CAPSULES

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority from Italian patent application no. 102018000001138 filed on January 17, 2018, the entire disclosure of which is incorporated herein by reference .

TECHNICAL FIELD

The present invention relates to a method of feeding articles into an automatic multi-line machine for the production of beverage capsules and to an automatic multi- line machine for the production of beverage capsules.

PRIOR ART

A standard beverage capsule comprises a cup-shaped container, a porous filter that is fastened (typically welded) to an upper and circular edge of the container, a dose of powdered product that is arranged in the container and is enclosed by the porous filter, and a circular lid that closes the container and is fastened (typically welded) to the upper circular edge of the container.

An automatic multi-line machine for the production of beverage capsules comprises a plurality of processing lines comprising respective processing conveyors, which advance parallel to each other along respective processing paths. Each processing path passes through a first feeding unit in which a corresponding empty container is fed to each processing conveyor, through a second feeding unit in which a porous filter is fed to each processing conveyor and inserted inside a container, through a first welding unit in which each porous filter is welded to the edge of the container, through a third feeding unit in which a dose of powdered product is fed to each processing conveyor and inserted inside a container, through a fourth feeding unit in which a lid is fed to each processing conveyor and connected to a container, and through a second welding unit in which each lid is welded to the edge of the container.

In an automatic multi-line machine, when a processing line has problems (e.g. a clogging in the processing conveyor, a malfunctioning of the elements of a feeding unit or a welding unit...) , only the problematic processing line is normally deactivated (stopped), while all other processing lines keep working with the aim of not excessively penalizing the average hourly productivity (i.e. calculated over a long period of time, e.g. an entire eight-hour work shift) of the automatic multi-line machine. In order to deactivate a processing line it is necessary to stop feeding all the articles (containers porous filters powdered product, lids) to the deactivated processing line, while still feeding all the articles to the other processing lines that are still active.

Stopping feeding an article only in a deactivated processing line (i.e. not stopping feeding the articles to the other processing lines that are still active) is simple when the article comes from a stack (e.g. vertical) of single articles (as in the case of containers) or when the article comes from a hopper that contains a large amount of the article (as in the case of the powdered product), since feeding the article to each processing line is substantially independent of feeding the same article to the other processing lines.

On the other hand, stopping feeding an article only in a deactivated processing line (i.e. not stopping feeding the article to the other processing lines that are still active) is problematic when the article is separated (typically cut) from a continuous band of material (as in the case of the porous filter or of the lid) , since the cutting device (for the sake of simplicity and manufacturing inexpensiveness) is generally a single one for all processing lines (i.e. including several knives operated by a single actuator) and therefore, it is not possible to avoid cutting the article in a single deactivated processing line without at the same time avoiding cutting the article in the other processing lines that are still active. In this case, obviously, the cutting of the articles from the continuous band of material is not interrupted (so that the still active processing lines keep working) , whereas the articles for the deactivated processing line are intercepted and discarded (namely directed to a waste collection container) . However, while allowing the automatic multi-line machine to work even when a processing line is deactivated, this operating mode necessarily obliges to discard a large number of articles (typically porous filters and/or lids) that are fully compliant with the specifications (i.e. which do not show any defect) with an evident increase both in the average production costs and in the environmental production impact .

US2017320671A1 describes a method of feeding articles 2 (in particular toilet paper rolls or kitchen paper rolls) in an automatic multi-line machine. The feeding method comprises the steps of: moving along respective parallel and adjacent processing paths a plurality of processing conveyors 3, each of which is designed to support a first succession of articles 2; moving along a feeding path that is perpendicular (but not offset) with respect to the processing paths a feeding conveyor 6 that is designed to support a second succession of articles 2 and crosses the processing conveyors 3 in an output station; cyclically and simultaneously transferring to the feeding conveyor 6 by means of a first transferring device 9 arranged in an input station that is located upstream of the output station a group of articles 2 equal to the number of processing conveyors 3; cyclically and simultaneously transferring from the feeding conveyor 6 to the corresponding processing conveyors 3 by means of a second transferring device 10 arranged in the output station a group of articles 2 equal to the number of processing conveyors 3 when all the processing conveyors 3 are active; and cyclically and simultaneously transferring from the feeding conveyor 6 to the corresponding processing conveyors 3 by means of the second transferring device 10 arranged in the output station a group of articles 2 equal to the number of active processing conveyors 3 when at least one processing conveyor 3 is deactivated.

