Thermoformed Capsule Edge Sealing via Deformable Cushion
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Solution Overview
Problem
Existing beverage capsules for automatic dispensing machines face issues with hygiene due to wear and deterioration of elastomeric sealing washers, which come into contact with the product and fluid, and require precise manufacturing to prevent leaks, making them expensive and difficult to produce.
Innovation Solution
A capsule design featuring a thermoformable plastic casing with a deformable sealing element formed by a protrusion on the edge, which creates a cushion for sealing when compressed, eliminating the need for specific sealing washers and allowing for simpler, cost-effective production through thermoforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastomeric sealing washers are used between the capsule and housing, then sealing is achieved, but hygiene deteriorates due to wear and deterioration of the washer contacting product and fluid
Solution Approach 1:
The sealing function is extracted from the dispensing machine housing and transferred entirely to the capsule itself. The capsule edge is designed with an integrated sealing structure that directly engages with the housing, eliminating the intermediate elastomeric washer that causes hygiene issues. This is achieved by providing a capsule edge with a sealing surface that abuts against the housing sealing surface under compression during dispensing.
Solution Approach 2:
The capsule provides its own sealing function through its own structural features rather than relying on separate sealing components. The capsule edge is self-contained with the necessary sealing geometry and materials, making the capsule self-sufficient for sealing purposes and eliminating components that require maintenance and replacement.
2Reliability
If separate sealing elements made of silicone rubber are added to the capsule, then sealing is improved, but manufacturing complexity and cost increase due to difficult heat-sealing connection
Solution Approach 1:
The sealing function is merged into the capsule structure itself rather than being a separate component. The sealing surface is integrated into the capsule edge during the same manufacturing process (injection molding), eliminating the need for separate sealing elements and their complex attachment processes. The capsule body and sealing structure become a unified component.
Solution Approach 2:
The capsule is made entirely from the same thermoplastic material throughout, including the sealing edge. This homogeneity of material allows for simplified manufacturing using a single injection molding process, avoiding the need to bond different materials (such as silicone rubber to plastic) which would increase complexity and cost.
3Reliability
If precise manufacturing is used to prevent leaks in capsules, then sealing reliability is improved, but production cost increases
Solution Approach 1:
The sealing function is segmented into distinct geometric features on the capsule edge, including a sealing surface, a compression zone, and engagement features. This segmentation allows each feature to be optimized for its specific function while being manufactured as an integrated whole, achieving reliable sealing through design rather than expensive manufacturing processes.
Solution Approach 2:
The sealing mechanism relies on controlled compression parameters rather than ultra-precise manufacturing tolerances. The capsule edge is designed to deform elastically under controlled compression forces during dispensing, creating a reliable seal through parameter control (force, deformation) rather than requiring extremely tight manufacturing tolerances, thus reducing production cost.
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
Ensures an optimal seal during dispensing without specific sealing means, maintaining hygiene and reducing production costs while adapting to different dispensing machine models, ensuring effective sealing and easy manufacturing.
Implementation Method 1
the protrusion (10) is suitable for defining, with the edge (7) of the casing, a deformable cushion (11) for sealing
Implementation Method 2
the deformable cushion (11) for sealing... when compressed, ensures the seal
Implementation Method 3
A capsule design featuring a thermoformable plastic casing
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A capsule for beverages comprises a casing (2) in turn comprising a base wall (3) and a side wall (4) defining a cavity (5) suitable for containing an initial product (P) to be combined with a fluid (F) to obtain an end product, and further an edge (7) extending from the side wall (4). The capsule further comprises a covering element (8) fixed to the edge (7) to close the cavity hermetically (5), which is pierceable by extracting means of a dispensing machine (60) wherein said capsule is usable. The casing (2) is made by forming a sheet of thermoformable plastics and the edge (7) comprises a sealing element (9) comprising at least one protrusion (10) facing the base wall (3) that is also obtainable by said sheet forming that defines at least one further cavity (11) suitable for containing a fluid, for example air or inert gas. The covering element (8) is fixed to seal hermetically also the further cavity (1 1) so as to create a cushion that is deformable between the edge (7) and the covering element (8) that defines the sealing element (9) arranged for sealingly engaging, when compressed, with abutting means (64) of a dispensing machine (60).