CO2-Emitting Closure With Release-Rate Control for Longer Shelf Life
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Solution Overview
Problem
Current polymeric carbonated soda containers suffer from carbon dioxide permeation over extended storage times, leading to flat beverages.
Innovation Solution
A closure system with a carbon dioxide emitter and a release rate control layer that controls the release of carbon dioxide into the container, extending shelf life by replacing escaped CO2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If carbon dioxide is stored in polymeric containers for extended periods, then the beverage becomes flat due to CO2 permeation, but adding a carbon dioxide generator increases device complexity
Solution Approach 1:
The carbon dioxide emitter is nested within the closure structure, specifically positioned in a recess of the closure body. This integration allows the CO2 generation system to be housed within the existing closure dimensions without requiring additional external components, thereby extending shelf life while minimizing increases in device complexity
Solution Approach 2:
A release rate control layer is introduced as an intermediary component between the carbon dioxide emitter and the beverage. This layer mediates the CO2 release process by controlling the rate at which gas escapes into the container, preventing uncontrolled release while maintaining the desired carbonation levels over extended storage periods
2Ease of operation
If a release rate control layer is added to control CO2 emission, then CO2 release rate is controlled, but manufacturing complexity increases
Solution Approach 1:
The release rate control layer is merged with the closure structure through overmolding, where the control layer is formed as an integral part of the closure body in a single manufacturing process. This integration eliminates the need for separate assembly steps for installing the control layer, thereby achieving precise CO2 release control without significantly increasing manufacturing complexity
Solution Approach 2:
The manufacturing process parameters are optimized by forming the release rate control layer through overmolding at controlled temperatures and pressures. By adjusting molding parameters such as temperature, pressure, and cooling rate, the desired porosity and gas permeability characteristics of the control layer are achieved directly during closure fabrication, simplifying the overall manufacturing process
3Quantity of substance
If the carbon dioxide emitter size is increased to produce more CO2, then CO2 generation capacity increases, but the emitter may not fit in the closure
Solution Approach 1:
The carbon dioxide emitter utilizes a composite formulation containing bicarbonate base, organic acid, and pore-forming agents. This composite material structure provides high CO2 generation capacity per unit volume, allowing sufficient carbonation for extended shelf life while maintaining a compact size that fits within the closure recess
Solution Approach 2:
The emitter is formulated as a porous material with controlled pore structure created by pore-forming agents. The porous structure increases the surface area and internal volume available for CO2 generation reactions, maximizing gas production capacity within the constrained physical dimensions of the emitter that must fit in the closure
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 system doubles the shelf life of carbonated beverages in smaller containers to 10-14 weeks, maintaining acceptable CO2 levels and product quality.
Implementation Method 1
a release rate control layer that is configured to control release of carbon dioxide from the carbon dioxide emitter into the container
Implementation Method 2
carbon dioxide emitter... determining an amount of carbon dioxide to be released by the carbon dioxide emitter for extending a shelf life of a product stored within the container
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A closure for a container. The closure includes a carbon dioxide emitter, and a release rate control layer that is configured to control release of carbon dioxide from the carbon dioxide emitter into the container when the closure is coupled to the container.