Capsule, water distribution wall for such a capsule, and method for manufacturing such a capsule
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Solution Overview
Problem
Existing beverage capsules face issues with moisture and gas barrier disruptions during manufacturing, leading to compromised quality of the contained substance due to localized disruptions in the barrier layers caused by pressure and heat during sealing.
Innovation Solution
A capsule design with a layered structure comprising a cellulose-based body layer, a liner with a barrier layer, and a water distribution wall with a barrier layer, united along the circumference to ensure a tight seal, maintaining moisture and gas barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to seal the water distribution wall on the capsule body, then reliable sealing is achieved, but the barrier layer is disrupted locally allowing moisture or gas to enter
Solution Approach 1:
The capsule body is divided into multiple functional layers: a structural body layer and a separate barrier layer (liner). The water distribution wall seals to the body layer without compromising the barrier layer, as the barrier layer extends beyond the sealing zone or is positioned to avoid disruption. This segmentation allows the sealing function to be performed on the body layer while the barrier layer remains intact to prevent moisture and gas ingress.
Solution Approach 2:
The body layer acts as an intermediary between the water distribution wall and the barrier layer. The sealing operation is performed on the body layer, which serves as a sacrificial or protective intermediate layer that absorbs the sealing stress without transmitting it to the barrier layer. This intermediary structure allows reliable sealing while preserving the barrier properties.
2Ease of manufacture
If pressure and heat are applied during sealing, then the water distribution wall is sealed to the capsule body, but the protection and barrier layers become thin or disrupted
Solution Approach 1:
The capsule structure is segmented into a body layer for mechanical strength and sealing, and a separate barrier layer for moisture and gas protection. The sealing process applies pressure and heat only to the body layer, which has sufficient thickness to withstand these conditions without compromising the barrier layer. This segmentation allows manufacturing processes to be optimized for each layer's specific requirements.
Solution Approach 2:
Different regions of the capsule structure have different thicknesses and properties. The body layer has sufficient thickness in the sealing zone to withstand pressure and heat during manufacturing. The barrier layer maintains its thickness and integrity in the regions where moisture and gas protection is critical. This local differentiation of properties allows both sealing and barrier functions to be achieved.
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
The solution provides a reliable sealing of the water distribution wall without impacting the capsule's gas and moisture barrier properties, ensuring the quality of the contained substance and facilitating easy fluid distribution and beverage production.
Implementation Method 1
the liner barrier layer and the wall barrier layer are united, they are melted and thus form a sealing zone that can be suitably tight to moisture and/or gas
Implementation Method 2
injecting a fluid under pressure in said capsule
Implementation Method 3
said bottom wall being adapted to be opened when pressure increases inside the capsule
Data Source
AI summary
The present invention concerns a capsule (1) comprises a cup-shaped capsule body (2), a water distribution wall (10) delimiting a chamber (12) for a substance, and a bottom wall (14). The cup-shaped capsule body (2) comprises: a cellulose-based body layer (18) and a liner (20) comprising a liner barrier layer (22). The water distribution wall (10) and/or the bottom wall (14) comprises a wall barrier layer (32). The water distribution wall (10) and/or the bottom wall (14) is/are connected to the cup-shaped capsule body (2) such that the liner barrier layer (22) and the respective wall barrier layer (32) are united along a circumference of the body (2).