Method and apparatus for the construction of containers of precursors of liquid food products, and corresponding containers
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Solution Overview
Problem
The production of capsules for liquid food products using compostable materials is hindered by the difficulty in moulding them to achieve the required sectional dimensions and durability to withstand high temperatures and pressures, which is not efficiently addressed by existing methods.
Innovation Solution
A method and apparatus for injection moulding using a compostable polymeric mixture, such as polylactic acid, with a thermoplastic aliphatic polyester base, that forms a capsule with a cylindrical peripheral wall and an openwork bottom, enabling the production of capsules that can withstand high temperatures and pressures, and are compatible with existing beverage preparation machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If compostable materials are used to make capsules, then environmental sustainability is improved, but the ability to withstand high temperatures and pressures deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of a thermoplastic aliphatic polyester base (providing thermal and mechanical stability) combined with a compostable polymeric mixture (providing biodegradability). This composite approach allows the capsule to simultaneously achieve environmental sustainability and the necessary reliability to withstand beverage preparation conditions.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the compostable material by controlling the injection moulding process parameters (temperature, pressure, injection rate) to achieve optimal crystallinity and molecular orientation in the capsule walls, thereby enhancing the material's thermal and mechanical properties while maintaining compostability.
2Manufacturing precision
If injection moulding is used to produce capsules with required sectional dimensions, then manufacturing precision is improved, but the complexity of the moulding process increases
Solution Approach 1:
The patent applies different material formulations and processing conditions to different parts of the capsule during injection moulding. The base material provides structural integrity while the polymeric mixture is strategically positioned to ensure proper wall thickness and dimensional accuracy in critical areas, achieving precision without requiring overly complex moulding equipment.
3Reliability
If the capsule body is made to withstand high temperatures and pressures, then reliability is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The injection moulding process automatically achieves the required structural integrity through self-regulating mechanisms: the material's inherent thermal properties cause it to crystallize and set at appropriate rates during cooling, and the injection pressure automatically distributes material to areas needing reinforcement, eliminating the need for complex post-manufacturing reinforcement steps.
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
Enables the production of compostable capsules that can be used in commercial beverage preparation machines without deformation, maintaining structural integrity under conditions of high temperature and pressure, and reducing waste through efficient moulding processes.
Implementation Method 1
injection moulding of a compostable material, classifiable as packaging recoverable by means of composting and biodegradation
Implementation Method 2
injection moulding of a compostable material... obtainable via injection moulding... having a substantially cup-shaped body
Data Source
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AI summary
Described herein is a method for injection moulding of cup-shaped container bodies for precursors of liquid food products, in particular capsules for coffee and soluble products, the method comprising the steps of: a) providing a first mould part (40) having at least one cavity and a second mould part (40) having at least one core, the core being receivable by the cavity for delimiting therewith at least part of a corresponding moulding chamber; b) closing the first and second mould parts (40, 41) for delimiting the moulding chamber; c) injecting a compostable material in the fluid state into the moulding chamber to form the container body; d) waiting for at least partial solidification of the compostable material ; e) opening the first and second mould parts (40, 41); and f) extracting the formed container body from the core. In the course of a moulding operation, in the first mould part (40) a heating fluid is made to circulate and in the second mould part (41) a cooling fluid is made to circulate. In particular, in the course of at least one and the same step of the moulding operation, in the first mould part (40) and in the second mould part (41) the heating fluid and the cooling fluid, respectively, circulate simultaneously.