DESCRIPTION OF THE INVENTION

The object of the present invention is to provide a method of feeding articles into an automatic multi-line machine for the production of beverage capsules and an automatic multi-line machine for the production of beverage capsules, said feeding method and automatic multi-line machine being free from the aforesaid drawbacks and, at the same time being easy and inexpensive to manufacture.

In accordance with the present invention, it is provided a method of feeding articles and an automatic multi-line machine for the production of beverage capsules, as claimed in the appended claims .

The claims describe preferred embodiments of the present invention forming an integral part of the present disclosure .

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described with reference to the annexed drawings showing an example of non-limiting embodiment, in which:

• Figure 1 is a perspective view of a beverage capsule;

• Figure 2 is a perspective, exploded view of the beverage capsule of Figure 1;

• Figure 3 is a schematic view of an automatic multi-line machine that produces the beverage capsule of Figure 1;

• Figure 4 is a schematic plan view of a feeding unit of the automatic multi-line machine of Figure 3;

• Figure 5 is a schematic front view of the feeding unit of Figure 4;

• Figures 6-10 are respective schematic front views of the feeding unit of Figure 4 during the operation with a deactivated processing line;

• Figure 11 is a schematic plan view of an alternative embodiment of the feeding unit of Figure

4;

• Figure 12 is a schematic front view of the feeding unit of Figure 11; and

• Figures 13 and 14 are respective schematic front views of the feeding unit of Figure 4 during the operation with a deactivated processing line.

PREFERRED EMBODIMENTS OF THE INVENTION

In Figures 1 and 2, the reference number 1 shows as a whole a beverage capsule (e.g. coffee) comprising a cup-shaped container 2, a porous filter 3 that is fastened (typically welded) to an upper and circular edge 4 of the container 2, a powdered product dose 5 that is arranged in the container 2 and is enclosed by the porous filter 3, and a circular lid 6 that closes the container 2 and is fastened (typically welded) to the upper and circular edge 4 of the container 2.

In Figure 3, the reference number 7 shows as a whole an automatic multi-line machine that operates with an intermittent motion (namely with a cyclical alternation of stopping and moving phases) and produces the capsules 1 described above by using four processing lines that work in parallel (i.e. four capsules 1 are simultaneously produced at each cycle) . The automatic multi-line machine 7 comprises four processing lines comprising in turn respective processing conveyors 8, which advance parallel to each other along respective straight processing paths. Each processing path passes through a feeding unit U1 in which a corresponding empty container 2 is fed to each processing conveyor 8, through a feeding unit U2 in which a corresponding porous filter 3 is fed to each processing conveyor 8 and is inserted inside a corresponding container 2, through a welding unit U3 in which each porous filter 3 is welded to the edge 4 of the corresponding container 2, through a feeding unit U4 in which a corresponding dose of powdered product 5 is fed to each processing conveyor 8 and is inserted inside a corresponding container 2, through a feeding unit U5 in which a corresponding lid 6 is fed to each processing conveyor 8 and is coupled to a corresponding container 2, and through a welding unit U6 in which each lid 6 is welded to the edge 4 of the corresponding container 2.

In the feeding unit Ul, the containers 2 are taken from respective stacks 9, each of which stacks up a plurality of containers 2. In the feeding unit U2, the porous filters 3 are cut from a band 10 of porous material by means of a cutting device common to all processing lines. In the feeding unit U4, the powdered product 5 enters (by gravity) from corresponding output openings of a vertical hopper 11.

In the feeding unit U5, the lids 6 are cut from a band 12 of plastic or metal material by means of a cutting device common to all the processing lines.

From the foregoing, it is clear that each processing conveyor 8 is designed to move a succession of capsules 1 as the capsules 1 are formed. Therefore, each processing conveyor 8 is designed to move first (downstream of the feeding unit U2) a succession of containers 2 to which a succession of porous filters 3 (at the feeding unit U2), a succession of products 5 in powder form (at the feeding unit U4) and a succession of lids 6 (at the feeding unit U5) are then added. Obviously, the porous filters 3 are coupled to the containers 2, the powdered products 5 are arranged in the porous filters 3 and the lids 6 close the containers 2.

