Method of forming and inserting filter elements in cup-shaped containers

• US 6,440,256 B1
• Filed: 06/20/2000
• Issued: 08/27/2002
• Est. Priority Date: 06/20/2000
• Status: Expired due to Term

• Current Assignee: Keurig Green Mountain, Inc. (Keurig Dr Pepper, Inc.)
• Original Assignee: Keurig, Inc. (Keurig Dr Pepper, Inc.)
• Inventors: Christopher, Anthony J., Walsh, Kevin, Boccuti, A. David, Gordon, Steven J., Anderson, Brett, Wolf, Jim, Helmbrecht, Mike, Sallum, Hani, Ramler, David, Sweeney, Richard P.
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): Kilkenny, Todd J.
• Application Number:
  US09/597,455
• Time in Patent Office: 798 Days
• Field of Search: 210/497.01, 210/497.2, 210/497.3, 992/95, 993/17, 426/77, 426/79, 156/293, 156/267, 156/269, 156/270, 156/200, 156/201, 156/217, 156/227, 156/199, 156/204, 156/308.4
• US Class Current: 156/293
• CPC Class Codes: A47J 31/08 Paper filter inlays therefor to be disposed after use
• CPC Class Codes: B65B 29/02 Packaging of substances, e.g. tea, which are intended to be infused in the package
• CPC Class Codes: B65B 29/022 packaging infusion material into capsules
• CPC Class Codes: B65B 29/06 Packaging of substances to which a further ingredient, e.g. water, is to be added in the package by the user for mixing prior to dispensing
• CPC Class Codes: B65B 43/10 by folding the material
• CPC Class Codes: B65B 43/18 by suction-operated grippers
• CPC Class Codes: B65B 43/46 using grippers
• CPC Class Codes: Y10T 156/101 Prior to or during assembly with additional lamina
• CPC Class Codes: Y10T 156/1015 Folding
• CPC Class Codes: Y10T 156/1036 Bending of one piece blank and joining edges to form article
• CPC Class Codes: Y10T 156/1051 by folding
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal
• CPC Class Codes: Y10T 156/1085 One web only

Abstract

A method of forming and inserting filter elements into cup-shaped containers comprises the steps of:

a) folding a continuous web of filter material into two adjacent plies which have separable upper edges and are joined one to the other along a bottom fold line;

b) blanking the adjacent plies to form their upper edges into a scalloped pattern;

c) inserting carrier mandrels between the adjacent plies;

d) joining the adjacent plies along seams extending transversely with respect to the bottom fold line to form a series of collapsed frustoconical filter elements interconnected by scrap segments and supported internally by the carrier mandrels;

e) separating the filter elements one from the other by blanking and removing the scrap segments;

f) transferring the filter elements from the carrier mandrels into cup-shaped containers arranged therebeneath; and

g) securing the thus inserted filter elements to interior surfaces of the cup-shaped containers.

Claims

1. A method of forming and inserting filter elements into cup-shaped containers comprising the steps of:

a) folding a continuous web of filter material into two adjacent plies which have separable upper edges and are joined one to the other along a bottom fold line;

b) blanking said adjacent plies to form said upper edges into a scalloped pattern;

c) inserting carrier mandrels between said adjacent plies;

d) joining said adjacent plies along seams extending transversely with respect to said bottom fold line to form a series of collapsed frustoconical filter elements interconnected by scrap segments and supported internally by said carrier mandrels;

e) separating said filter elements one from the other by blanking and removing said scrap segments;

f) transferring said filter elements from said carrier mandrels into cup-shaped containers arranged therebeneath; and

g) securing the thus inserted filter elements to interior surfaces of said cup-shaped containers.

2. The method of claim 1 wherein said filter material is heat sealable, and wherein the adjacent plies are joined one to the other along weld lines.

3. The method of claim 1 wherein said filter material is heat sealable, and wherein insertion of said filter elements into said cup-shaped containers is accompanied by tack welding said filter elements to the bottoms of said cup-shaped containers.

4. The method of claim 1 wherein said filter material is heat sealable, and wherein step (g) is effected by welding said filter elements to interior surfaces of said cup-shaped containers.

5. The method of claim 1 wherein step (g) is preceded by the step of expanding the thus inserted filter elements radially outwardly against the sides of said cup-shaped containers.

6. The method of claim 1 wherein step (c) is accompanied by a positive gripping of at least one of said plies against said mandrels.