Paper-Polymer Composite Capsule Flange for Beverage Sealing

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Solution Overview

Problem

Paper-based capsules for beverage preparation devices face issues with imperfect sealing due to folds and creases, leading to oxidation of sensitive ingredients like roast and ground coffee, and lack of rigidity for proper interaction with the device.

Innovation Solution

A capsule design combining a paper-based body with a polymer-based flange that covers the paper part, providing mechanical support and a tight seal by molding polymer material over the paper flange to fill in creases and enhance rigidity, ensuring a gas-tight and leak-resistant structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If paper-based material is used for the capsule body, then environmental impact is reduced, but sealing quality deteriorates due to folds and creases

Engineering Contradiction:

Improveenvironmental impactVSAvoidsealing quality

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The flange is constructed as a composite structure combining paper-based material (for environmental benefits) with polymer material (for sealing performance). The polymer is molded over the paper flange to create a composite component that exhibits both the ecological advantages of paper and the sealing reliability of polymer, directly resolving the contradiction between environmental impact and sealing quality.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If paper-based material is used for the flange, then environmental benefits are maintained, but structural rigidity deteriorates

Engineering Contradiction:

Improveenvironmental benefitsVSAvoidstructural rigidity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The polymer is molded over the paper-based flange to create a composite structure where the polymer provides the necessary structural rigidity and strength, while the paper-based material maintains environmental benefits. This composite approach allows the flange to satisfy both ecological requirements and mechanical performance demands.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the flange are assigned different materials with different properties: the paper-based material provides environmental benefits in non-critical areas, while the polymer material provides structural rigidity and sealing surfaces in critical areas. This local differentiation resolves the contradiction between environmental benefits and structural rigidity.

Inventive Principle:

Principle #3Local quality

3Reliability

If polymer is molded over paper flange, then sealing performance improves, but manufacturing complexity increases

Engineering Contradiction:

Improvesealing performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The manufacturing process merges the formation of the paper flange and the polymer molding into a single integrated operation. The polymer is molded directly over the pre-formed paper flange in one step, combining what could be seen as separate operations into a unified manufacturing process, thereby reducing overall complexity despite the multi-material nature of the component.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240351778A1Capsule for preparing a beverage such as coffee and the like

Publication Date: 2024.10.24 SOCIETE DES PRODUITS NESTLE SA

AI summary

A capsule for the preparation of a beverage in a beverage preparation device having a flange partially made of paper and partially made of polymer so as to improve the inside tightness of the capsule, such as to prevent air enters inside the capsule via folds and creases, is disclosed. Methods of producing and using the capsule are also disclosed.