Compostable Barrier-Lid Capsules for Pressure Extraction
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Solution Overview
Problem
Existing single-serve capsules do not meet compostability requirements and often suffer from material elongation at break, leading to dispensing issues and increased manufacturing costs due to the need for non-compostable barrier enclosures.
Innovation Solution
A compostable capsule design with oxygen and moisture barrier lids made from compostable materials, allowing for integration with existing machines without piercing the bottom wall, ensuring effective liquid extraction and preservation of organoleptic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If non-compostable materials (aluminum, plastic) are used for capsule lids and enclosures, then oxygen and moisture barrier properties are achieved, but compostability requirements are not met
Solution Approach 1:
The patent employs composite material structures for capsule lids and enclosures, combining compostable base materials with barrier coatings or layers. The lid comprises a compostable material matrix integrated with oxygen and moisture barrier properties, while the enclosure uses compostable material with deposited barrier layers, achieving both protection and compostability
Solution Approach 2:
The patent modifies the physical and chemical parameters of compostable materials through surface treatments, coatings, or compositional adjustments to enhance their barrier properties against oxygen and moisture without compromising their compostable nature, transforming ordinary compostable materials into functional barrier materials
2Object-generated harmful factors
If compostable materials are used for capsule lids, then compostability requirements are met, but material elongation at break causes dispensing issues
Solution Approach 1:
The patent adjusts the mechanical parameters of compostable lid materials by modifying their composition, cross-linking density, or adding reinforcement elements to control elongation at break within an optimal range that prevents both excessive flexibility causing wrapping and excessive brittleness causing breakage during dispensing
Solution Approach 2:
The patent creates composite lid structures combining compostable materials with appropriate mechanical properties, potentially integrating reinforcing fibers, layers, or structural designs that maintain flexibility for machine integration while ensuring sufficient strength and controlled elongation for reliable dispensing
3Object-generated harmful factors
If filter paper cartridges are used without barrier enclosures, then compostability is improved, but organoleptic properties of the product deteriorate
Solution Approach 1:
The patent replaces traditional filter paper with composite lid structures made of compostable materials that inherently provide barrier properties against oxygen and moisture, eliminating the need for separate aluminum barrier enclosures while maintaining both compostability and product protection
Solution Approach 2:
The patent merges the functions of filtration, sealing, and barrier protection into a single integrated compostable lid structure, combining multiple functionalities that were previously distributed across separate components (filter paper, aluminum enclosure, sealing mechanisms) into one unified compostable element
4Object-affected harmful factors
If barrier enclosures are added to filter paper cartridges, then organoleptic properties are preserved, but manufacturing costs and power consumption increase
Solution Approach 1:
The patent merges the barrier function with the structural lid and enclosure components made of compostable materials, eliminating the need for separate aluminum barrier enclosures and reducing the number of manufacturing steps, assembly operations, and energy-intensive processes while maintaining product protection
Solution Approach 2:
The patent uses composite compostable materials with inherent or enhanced barrier properties that replace the need for additional aluminum enclosures, reducing material layers, manufacturing complexity, and associated costs while maintaining protection of organoleptic properties
Data Source
AI summary
A capsule for a soluble or extractable product, using a pressurized extraction fluid, may include: a container body defining a volume for housing the product, having a lower base, an upper base, and a side wall extending between the lower and upper bases; a first compostable barrier lid sealed to the upper base; and a second compostable barrier lid, which is a barrier against oxygen and moisture and is sealed to an inner surface of the lower base by a sealing region. The lower base may include: inner and outer surfaces; and openings for passage of the pressurized extraction fluid from the outer surface to the inner surface. The openings of the lower base may be closed by the second compostable barrier lid. The sealing region may be configured to seal the second compostable barrier lid to the inner surface until application of a predetermined fluid pressure.