Multilayer Beverage Capsule Cover With Segmented Weakness Lines
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Solution Overview
Problem
Existing cover elements for beverage capsules fail to reliably break at predetermined pressures, leading to issues such as pump blocking, incomplete dispensing, or premature opening at high humidity conditions, especially when water delivery pressure exceeds 12 bar.
Innovation Solution
A cover element comprising a compostable main layer with lines of weakness, a protective lacquer layer, a food-grade filtering layer, and a metallic waterproof layer, where the lines of weakness are calibrated to break at specific pressures, ensuring proper dispensing without compromising the filtering layer's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover element is made with a waterproof layer and filtering layer without lines of weakness, then the sealing reliability is improved, but the capsule cannot break at predetermined pressure for proper dispensing
Solution Approach 1:
The cover element is segmented into different functional layers: a waterproof layer without lines of weakness for sealing, and a main layer with lines of weakness for controlled breaking. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between sealing reliability and ease of breaking.
Solution Approach 2:
Different regions of the cover element have different properties: the waterproof layer has high strength and no lines of weakness for reliable sealing, while the main layer has lines of weakness for controlled breaking. This local differentiation of properties allows the cover element to simultaneously achieve both sealing reliability and ease of operation.
2Strength
If cuts extend through all layers including the filtering layer, then the capsule breaks at lower pressure, but the filtering layer integrity is compromised affecting its filtering function
Solution Approach 1:
The cutting pattern is segmented to stop at the boundary between the main layer and the waterproof layer, rather than extending through all layers. This segmentation allows the capsule to break at the intended pressure point while preserving the integrity of the filtering layer, maintaining both breaking performance and filtering function.
Solution Approach 2:
The lines of weakness are localized to specific regions (the main layer) where breaking is desired, while the filtering layer and waterproof layer remain intact. This local application of lines of weakness allows controlled breaking without compromising the filtering layer's integrity and function.
3Reliability
If the capsule uses a multilayer structure with waterproof and filtering layers, then the sealing and filtering performance are improved, but the device complexity increases
Solution Approach 1:
Multiple functional layers (waterproof layer, filtering layer, main layer) are merged into a single integrated cover element structure. This merging approach maintains the benefits of each layer while presenting a unified component that simplifies assembly and reduces overall system complexity despite the multilayer construction.
Solution Approach 2:
The cover element is designed as a mult functional component where the main layer provides structural support and controlled breaking, the waterproof layer provides sealing, and the filtering layer provides filtration. This multi-functionality is achieved within a single integrated structure, improving performance without proportionally increasing complexity.
Data Source
AI summary
A cover element for sealing capsules for use in making brewed beverages may include: a main layer having an inner surface configured to face a housing zone of a capsule for making the brewed beverages and having an outer surface that faces away from the inner surface, wherein the main layer is made of compostable material; a protective layer overlying the outer surface of the main layer; a waterproof layer, applied on the inner surface of the main layer and including at least one metallic layer; and a filtering layer underlying the inner surface of the main layer. The main layer may have a plurality of lines of weakness formed at least on the outer surface. The waterproof layer may be free of lines of weakness. The filtering layer may be free of lines of weakness.