In the automatic multi-line machine 7, when a processing line has problems (e.g. a clogging of the corresponding processing conveyor 8, a malfunctioning of the corresponding elements of a feeding unit Ul, U2, U4, U5 or of a welding unit U3, U6...) only the problematic processing line is normally deactivated (stopped), while all other processing lines keep working with the aim of not excessively penalizing the average hourly productivity

(i.e. calculated over a long period of time, e.g. an entire eight-hour work shift) of the automatic multi-line machine

7. In order to deactivate a processing line it is necessary to stop feeding all the articles (containers 2, porous filters 3, powdered product 5, lids 6) to the deactivated processing line while still feeding all the articles (containers 2, porous filters 3, powdered product 5, lids 6) to the other processing lines that are still active. Stopping feeding an article (container 2, porous filter 3, powdered product 5, lid 6) only in a deactivated processing line (i.e. not stopping feeding the article to the other processing lines that are still active) is simple when the article comes from a stack 9 of single articles (as in the case of the containers 2) or when the article comes from the hopper 11 (as in the case of the powdered product 5), since feeding the article at each processing line is substantially independent of feeding the same article to the other processing lines.

On the other hand, stopping feeding an article only in a deactivated processing line (i.e. not stopping feeding the article to the other processing lines that are still active) is problematic when the article is separated (typically cut) from a band 10 or 12 as in the case of the porous filter 3 or of the lid 6, since the cutting device of the band 10 or 12 (for the sake of simplicity and manufacturing inexpensiveness) is a single one for all processing lines (i.e. it includes several knives operated by a single actuator) and therefore it is not possible to avoid cutting the article in a single deactivated processing line without at the same time avoiding cutting the article in the other still active processing lines. In this case, according to a simpler embodiment, the cutting of the articles (porous filters 3 or lids 6) from the continuous band of material is not interrupted (so that the still active processing lines keep working) and the articles (porous filters 3 or lids 6) for the deactivated processing line are intercepted and discarded (namely directed to a waste collection container) . However, while allowing the automatic multi-line machine 7 to work even when a processing line is deactivated, this operating mode necessarily obliges to discard a large number of articles (typically porous filters 3 and lids 6) that are fully compliant with the specifications (i.e. that do not show any defect) with an evident increase both in the average production costs and in the environmental production impact .

According to the embodiment shown in Figures 4 and 5, the feeding unit U2 comprises a feeding conveyor 13 that moves along a feeding path, which is perpendicular and offset

(namely arranged on a different plane as shown in Figure 5) with respect to the processing paths and is designed to support a succession of articles (in particular porous filters 3) by means of respective pockets 14. In other words, the feeding conveyor 13 supports a plurality of pockets 14, each of which is designed to receive and house a corresponding article (in particular a porous filter 3) to move the article along the feeding path. In the embodiment shown in the accompanying figures, the feeding conveyor 13 comprises a closed loop band that winds around two end pulleys and supports the pockets 14. Alternatively, the feeding conveyor 13 comprises a wheel, which is rotatably mounted and supports the pockets 14. According to a preferred embodiment shown in the accompanying figures, each pocket 14 is designed to contain a corresponding article (in particular a porous filter 3) and has a tubular shape having an input opening (arranged above) through which the corresponding article enters the pocket 14 and an output opening (arranged below and opposite the input opening) through which the corresponding article leaves the pocket 14.

The feeding path extends between an input station SI located at a cutting device 15, which cyclically cuts the porous material band 10, and an output station S2 located at the processing conveyors 8 (i.e. the feeding conveyor 13 crosses the processing conveyors 8 in the output station

S2) . During the normal operation of the feeding unit U2, in the input station SI four pockets 14 of the feeding conveyor 13 receive four articles (i.e. four porous filters 3) from the cutting device 15 and, at the same time, in the output station S2 four pockets 14 of the feeding conveyor 13 hand over four articles (i.e., four porous filters 3) to the corresponding processing conveyors 8.

