Foamed Regrind Multi-Layer Beverage Pod Base
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Solution Overview
Problem
Current beverage pods for single-serve brewing machines face challenges in achieving a lightweight, cost-effective barrier structure that maintains mechanical rigidity and barrier performance against oxygen and moisture, while also being recyclable.
Innovation Solution
A multi-layer thermoformed plastic beverage pod base is designed with a foamed regrind polymer-based material layer, separated from a barrier layer, and enhanced with mineral fillers in the exterior layers to reduce weight by 5-15% without compromising mechanical properties, and the pod bases can be reground and reused for further production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer barrier structure is used to protect beverage extract from oxygen and moisture, then barrier performance is improved, but weight and material cost increase
Solution Approach 1:
The pod base wall is divided into multiple functional layers: an outer polyolefin layer providing structural integrity, an intermediate EVOH barrier layer blocking oxygen and moisture, and an inner polyolefin layer providing chemical resistance. This segmentation allows each layer to perform its specific function efficiently, achieving high barrier performance while optimizing material usage and weight
Solution Approach 2:
Different regions of the pod base receive different treatments: the rim portion uses a multi-layer coextruded structure for optimal barrier performance where sealing occurs, while the base portion uses a simpler single-layer structure. This local differentiation ensures barrier performance is concentrated where most needed, reducing overall weight and material cost
2Strength
If material thickness is increased to improve mechanical rigidity and barrier properties, then mechanical strength is improved, but weight and material cost increase
Solution Approach 1:
The invention uses composite multi-layer materials combining polyolefin and EVOH with different thicknesses optimized for their respective functions. The EVOH layer provides exceptional barrier properties at thin sections, while the polyolefin layers provide mechanical strength. This composite approach achieves high strength-to-weight ratio and superior barrier performance compared to single-material designs
Solution Approach 2:
Instead of increasing thickness in one dimension, the invention distributes protective functions across multiple layers in the radial dimension. The multi-layer structure provides barrier and mechanical properties through layer composition rather than sheer thickness, reducing overall weight while maintaining performance
3Reliability
If a protective barrier layer is added between the beverage extract and the multi-layer wall, then protection from degradation is improved, but device complexity increases
Solution Approach 1:
The protective barrier function is merged directly into the pod base wall structure itself through the EVOH layer. Instead of adding a separate protective layer, the barrier properties are integrated into the multi-layer coextruded wall, providing protection while maintaining structural integrity and avoiding additional complexity
4Reliability
If multi-layer material is used for pod bases to achieve barrier performance, then barrier properties are improved, but recyclability becomes more difficult
Solution Approach 1:
The invention designs the multi-layer pod base with recyclability in mind, using materials and structures that can be effectively processed in existing recycling streams. The polyolefin and EVOH layers are configured to allow for efficient separation and recovery, enabling the pod base to be recycled while maintaining barrier performance during use
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 achieves weight reduction while maintaining mechanical and barrier performance, enabling recyclability and environmental benefits without significant reduction in mechanical properties, ensuring the beverage extract remains fresh and the pod withstands machine usage.
Implementation Method 1
Selective foaming of the regrind layer provides a weight reduction of for example, 5 to 15% compared to a pod base wall of the same thickness without foaming
Implementation Method 2
the barrier is typically an oxygen barrier material; it may also provide a barrier to moisture
Implementation Method 3
The mineral fillers are added in an amount desired to enhance the mechanical properties of the pod base
Data Source
AI summary
A thermoformed plastic beverage pod base and method of forming, the pod base being configured for use in a single-serve brewing machine wherein the pod base is filled with a beverage extract and sealed with a lid prior to insertion into the machine. The pod base is made from a multi-layer film that includes one or more layers of a foamed regrind polymer (e.g., polypropylene (PP) based material. The foamed material provides a desired reduction in weight, while preserving barrier function, recyclability and mechanical performance.