Composite Cork Stoppers for Sparkling Wine Sealing
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Solution Overview
Problem
Current cork stoppers for sparkling wines fail to consistently maintain pressure and preserve organoleptic characteristics due to inferior manufacturing processes and raw materials, leading to unreliable sealing and ageing issues.
Innovation Solution
Cork stoppers made from two types of closely bonded cork agglomerates with different granulometry, produced using an individual moulding process with two mixers, ensuring a strong and homogeneous bond between the agglomerates, which are then polymerized for mechanical stability and de-moulded without excessive expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cork agglomerate stoppers are produced by conventional extrusion or individual moulding processes using single granulometry, then production cost is reduced and manufacturing is simplified, but the stoppers exhibit inferior quality, random ageing of organoleptic characteristics, and unreliable CO2 preservation
Solution Approach 1:
The stopper is divided into two distinct agglomerate zones with different granulometries: a first agglomerate (40-60% volume) with larger granules (2-10mm) providing structural integrity, and a second agglomerate (60-40% volume) with finer granules (0.25-4mm) providing density and sealing properties. This segmentation allows each zone to perform its specific function optimally.
Solution Approach 2:
Different regions of the stopper are given different material properties through the two-agglomerate structure. The first agglomerate region provides mechanical strength and elasticity, while the second agglomerate region provides density and sealing capability. This local differentiation of material properties resolves the contradiction between reliability and manufacturing complexity.
2Manufacturing precision
If two types of cork agglomerate with different granulometry are used, then sealing performance and organoleptic preservation are improved, but the manufacturing process becomes more complex requiring two mixers and precise bonding control
Solution Approach 1:
The two types of cork agglomerate are prepared separately in advance using two independent mixers, allowing each agglomerate type to be optimized for its specific granulometry and properties. This preliminary preparation ensures homogeneous mixing and proper bonding agent distribution before the bonding step, achieving manufacturing precision while managing process complexity.
Solution Approach 2:
A bonding agent is used as an intermediary substance to join the two different agglomerate types. The bonding agent facilitates the connection between the first and second agglomerates, ensuring they remain closely bonded during the polymerization process and final use, thereby achieving the required manufacturing precision.
3Stability of the object's composition
If conventional single-agglomerate stoppers are used, then manufacturing is simpler, but the stoppers show random ageing of organoleptic characteristics and unreliable CO2 preservation behavior
Solution Approach 1:
The invention changes the physical parameters of the stopper composition by incorporating two distinct agglomerate types with different granulometries. The first agglomerate (larger granules) provides structural stability, while the second agglomerate (finer granules) provides density and sealing properties. This parameter differentiation ensures consistent organoleptic characteristics and reliable CO2 preservation throughout the stopper's service life.
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 solution results in stoppers that are resistant to twisting rupture, exhibit excellent elasticity, and maintain consistent mechanical and organoleptic properties, ensuring reliable sealing and preserving the characteristics of sparkling wines.
Implementation Method 1
Compacting induces the filling in of the spaces between the granules with prepolymer additive, which under temperature polymerises the edges of the agglomerated granulation
Implementation Method 2
The granulation is then compacted in the moulds by two cylindrical pistons. The pressure applied for several minutes in the hot mould allows polymerisation reaction to reach a high level of transformation
Implementation Method 3
The sealant has to guarantee the seal in such a way as ensure that pressure inside the bottle is maintained
Data Source
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AI summary
This invention concerns stoppers made from composite material for sparkling wines consisting of two types of cork agglomerate which are closely bonded and produced from two ranges of granulates of different granulometry, where the joining surface between the two agglomerates is irregular due to their interpenetration. The invention also concerns the production process of these stoppers by individual moulding (piece by piece), whereby the simultaneous feeding of the two types of granulate and the respective additives is done and the mould is closed by compression and then heated for a time for polymerisation. The granulates used are normally treated with a reactive agglomerant consisting of, for example, quasi -prepolymer based od TDI or quasi -prepolymer based on MDI base. After de-moulding, the unfinished stopper is stabilised, and later machined to the final dimensions.