As previously stated, each pocket 14 of the feeding conveyor 13 has a tubular shape and has an input opening through which the corresponding article (in particular a porous filter 3) enters the input station SI, as well as an output opening through which the corresponding article (in particular a porous filter 3) leaves the output station S2. The feeding unit U2 comprises a transferring device 16 (schematically shown in Figure 4), which is arranged in the input station SI (located upstream of the output station S2 in the direction of advancement of the feeding conveyor 13) and is designed to cyclically and simultaneously transfer to four pockets 14 of the feeding conveyor 13 a group of four (equal to the number of processing conveyors 8) articles (i.e. four porous filters 3) . The transferring device 16 comprises four pushers, pushing vertically downwards a corresponding article (i.e. a porous filter 3) to pick up the article from the cutting device 15 and insert the article from above into an underlying pocket 14 of the feeding conveyor 13. The feeding unit U2 comprises a transferring device 17

(schematically shown in Figure 5), which is arranged in the output station S2 and is able to cyclically and simultaneously transfer from the feeding conveyor 13 to the corresponding processing conveyors 8 a group of four (equal to the number of processing conveyors 8) articles (i.e. four porous filters 3) when all processing conveyors 8 are active. On the other hand, the transferring device 17 is able to cyclically and simultaneously transfer from the feeding conveyor 13 to the corresponding processing conveyors 8 a group of articles (namely, porous filters 3) equal to the number of active processing conveyors 8 when at least one processing conveyor 8 is deactivated. In other words, when a processing conveyor 8 is deactivated, the transferring device 17 does not transfer an article (i.e. a porous filter 3) from the feeding conveyor 13 to the deactivated processing conveyor 8. The transferring device 17 comprises four pushers pushing vertically downwards a corresponding article (i.e. a porous filter 3) to remove the article from the corresponding pocket 14 of the feeding conveyor 13 and insert from above the article in an underlying container 2 carried by a processing conveyor 8. In other words, each pusher of the transferring device 17 passes through (i.e. from the input opening to the output opening) a pocket 14 of the feeding conveyor 13 to remove an article (i.e. a porous filter 3) from the pocket 14 and then insert the article into an underlying container 2 carried by a processing conveyor 8.

The feeding unit U2 comprises a buffer conveyor 18, which moves along a buffer path parallel to the feeding path and is designed to support a succession of articles (in particular of porous filters 3) by means of respective pockets 19. In other words, the buffer conveyor 18 supports a plurality of pockets 19, each of which is designed to receive and house a corresponding article (in particular a porous filter 3) to move the article along the buffer path. In the embodiment shown in the accompanying figures, the buffer conveyor 18 comprises a closed loop belt that winds around two end pulleys and supports the pockets 19. Alternatively, the buffer conveyor 18 comprises a wheel, which is rotatably mounted and supports the pockets 19. According to a preferred embodiment shown in the accompanying figures, each pocket 19 is designed to contain a corresponding article (in particular a porous filter 3) and has a tubular shape that is completely similar to the tubular shape of the pockets 14 of the feeding conveyor 13. The feeding unit U2 comprises a transferring device 20 (schematically shown in Figure 5), which is arranged in an exchange station S3 located between the input station SI and the output station S2 and is able to transfer from the feeding conveyor 13 to the buffer conveyor 18, when at least one processing conveyor 8 is deactivated, a number of articles (namely porous filters 3) equal to the number of deactivated processing conveyors 8. In other words, if there are one, two or three deactivated conveyors 8, the transferring device 20 is designed to transfer into the exchange station S3 one, two or three articles (porous filters 3) from the corresponding pockets 14 of the feeding conveyor 13 to the corresponding pockets 19 of the buffer conveyor 18. The transferring device 20 comprises four pushers (that can be individually activated, namely independently of each other) , each of which pushes vertically downwards a corresponding article (i.e. a porous filter 3) to remove the article from the corresponding pocket 14 of the feeding conveyor 13 and insert the article from above into an underlying pocket 19 of the buffer conveyor 18. In other words, each pusher of the transferring device 20 passes through (i.e. from the input opening to the output opening) a pocket 14 of the feeding conveyor 13 to remove an article (namely a porous filter 3) from the pocket 14 and then insert the article in an underlying pocket 19 of the buffer conveyor 18.

