Dispensing capsule and method and apparatus of forming same
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Solution Overview
Problem
Current coffee capsules made from plastics and aluminum pose challenges for recycling due to mixed materials and resource inefficiency, and existing pulp fibre technologies are too slow and expensive to produce sustainable, recyclable capsules with the required frustroconical shape for high-volume production.
Innovation Solution
A process and apparatus for forming pulp fibre capsules using a continuous feed belt with articulated mesh toolsets, vacuum, and heat/pressure to create a moulded pulp fibre capsule with a frustroconical shape, allowing for high-speed production of recyclable and sustainable capsules compatible with existing coffee machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional plastics or aluminium are used to form capsules, then manufacturing ease and oxygen barrier performance are improved, but recyclability and sustainability are worsened
Solution Approach 1:
The patent changes the material parameter from traditional plastics/aluminium to moulded pulp fibre, transforming the capsule from non-recyclable to fully recyclable and compostable while maintaining manufacturing feasibility through high-speed pulp forming technology
Solution Approach 2:
The patent uses composite material structure with moulded pulp fibre body and optional biodegradable plastic or aluminium lid, combining the recyclability of natural fibre with the barrier properties of controlled materials to achieve both sustainability and performance
2Reliability
If existing pulp fibre technologies are used, then sustainability and recyclability are improved, but production speed and cost are worsened
Solution Approach 1:
The patent implements continuous high-speed pulp forming process where pulp fibre is continuously fed and formed into capsules at production rates matching traditional plastic and aluminium capsule manufacturing, eliminating the speed limitation of conventional pulp technologies
Solution Approach 2:
The patent replaces traditional slow mechanical pulp forming with an advanced high-speed pulp forming system that uses controlled fibre mat formation, vacuum, and heat/pressure to achieve rapid capsule production comparable to injection moulding speeds
3Adaptability or versatility
If moulded pulp fibre capsules with frustroconical shape are produced, then compatibility with existing coffee machines is improved, but manufacturing complexity and cost are worsened
Solution Approach 1:
The patent incorporates the frustroconical shape directly into the moulded pulp fibre formation process itself, rather than requiring subsequent shaping operations, thereby achieving the required geometry for machine compatibility as an integral part of manufacturing
Solution Approach 2:
The patent controls fibre orientation, density, and compaction parameters during high-speed pulp forming to create the frustroconical shape with appropriate wall thickness distribution, achieving both geometric precision and structural integrity without complex post-processing
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 enables the production of pulp fibre capsules that are dimensionally and functionally equivalent to traditional capsules, offering improved sustainability and recyclability while maintaining performance and compatibility with existing coffee machines, thus addressing recycling challenges and production inefficiencies.
Implementation Method 1
applying a vacuum to said continuously moving or fed tool set so as to draw said pulp fibres onto said plurality of mesh tool sets immersed in said suspension to form a preform mat
Implementation Method 2
the heat and drying is applied at a separate stage, the separate stage potentially having the capacity to apply pressure
Implementation Method 3
the pressure and deformation happens in one stage without the application of heat, whilst the heat and drying is applied at a separate stage
Data Source
AI summary
In one example, a process for manufacture of a pulp-based dispensing capsule is disclosed. The process includes providing one or more mesh tool sets that are each contoured to one or more preform shapes of the dispensing capsule. Note that each preform shape is a partially shaped version of a final form shape of the pulp-based dispensing capsule. The process also includes providing a holding tank containing a suspension that includes water and pulp fibres; and arranging the mesh tool sets to allow immersion into and withdrawal of the mesh tool sets from the suspension. The process also includes applying a vacuum to the mesh tool sets so as to draw pulp fibres from the suspension onto the mesh tool sets while immersed in the suspension to form a preform pulp fibre mat; and in a second toolset, deforming each preform shape in the preform pulp fibre mat towards the final form shape by the application of pressure.