Capsule Co-Injected Multilayer Barrier and Embedded Opening
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Solution Overview
Problem
Existing capsules for beverage preparation face high material costs and limited design options due to thermo-forming or deep drawing methods, and co-injection moulding processes with extended barrier layers increase manufacturing complexity and costs.
Innovation Solution
A capsule with an integrally formed bottom structure and side wall, utilizing a co-injected multilayer section for enhanced barrier properties, where the opening means are embedded within the side wall, allowing for cost-effective manufacturing and preventing contamination during beverage extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If co-injection moulding process with extended barrier layer is used, then barrier properties against oxygen and moisture are improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies local quality by providing barrier properties only where needed - the co-injected multilayer section with enhanced barrier properties is localized to specific areas of the capsule wall, while other areas use simpler single-layer material. This resolves the contradiction by achieving adequate barrier protection without extending the complex multilayer structure throughout the entire capsule, thus reducing manufacturing complexity while maintaining reliability.
2Reliability
If co-injection moulding process with extended barrier layer is used, then barrier properties against oxygen and moisture are improved, but manufacturing costs increase
Solution Approach 1:
The patent reduces manufacturing costs by applying the expensive co-injected multilayer material only locally where barrier properties are critical, rather than using it throughout the entire capsule. This selective application maintains the necessary barrier protection against oxygen and moisture while significantly reducing material costs and manufacturing complexity.
Solution Approach 2:
The patent uses composite materials by combining different polymeric materials in a co-injected multilayer structure. This composite approach provides enhanced barrier properties in the critical areas where the multilayer section is applied, while allowing the use of simpler, less expensive single-layer materials in non-critical areas, thus resolving the cost versus performance contradiction.
3Object-affected harmful factors
If opening means are integrated in the side wall, then contamination during beverage extraction is prevented, but device complexity increases
Solution Approach 1:
The patent merges the opening means with the capsule wall structure itself, integrating the opening function directly into the side wall rather than using a separate mechanism. This integration prevents contamination by eliminating the need for external opening devices that would contact the beverage, while the complexity is managed through the co-injection moulding process that creates the integrated structure in a single manufacturing step.
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 capsule achieves reduced manufacturing costs, optimal barrier properties against oxygen and moisture, and facilitates the preparation of different beverages without taste contamination or cross-contamination, using a co-injected multilayer section and embedded opening means that are activated by pressure.
Implementation Method 1
at least the core layer (5b) comprises enhanced barrier properties against oxygen and moisture
Implementation Method 2
the rise in pressure within the capsule will press a lower thin film arranged at the outlet area of the capsule against raised and recessed elements situated in a bottom portion of the capsule
Data Source
Figure 1~2
AI summary
The invention relates to a capsule (10) designed for food or beverage preparation, the capsule (10) comprising a cup-shaped base body (1), a top wall (2) and a bottom retaining wall (3) for holding food or beverage preparation ingredients, wherein the base body (1) is made of one single injection-molded piece and wherein a side wall (4) of the base body comprises at least one co-injected multilayer section (5) having two outer layers (5a) being made from a different polymeric material than a core layer (5b), and wherein the base body (1) further comprises a bottom structure (6) which is integrally molded with the side wall (4) and comprising opening means (7) allowing the capsule to be opened at the time of its use.