Cube-Shaped Coffee Capsule Sealing for Dense Stacking
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Solution Overview
Problem
Existing portion capsules for brewed beverages face challenges such as material inefficiency, complex packaging, and turbulence of extraction material during brewing, particularly due to their conical shape and reliance on protruding collars for sealing, which complicates compression and stacking.
Innovation Solution
A cube or parallelepiped-shaped capsule without protruding collars, made from a uniform material composition, allowing for compression from multiple sides and improved packability, with a sealing mechanism that prevents brewing liquid from entering the discharge device, and produced using deep-drawing techniques to reduce material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conical shape capsules with protruding collars are used for sealing, then sealing reliability is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The invention removes the protruding collar from the capsule design entirely. Instead of having a separate collar structure for sealing, the capsule uses its own rim or flange for sealing purposes, integrating the sealing function directly into the capsule body without requiring additional protruding elements.
Solution Approach 2:
Rather than having the capsule protrude outward with collars for sealing, the invention inverts the approach by having the capsule sit flush or recessed in the holder, with the sealing surface positioned at the interface between the capsule rim and the holder, eliminating the need for outward-protruding sealing structures.
2Object-generated harmful factors
If extraction material is strongly compressed during capsule filling, then turbulence during brewing is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention performs compression of the extraction material as a preliminary step during the capsule filling process itself, rather than requiring separate complex compression mechanisms during brewing. The material is compressed into the capsule cavity before sealing, ensuring proper density and reducing turbulence during extraction.
3Productivity
If cube-shaped capsules without protruding collars are used, then packability and stacking efficiency are improved, but sealing reliability may be compromised
Solution Approach 1:
The invention applies different geometric characteristics to different parts of the capsule: the main body is cube-shaped for efficient packing, while the rim or flange area is designed with specific sealing surfaces that ensure reliable sealing. This local differentiation of form and function resolves the contradiction between compact shape and sealing reliability.
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 cube-shaped capsule enables efficient compression and stacking, reduces waste, and ensures reliable sealing, while minimizing energy consumption and user error due to its uniform design and simplified manufacturing process.
Implementation Method 1
the extraction material is sealed, for example, in an airtight manner
Implementation Method 2
the capsule is pierced on two opposite sides
Implementation Method 3
liquid flows through the capsule at high speed
Implementation Method 4
the turbulence of the extraction material during the brewing process
Implementation Method 5
the capsule must be able to withstand a considerable internal pressure of, for example, 5-20 bar
Implementation Method 6
the collar is essential for sealing during the brewing process, as it ensures that no brewing liquid gets past the capsule and directly into the discharge device
Implementation Method 7
the conical shape, which fits very precisely into a corresponding receptacle in the brewing chamber
Data Source
Figure 1~2
Figure 3~4
Figure 5~10
AI summary
The method for manufacturing a portion capsule with a plastic wall in the shape of a cube or cuboid for a coffee machine comprises the following steps: - manufacturing a five-sided polyhedral base body (11) open on a sixth side and with a collar (12) arranged along the circumferential edge; - filling the base body (11) with an extraction material or extract; - attaching a lid (13) along a circumferential edge of the open sixth side, such that the resulting interior space is completely enclosed, - the lid being attached to the base body by ultrasonic welding.