Multilayer Coffee Capsule Cup Flange for Aroma-Preserving Sealing
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Solution Overview
Problem
Existing coffee capsules face challenges in achieving a reliable and efficient fluid-tight seal with coffee machines, particularly due to variations in the shape and size of the pressure hood and centring issues, leading to inefficiencies and increased production costs. Additionally, current solutions fail to effectively preserve the coffee aroma.
Innovation Solution
A coffee capsule cup design featuring a multilayer structure with an inner layer for rigidity, an outer soft layer for deformation, and an intermediate oxygen- and aroma-impermeable layer, incorporating an annular groove and ridge on the annular flange to create a robust seal with the pressure hood element, while minimizing material usage and maintaining aroma freshness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the capsule bottom is increased to facilitate the cutting action of the knives, then the rigidity of the capsule bottom is improved, but the weight and production costs increase due to larger material usage
Solution Approach 1:
The capsule cup is constructed with a multilayer composite structure consisting of an inner layer made of rigid plastic material providing structural strength, and an outer layer made of soft plastic material enabling deformation for sealing. This composite approach allows the bottom to maintain sufficient rigidity for knife cutting without requiring excessive thickness, thereby reducing overall material usage and weight while preserving the necessary mechanical properties for both cutting and sealing operations.
2Strength
If the thickness of the capsule bottom is increased to facilitate the cutting action of the knives, then the rigidity of the capsule bottom is improved, but the production costs increase due to larger material usage
Solution Approach 1:
The multilayer composite structure allows optimization of material distribution: the rigid inner layer provides cutting resistance with minimal thickness, while the soft outer layer is applied only where needed for sealing. This reduces total material consumption and production costs compared to using uniformly thick rigid material throughout the entire capsule bottom.
3Object-affected harmful factors
If an outer wrapper made of impermeable material is used to preserve coffee aroma, then the aroma preservation is improved, but additional costs are incurred and manual tearing is required
Solution Approach 1:
The aroma-impermeable layer is integrated directly into the capsule cup wall as part of the multilayer composite structure, eliminating the need for a separate outer wrapper. This integrated approach provides effective aroma preservation while reducing structural complexity and eliminating the need for manual opening operations.
Solution Approach 2:
The aroma-impermeable layer is merged with the structural layers of the capsule cup to form a unified multilayer construction. This combines the protective function of aroma preservation with the structural function of the cup wall, eliminating the need for separate wrapper components and simplifying the overall structure.
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 multilayer structure ensures a consistent and effective seal across various machine configurations, reduces material costs, and effectively preserves coffee aroma by limiting oxygen exposure, enhancing both the usability and quality of the coffee-making process.
Implementation Method 1
an intermediate layer arranged between the inner layer and the outer layer and made of a material impermeable to aromas and to oxygen
Implementation Method 2
an outer layer made of soft plastic material; the outer layer defines the rear face of the annular flange and the outer surface of the containment body
Data Source
AI summary
A cup for a coffee capsule, including a containment body (2) extending between a bottom (2a) and an upper edge (2b) and further including, at the upper edge (2b), an annular flange (3) which extends around an axis (X) and which has a rear face (3a) directed towards the containment body (2) and a front face (3b) adapted to receive a sealing lid (40), where the containment body (2) and the annular flange (3) are defined by a multilayer structure having an inner layer (S1) made of a plastic material, defining the front face (3b) of the annular flange (3) and the inside surface of the containment body (2), an outer layer (S2) made of a plastic material whose hardness is less than that of the inner layer (S1), and an intermediate layer (S3) between the inner layer (S1) and the outer layer (S2) and made of a material impermeable to oxygen and aromas, and where the annular flange (3) has, on its rear face (3a), an annular ridge or tooth (6) and an annular groove (4) which extend around the axis (X) and which are configured to act in conjunction with an end edge (101) of a pressure hood element (100) of a coffee machine.