Plastic Coffee Container Top Load Support via Particulate Mass
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Solution Overview
Problem
Existing containers for particulate coffee products, especially those made of plastic, are expensive to manufacture due to the need for strong structural support to withstand top loads and pressure changes, as they must be both air-tight and robust to prevent damage from built-up gases.
Innovation Solution
A rigid container design with a predetermined minimum headspace that allows the particulate product to provide significant top load support, featuring a flexible closure with a one-way valve and varying wall thickness, reducing the need for thick container walls and enabling cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the container walls are made thicker to support top loads, then the strength and robustness of the container is improved, but the manufacturing cost increases due to more material needed
Solution Approach 1:
The particulate coffee product acts as an intermediary medium between the top load and the container walls. When coffee is packed into the container, it forms a dense particulate mass that distributes and absorbs the top load forces, preventing these forces from being directly transmitted to the container walls. This allows the use of thinner, less expensive wall material while still achieving the required strength and top load support.
2Reliability
If the container is made air-tight to prevent air ingress, then the protection of coffee from air is improved, but the ability to vent built-up gases is worsened
Solution Approach 1:
The closure system incorporates a one-way valve that provides different properties at different locations and conditions. The closure remains air-tight under normal conditions to prevent air ingress, but the one-way valve opens locally when internal pressure exceeds external pressure, allowing gases to escape. This localized functional differentiation resolves the contradiction between maintaining air-tightness and enabling gas venting.
3Quantity of substance
If the headspace is reduced to increase coffee volume, then the quantity of coffee stored is improved, but the top load support capability is worsened
Solution Approach 1:
The invention identifies and optimizes the headspace parameter to a specific minimum value that provides the threshold top load support capability. By carefully controlling the headspace to this minimum required amount, the container achieves sufficient top load support (top load ratio of at least 3:1) while maximizing the coffee storage volume. This parameter optimization resolves the contradiction between quantity and strength.
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 container achieves a top load ratio of at least 3:1, allowing for reduced wall thickness and material savings while effectively managing pressure changes through the one-way valve, enhancing durability and cost-effectiveness.
Implementation Method 1
The predetermined minimum headspace is that headspace which produces a top load ratio of at least 3:1; where the top load ratio is defined as a ratio of the top load force sufficient to cause a 0.30'' deflection in the plastic container when filled to the predetermined minimum headspace
Implementation Method 2
able to vent excess pressure therein to atmosphere through a suitable one-way valve which is most preferably provided in the flexible closure
Implementation Method 3
the predetermined minimum headspace is also sufficient so that when a pressure of the main interior volume is about 3 psi less than ambient, which pressure causes the flexible closure to flex inward
Data Source
AI summary
A rigid container for a particulate product with enhanced top load support includes an interior volume formed by a base, a surrounding wall member upstanding from the base, and an opening formed in a top. A particulate product, such as coffee, is provided in the interior volume, and is provided in sufficient quantity to fill the interior volume up to a predetermined minimum headspace. The predetermined minimum headspace is that headspace which produces a top load ratio of at least 3:1; where the top load ratio is defined as a ratio of the top load force sufficient to cause a 0.30″ deflection in the container when filled to the top load force sufficient to cause a 0.30″ deflection in the container when empty. In a preferred embodiment, the container is made of plastic and includes a flexible closure attached to the top and spanning the top opening.