Thermoplastic Elastomer Stopper with Activated Carbon
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Solution Overview
Problem
Cork stoppers can cause sensory defects in products due to residual chemical compounds, while synthetic stoppers face challenges in manufacturing costs and scalability, and existing plastic stoppers lack effective filtering properties.
Innovation Solution
A stopper made from a thermoplastic elastomeric polymer, such as biodegradable bioplastics like polylactic acid, incorporating activated carbon particles for improved filtering and visual identification, with the activated carbon providing a dark color and enhanced sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cork stoppers are used, then aesthetic and functional properties are improved, but sensory defects occur due to residual chemical compounds
Solution Approach 1:
The harmful residual chemical compounds are extracted/removed from the stopper material by replacing cork with plastic material, while retaining the desired sealing function. The plastic material composition eliminates the source of sensory defects while maintaining stopper functionality.
Solution Approach 2:
The invention uses composite plastic material compositions (e.g., styrene/ethylene-butylene/styrene with polypropylene, or thermoplastic elastomeric polymers) that combine the benefits of sealing performance with the elimination of harmful substances found in natural cork.
2Productivity
If synthetic plastic stoppers are used, then manufacturing cost and production time are reduced, but filtering properties are insufficient
Solution Approach 1:
The plastic stopper incorporates porous structures or activated carbon particles that provide filtering capabilities while maintaining the manufacturing advantages of synthetic materials. This allows the stopper to filter gases and substances during wine aging while being produced efficiently through injection molding.
Solution Approach 2:
Activated carbon or porous structures act as intermediary elements within the plastic stopper, providing the filtering function that plain plastic lacks, while the plastic matrix maintains the manufacturing efficiency and structural integrity.
3Reliability
If activated carbon particles are added to plastic material, then filtering properties are improved, but material complexity increases
Solution Approach 1:
The invention merges activated carbon particles directly into the plastic material matrix during the injection molding process, creating a composite material that provides filtering properties without requiring separate filtering components or complex multi-step manufacturing procedures.
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 stopper effectively filters gases and substances, offers biodegradability, and is cost-effective with improved manufacturing efficiency, while the activated carbon provides a distinct visual identifier and optimal elasticity for sealing.
Implementation Method 1
a stopper for a container made entirely or at least in part of a plastic material including a dispersion of activated carbon particles
Data Source
AI summary
The present invention relates to a stopper made entirely or at least in part of plastic material, wherein the plastic material is a thermoplastic elastomeric polymer and includes a dispersion of activated carbon particles. The present invention also relates to a method to manufacture a stopper for a container by means of injection molding comprising: heating granules or pellets of plastic material until the granules or pellets become soft and flexible; adding activated carbon particles to the soft and flexible granules or pellets of plastic material; injecting the softened plastic into a mold, thereby obtaining a desired shape for the stopper; leaving the plastic material to cool until hardening; and opening the mold and removing the stopper.