In the embodiment shown in Figure 5, the feeding unit U2 comprises a transferring device 21 (schematically shown in

Figure 5), which is arranged in the exchange station S3 and is designed to transfer a group of articles (i.e. porous filters 3) equal to the number of active processing conveyors 8 from the conveyor buffer 18 to the feeding conveyor 13. In other words, the transferring device 21 is designed to transfer into the exchange station S3 a group of articles (porous filters 3) equal to the number of active processing conveyors 8 from the corresponding pockets 19 of the buffer conveyor 18 to the corresponding pockets 14 of the feeding conveyor 13. The transferring device 21 comprises four pushers (that can be individually activated, namely independently of each other) , each of which pushes vertically upwards a corresponding article (i.e. a porous filter 3) to remove the article from the corresponding pocket 19 of the buffer conveyor 18 and insert the article from below into an overlying pocket 14 of the feeding conveyor 13. In other words, each pusher of the transferring device 21 passes through a pocket 19 of the buffer conveyor 18 to extract an article (i.e. a porous filter 3) from the pocket 19 and then insert the article into an overlying pocket 14 of the feeding conveyor 13. Together with the activation of the transferring device 21 (to transfer a group of articles equal to the number of active processing conveyors 8 from the buffer conveyor 18 to the feeding conveyor 13), the transferring device 16 is temporarily stopped to stop transferring a complete group of four articles to the feeding conveyor 13 in the input station SI so as to create in the feeding conveyor 13 some space to house a group of articles equal to the number of active processing conveyors 8 from the buffer conveyor 18 in the exchange station S3.

In other words, when at least one processing conveyor 8 is deactivated, the transferring device 20 arranged in the exchange station S3 transfers from the feeding conveyor 13 to the buffer conveyor 18 a number of articles equal to the number of deactivated processing conveyors 8. When the buffer conveyor 18 contains a number of articles at least equal to the number of active processing conveyors 8, the transferring device 21 transfers for a cycle a group of articles equal to the number of active processing conveyors 8 from the buffer conveyor 18 to the feeding conveyor 13 and at the same time the transferring device 16 is stopped for a cycle to prevent the transfer of a complete group of articles to the feeding conveyor 13 so as to create some space in the feeding conveyor 13 to house a group of articles equal to the number of active processing conveyors 8 from the buffer conveyor 18 in the exchange station S3.

In other words, when at least one processing conveyor 8 is deactivated, the transferring device 20 arranged in the exchange station S3 transfers from the feeding conveyor 13 to the buffer conveyor 18 a number of articles equal to the number of deactivated processing conveyors 8. When the buffer conveyor 18 contains a number of articles at least equal to the number of active processing conveyors 8, the transferring device 21 transfers for a cycle a group of articles equal to the number of active processing conveyors 8 from the buffer conveyor 18 to the conveyor 13 and at the same time the transferring device 16 is stopped for a cycle to prevent the transfer of a complete group of articles to the feeding conveyor 13 so as to create some space in the feeding conveyor 13 to house a group of articles equal to the number of active processing conveyors 8 from the buffer conveyor 18 in the exchange station S3. What previously described is shown in Figures 6-10. Figures 6-8 show that the second processing line from the left is deactivated (thus having no corresponding container 2, unlike the other processing lines) and therefore the transferring device 20 transfers in the exchange station S3 in succession three articles destined to the deactivated processing line from a corresponding pocket of the feeding conveyor 13 to a corresponding pocket 19 of the buffer conveyor 18 until the three articles accumulate in the conveyor 18 (namely a number of articles equal to the number of processing lines that are still active) . Figures 9 and 10 show that in the buffer conveyor 18 three articles have accumulated (i.e. a number of articles equal to the number of processing lines that are still active) , which are then transferred together by the transferring device 21 from the buffer conveyor 18 to the feeding conveyor 13, thus filling a "hole" (i.e. some free space) that had been previously created in the feeding conveyor 13 by stopping for a cycle the transferring device 16.

