Vertical Axis Filter Bag Machine with Pusher Filling
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Solution Overview
Problem
Current machines for producing filter bags with significant three-dimensional dimensions, such as wide-leaf infusion products, face challenges with low operating speeds and productivity due to the limitations of both horizontal and vertical feed/production axis designs, leading to issues with product placement and bag quality.
Innovation Solution
A machine with a vertical feed axis that incorporates a controlled filling station using a pusher element to accelerate product placement onto the filter bag, combined with a compact handling and control unit for precise positioning and rapid filling, allowing for high-speed and high-productivity production of filter bags with integrated auxiliary stations for additional elements like string and outer envelopes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a vertical feed axis is used to make pyramid-shaped filter bags with significant three-dimensional dimensions, then the bag geometry and three-dimensional dimensions are improved, but the operating speed and productivity are reduced
Solution Approach 1:
The patent combines the filling station, forming station, and closing station into a single integrated machine unit operating on a vertical feed axis. This merging of previously separate functions into one cohesive system enables synchronized operation at high speed while maintaining the ability to produce pyramid-shaped filter bags with significant three-dimensional dimensions.
Solution Approach 2:
The patent employs a pusher element that preliminarily positions and accelerates the product charge onto the filter bag before the bag is formed and closed. This preliminary action ensures precise product placement and maintains high operating speeds by preparing the product in advance of the forming cycle.
2Productivity
If a horizontal feed axis is used to maintain high operating speeds, then productivity is improved, but the ability to make filter bags with significant three-dimensional dimensions is reduced
Solution Approach 1:
The patent transitions from a horizontal feed axis to a vertical feed axis, utilizing the vertical dimension to achieve both high productivity and the formation of filter bags with significant three-dimensional dimensions. This dimensional change enables the pusher element to accelerate product vertically while the forming station creates the desired pyramid shape.
3Manufacturing precision
If the operating speed is reduced to accommodate wide-leaf product on a horizontal feed machine, then product placement quality is improved, but productivity is reduced
Solution Approach 1:
The pusher element performs preliminary acceleration of the product charge onto the filter bag at high speed, ensuring precise product placement and maintaining charge integrity. This preliminary action allows the system to operate at high speeds while still achieving the manufacturing precision required for quality product placement.
Solution Approach 2:
The pusher element acts as an intermediary mechanism between the high-speed feed system and the product charge. It mediates the interaction by accelerating and positioning the product precisely onto the moving filter bag, enabling both high speed and high precision simultaneously.
4Adaptability or versatility
If additional independent machines are connected to apply accessories like string and tags, then the functionality is improved, but the device complexity and machine dimensions are increased
Solution Approach 1:
The patent integrates the filling, forming, and closing functions into a single machine unit, eliminating the need for multiple independent machines. This merging reduces overall device complexity and machine dimensions while maintaining the versatility to apply accessories through the integrated system.
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 enables the production of filter bags with considerable three-dimensional dimensions at high operating speeds and productivity, ensuring precise filling and forming while reducing machine dimensions and the need for additional machinery, thus improving bag quality and production efficiency.
Implementation Method 1
a pusher element, able to move in both directions along the vertical feed axis, which pushes in acceleration a charge of product onto the bottom end of the filter bag being formed
Implementation Method 2
first support and control means for pulling the tubular web of filter paper downwards
Implementation Method 3
a feed channel extending vertically on which a continuous web of filter paper is wrapped to form a tube, into which the product is made to fall by gravity
Data Source
AI summary
A machine for making filter bags (1) with infusion products comprises: a feed station (3) for a continuous web (S) of filter paper; a station (4) for forming and joining the continuous web (S) in a closed tubular shape which is fed along a vertical feed axis (Z); a station (5) for filling the product with a pusher element (9) able to move along the vertical feed axis (Z); a station (6) for joining an open lower end of the continuous tubular web (S) forming, alternately, the bottom end (F) and the top end (T) of individual filter bags (1); a handling and control unit for the bottom end (F) able to move in such a way that it is synchronized with the joining station (6) along the vertical feed axis (Z) for pulling the web of filter paper (S) and controlling the position of the bottom end (F) of the filter bag (1) being formed.