Multilayer Aluminum Capsule for Wine Bottles
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Solution Overview
Problem
Existing wine and liquor bottle capsules, particularly those made of aluminum, are costly, complex to produce, and non-recyclable, leading to the formation of sharp burrs when removed from bottles, and require complex manufacturing processes.
Innovation Solution
A recyclable aluminum capsule produced by adhering multiple aluminum layers of 4-50 microns thickness, cut to size, folded, and glued to form a seamless capsule body with an aluminum disc on top, eliminating the need for deep-drawing and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If deep-drawing method is used to produce aluminum capsules, then the capsule can be formed, but the manufacturing process becomes very complex requiring annealing step after deep-drawing
Solution Approach 1:
The capsule is divided into multiple aluminum layers (typically 3-5 layers) that are formed separately and then assembled together. Each layer can be produced using simpler forming processes without requiring complex deep-drawing and annealing sequences, thereby reducing overall manufacturing complexity
Solution Approach 2:
The invention uses composite aluminum layer structures where multiple thin aluminum layers are combined to create a capsule with properties superior to single-layer capsules. This composite approach allows each layer to be manufactured more easily while the assembled structure provides the required strength and formability
2Quantity of substance
If aluminum capsule thickness is reduced for cost-effectiveness, then material cost decreases, but sharp burrs are formed when capsule is removed from bottle
Solution Approach 1:
Multiple thin aluminum layers are combined to create a composite structure where the cumulative thickness provides sufficient strength and edge quality. The layered construction prevents burr formation that would occur with single thin layers, while maintaining cost-effectiveness through reduced total material usage
Solution Approach 2:
The capsule uses thin aluminum layers (typically 12-50 micrometers per layer) that are flexible enough to conform to bottle necks but when assembled in multiple layers provide sufficient structural integrity to prevent sharp burr formation during removal
3Ease of operation
If tin material is used for capsule, then capsule is highly malleable and easy to form, but raw material cost and manufacturing cost increase significantly
Solution Approach 1:
The invention uses aluminum, a cheaper and more sustainable material compared to tin, while maintaining the necessary formability through multi-layer construction. The capsule is designed as a disposable item where the focus is on achieving adequate formability at lower material cost rather than extensive reuse
4Adaptability or versatility
If aluminum capsule is made completely recyclable, then environmental sustainability improves, but production method must be simplified to eliminate complex deep-drawing and annealing steps
Solution Approach 1:
The capsule is segmented into multiple aluminum layers that can be produced using simpler, more direct forming processes. This segmentation eliminates the need for complex deep-drawing and post-forming annealing steps, simplifying manufacturing while maintaining full aluminum recyclability
Data Source
AI summary
A multilayer capsule made exclusively of aluminum that cover the neck of wine or liquor bottles and to the production method for producing said capsule.