Biodegradable Capsule with Composite Barrier
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Solution Overview
Problem
Current single-use coffee capsules do not meet the requirements of being biodegradable by industrial composting, domestic composting, and having a barrier function against oxygen and water vapor, while also ensuring the quality of the coffee when used in espresso machines.
Innovation Solution
The development of a closed capsule with a container and seal made from a formulation comprising polyhydroxybutyrates, silicates, vitamin E, and plasticized proteins, which are biodegradable and compostable, and a seal that provides a barrier against oxygen and water vapor, using injection molding and a multilayer structure for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional aluminum or plastic materials are used for capsule container and seal, then the capsule has good barrier function against oxygen and water vapor, but the capsule is not biodegradable and not compostable
Solution Approach 1:
The patent uses composite materials consisting of biodegradable polymers (PLA, PHA, PBS) combined with natural barrier substances (waxes, proteins, cellulose, chitosan) to create a capsule structure that provides both barrier function and biodegradability. The multilayer composite structure allows each material to contribute its specific properties: polymers provide structural integrity while natural substances provide oxygen and moisture barrier properties, and all components are compostable.
Solution Approach 2:
The patent changes the chemical composition parameters of the capsule materials from synthetic non-biodegradable materials (aluminum, conventional plastics) to biodegradable polymers with specific molecular structures (PLA, PHA, PBS) that can be broken down by microorganisms. The formulation includes specific ratios of biodegradable polymers (50-95%), natural barrier substances (5-30%), and processing aids (1-10%) to optimize both barrier performance and compostability.
2Object-generated harmful factors
If biodegradable materials are used for capsule container and seal, then the capsule becomes compostable, but the barrier function against oxygen and water vapor deteriorates
Solution Approach 1:
The patent employs composite materials where biodegradable polymers (PLA, PHA, PBS) serve as the matrix and natural barrier substances (waxes, proteins, cellulose, chitosan) are incorporated as functional additives. This composite structure maintains compostability while the natural substances provide enhanced oxygen and moisture barrier properties that compensate for the inherently lower barrier performance of biodegradable polymers alone.
Solution Approach 2:
The patent implements a multilayer nested structure where different biodegradable materials are arranged in layers, with barrier-functional layers (containing waxes, proteins, or cellulose) embedded within or between structural polymer layers. This nested architecture allows each layer to perform its specific function: outer layers provide structural integrity while inner layers provide barrier protection, all while maintaining overall biodegradability.
3Reliability
If a multilayer structure with multiple materials is used to enhance barrier function, then the barrier performance improves, but the capsule complexity increases and may affect compostability
Solution Approach 1:
The patent uses composite materials with a limited number of carefully selected biodegradable components (polymers, waxes, proteins, cellulose, chitosan) that can be processed together in a coordinated manner. The multilayer structure is achieved through co-extrusion or sequential lamination of compatible biodegradable materials, avoiding the need for complex assembly processes and ensuring all layers compost together as a single system.
Solution Approach 2:
The patent maintains homogeneity in the sense that all materials in the multilayer structure are biodegradable and compostable, ensuring uniform degradation behavior. The formulation uses materials with compatible processing temperatures and degradation characteristics, allowing the entire capsule structure to be manufactured in one process and decomposed uniformly in composting conditions, despite having multiple functional layers.
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 capsules are compostable under both industrial and domestic conditions, maintain a high barrier function against oxygen and water vapor, and ensure the quality of coffee when used in espresso machines, meeting international and national standards for biodegradability and storage stability.
Implementation Method 1
at least one ingredient chosen from silicates, vitamin E, plasticized proteins of animal or plant origin
Implementation Method 2
The capsules are compostable under both industrial and domestic conditions, maintain a high barrier function against oxygen and water vapor
Data Source
AI summary
The present invention relates to the field of single-use closed capsules biodegradable by industrial composting and by domestic composting, containing at least one substance in powder form for the preparation of a drink, e.g. coffee, intended for being extracted under pressure, said capsule including a container with a bottom and a side wall having a circular rim, and a seal welded on the circumference of the rim of the container, characterized in that the bottom, the side wall and the circular rim are formed by injection molding of at least one formulation comprising:(i) at least one polymer chosen from polyhydroxybutyrates, and(ii) at least one ingredient chosen from silicates, vitamin E, plasticized proteins of animal or plant origin, or mixtures thereof.