is reduced to lower energy expenditure, then the energy consumption is improved, but the productivity deteriorates
Solution Approach 1:
The system segments the packaging process into multiple independent vacuum bells operating in parallel. Each bell is sized appropriately for low energy consumption, while the collective parallel operation of multiple bells maintains high overall productivity.
4Productivity
If multiple support elements advance along a closed route with multiple operative stations, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The support elements and vacuum bells are designed with multi-functionality, where each component serves multiple purposes in the packaging process. This reduces the need for additional specialized components, thereby controlling complexity while maintaining high productivity.
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 solution ensures that each capsule meets specifications, reduces waste, and lowers energy consumption by allowing independent vacuum control and skipping defective capsules, thereby enhancing productivity and cost-effectiveness.
Implementation Method 1
a vacuum generating apparatus, adapted to reduce the inner volume of each bell-shaped member independently from the other bell-shaped members
Data Source
AI summary
An apparatus (100) for manufacturing capsules (10) under vacuum for preparing beverages is described, comprising: a plurality of support elements (105) and a driving system (120) adapted to move said support elements (105) and stop them in a plurality of operative stations, wherein each support element (105) comprises a row of housing seats (115), wherein the operative stations comprise at least: a loading station (145) for inserting into the housing seats (115) a glass-shaped body (15), a filling station (150) for filling glass-shaped bodies (15) with a food substance adapted to produce a beverage, a covering station (155) for applying and fixing on the glass/shaped bodies (15) a closing film (45), and a sealing station (160) for placing under vacuum the inner volume of the glass-shaped bodies (15) and for sealing the closing film (45) and wherein said sealing station (160) comprises: a plurality of bell-shaped members (280), each of which is adapted to overlay to one respective housing seat (115) and has mouthpiece directed downward, a movement apparatus (300) for moving each bell-shaped member (280) in vertical direction between a raised position to a lowered position, a vacuum generating apparatus (340) to reduce the inner volume of bell-shaped members (280), and a plurality of welding elements (390), each of which is contained inside a respective bell-shaped member (280) for airtightly welding the closing film (45) on the glass-shaped body (15) contained in the housing seat (115).