In the embodiment shown in Figures 4-10, the buffer conveyor 18 constitutes a "temporary parking" of the articles (namely the porous filters 3) that, being unable to be fed to the corresponding deactivated processing conveyors 8, are temporarily accumulated in the buffer conveyor 18 to compose groups of articles equal to the number of processing conveyors 8 that are still active. At this point, the groups of articles equal to the number of processing conveyors 8 that are still active are transferred from the buffer conveyor 18 to the feeding conveyor 13 in which a "hole" (namely some free space) has been created by stopping for one cycle the transferring device 16.

In the variant shown in Figures 11-14, the buffer conveyor 18 (that collects the "excess" articles, since they were destined to the deactivated processing conveyors 8) extends up to the processing conveyors 8 (i.e. up to the output station S2 that is in correspondence with the processing conveyors 8) and therefore the groups of articles equal to the number of active processing conveyors 8 that are in the buffer conveyor 18 are transferred directly from the buffer conveyor 18 to the active processing conveyors 8 in the output station S2. Obviously, the variant shown in Figures 11-14 lacks the transferring device 21 (since the articles never return from the buffer conveyor 18 to the feeding conveyor 13) . In the variant shown in Figures 11-14, besides transferring the articles from the feeding conveyor 13 to the processing conveyors 8, the transferring device

17 may also transfer the articles from the buffer conveyor

18 to the processing conveyors 8 (as shown in the attached figures) in the output station S2. Alternatively, a further transferring device (different and independent of the transferring device 17) could be provided, which transfers the articles from the buffer conveyor 18 to the processing conveyors 8 in the output station S2.

What has been described above is shown in Figures 13 and 14. Figure 13 shows that the second processing line from the left is deactivated (thus having no corresponding container 2, unlike the other processing lines) and therefore the transferring device 20 transfers in the exchange station S3 the articles destined to the deactivated processing line from a corresponding pocket of the feeding conveyor 13 to a corresponding pocket 19 of the buffer conveyor 18 until accumulating in the conveyor buffer 18 three articles (i.e. a number of articles equal to the number of processing lines that are still active) . Figure 14 shows that in the buffer conveyor 18 three articles have accumulated (i.e. a number of articles equal to the number of processing lines that are still active) , which are then transferred together by the transferring device 17 from the buffer conveyor 18 to the active processing conveyors 8 due to the presence of a "hole" that has been previously created in the feeding conveyor 13 by stopping for a cycle the transferring device 16.

With reference to Figures 4-14, it has been described the feeding unit U2 of the porous filters 3, which allows avoiding feeding the porous filters 3 to the deactivated processing conveyors 8 without generating any waste of porous filters 3. Also the feeding unit U5 of the lids 6 can be structured like the feeding unit U2 of the porous filters 3 to avoid feeding the lids 6 to the deactivated processing conveyors 8 without generating any waste of lids 6. According to other embodiments not shown, the feeding unit U5 of the lids 6 may be of a conventional type (therefore lacking a buffer conveyor 18 and involving the discarding of the lids 6 intended for the deactivated processing conveyors 8) and the feeding unit U2 of the porous filters 3 may be of an innovative type (therefore having a buffer conveyor 18 and not involving the discarding of the porous filters 3 intended for the deactivated processing conveyors 8) or even vice versa (namely, the feeding unit U5 for the lids 6 is of the innovative type and the feeding unit U2 for the porous filters 3 is the conventional type) .

The embodiments described herein can be combined without departing from the scope of protection of the present invention .

The automatic multi-line machine 7 described above has numerous advantages.

First, the automatic multi-line machine 7 described above allows avoiding discarding the articles (porous filters 3 and/or lids 6) intended for the deactivated processing conveyors 8.

Moreover, the automatic multi-line machine 7 described above is generally simple and inexpensive to manufacture because it requires the addition of conventional parts (the buffer conveyor 18, the transferring devices 20 and 21), therefore individually easily manufactured with commercial components .

In the above description, reference has been made to an automatic multi-line machine 7 for the production of beverage capsules 1. However, the methods to avoid discarding articles intended for the deactivated processing conveyors can be implemented in any type of automatic multi-line machine, for example for the production of food packages or for the production of smoking articles.