Paper-Based Beverage Capsule Flange with Embedded Gas Barrier

Solution Overview

Problem

Paper-based beverage capsules face challenges in achieving a smooth surface for sealing, leading to potential oxidation of sensitive ingredients like roast and ground coffee due to deformation and irregular surfaces, which compromises the quality of the beverage and fails to provide adequate mechanical rigidity for industrial use.

Innovation Solution

A capsule design featuring a paper-based cup-like body with a flange formed from two polymers, where the second polymer acts as a gas barrier layer embedded within the first polymer, ensuring a tight seal and maintaining gas barrier integrity, while the flange is co-injected or thermoformed to provide mechanical strength and prevent oxidation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If paper-based material is used for the capsule body, then environmental friendliness and lightweight properties are improved, but sealing smoothness and mechanical rigidity deteriorate

Engineering Contradiction:

Improveenvironmental impactVSAvoidsealing surface smoothness

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The flange is constructed as a composite material combining a thermoplastic polymer matrix with an embedded gas barrier layer (such as EVOH, PVDC, or polyamide). This composite structure provides both the mechanical rigidity needed for smooth sealing surfaces and the gas barrier properties to prevent oxidation, while the overall capsule remains environmentally friendly due to the paper-based body and reduced plastic usage compared to conventional all-plastic capsules.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The gas barrier layer is selectively embedded only in the flange region where sealing and gas protection are most critical, rather than throughout the entire capsule. This localized application maintains the smooth sealing surface where needed while preserving the lightweight and biodegradable properties of the paper-based body in non-critical areas.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If paper-based material is used for the capsule body, then environmental friendliness is improved, but gas barrier properties and oxidation protection deteriorate

Engineering Contradiction:

Improveenvironmental impactVSAvoidoxidation risk

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The flange is constructed as a composite material combining a thermoplastic polymer matrix with an embedded gas barrier layer (such as EVOH, PVDC, or polyamide). This composite structure provides both the mechanical rigidity needed for smooth sealing surfaces and the gas barrier properties to prevent oxidation, while the overall capsule remains environmentally friendly due to the paper-based body and reduced plastic usage compared to conventional all-plastic capsules.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The gas barrier layer is selectively embedded only in the flange region where sealing and gas protection are most critical, rather than throughout the entire capsule. This localized application maintains the smooth sealing surface where needed while preserving the lightweight and biodegradable properties of the paper-based body in non-critical areas.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If paper-based material is used for the capsule body, then lightweight properties are improved, but mechanical rigidity and pressure resistance deteriorate

Engineering Contradiction:

Improvecapsule weightVSAvoidmechanical rigidity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The flange is constructed as a composite material combining a thermoplastic polymer matrix with an embedded gas barrier layer (such as EVOH, PVDC, or polyamide). This composite structure provides both the mechanical rigidity needed for smooth sealing surfaces and the gas barrier properties to prevent oxidation, while the overall capsule remains environmentally friendly due to the paper-based body and reduced plastic usage compared to conventional all-plastic capsules.

Inventive Principle:

Principle #40Composite materials

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 effectively reduces the risk of gas leakage and oxidation, maintaining the quality of beverage ingredients by ensuring a tight seal and mechanical stability, even under hydraulic pressure, while being lightweight and environmentally friendly.

Implementation Method 1

the flange is formed of a first polymer and a second polymer; the second polymer being a gas barrier layer overlapping with the cup-like body

Methodology Applied

Scientific EffectGas barrier: Permeation

Data Source

PatentEP3060498B1Capsule for preparing a beverage such as coffee and the like

Publication Date: 2017.06.14 NESTEC SA

Figure 1~2
Figure 3~5
Figure 6

AI summary

Capsule (1) for the preparation of a beverage in a beverage preparation device comprising a cup-like body (2), a sealing cover (3) for closing the cup-like body; a flange (4) for the cover to seal thereon; the cup-like body being formed of paper-based material comprising at least one gas barrier layer with a cavity wall (5) containing beverage ingredients; wherein the flange (4) is sealingly attached to body and the flange is formed of a first polymer and a second gas barrier polymer; the second polymer being a gas barrier layer overlapping with the cup-like body.