Single-Material PET Capsule for Beverage Dispensing
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Solution Overview
Problem
Existing beverage capsules face challenges in mechanical and thermal stress resistance, and environmental sustainability due to complex multi-material constructions, leading to ambiguity in disposal and potential for delamination under high pressures.
Innovation Solution
A single-material capsule made entirely of polyethylene terephthalate (PET) by injection molding, featuring a multi-layer cover and sealing disc, with a nozzle design and labyrinthine structure for reduced pressure and leakage, and recyclable components to facilitate easy differentiation and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-material construction is used for capsule components, then functional requirements are met, but environmental sustainability deteriorates due to disposal ambiguity and recycling difficulty
Solution Approach 1:
The patent applies homogeneity by making all capsule components (cup, cover, sealing disc, nozzle) from the same material - polyethylene terephthalate (PET). This eliminates material complexity while maintaining functional performance, allowing the entire capsule to be recycled together without separation, thus resolving the contradiction between functional reliability and environmental sustainability.
Solution Approach 2:
The patent merges previously separate multi-material components into a unified single-material structure. All parts that were previously made from different materials (paper, aluminum, plastics) are now made from PET, combining them into a homogeneous system that is both functionally adequate and environmentally friendly for recycling.
2Reliability
If multi-material components are used, then specific functional requirements are satisfied, but manufacturing complexity increases due to assembly and material compatibility
Solution Approach 1:
By using the same material (PET) for all components, the patent eliminates the need for complex assembly procedures required for multi-material capsules. The homogeneous material allows for simplified manufacturing processes, including injection molding of the cup and ultrasonic welding of components, reducing overall construction complexity while maintaining functional performance.
3Productivity
If high pressure is applied for beverage dispensing, then beverage extraction is effective, but delamination occurs in multi-material capsules
Solution Approach 1:
The patent eliminates delamination issues by using homogeneous PET material for all components. Since all parts are made from the same material with compatible thermal and mechanical properties, the capsule can withstand high dispensing pressures (up to 20 atmospheres) without the layer separation problems that plague multi-material constructions.
Solution Approach 2:
The patent changes the material parameters of all components to match PET properties, ensuring uniform thermal expansion, pressure resistance, and mechanical strength. This parameter harmonization across all components allows the capsule to maintain structural integrity under high pressure while enabling effective beverage extraction.
4Adaptability or versatility
If complex internal functional elements are added, then beverage preparation functionality is enhanced, but manufacturing difficulty increases
Solution Approach 1:
The patent simplifies manufacturing of complex internal elements by making them from the same PET material as the cup. The nozzle, sealing disc, and other internal components can be injection molded or formed from PET, eliminating the need for complex assembly of different materials and reducing manufacturing difficulty while maintaining enhanced beverage preparation functionality.
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 PET capsule provides high mechanical and thermal resistance, ensures easy recyclability, and reduces environmental impact by using a single, consistent material for all components, preventing delamination and simplifying waste management.
Implementation Method 1
the flow of hot water, delivered by an extraction machine, passes through the essence to be infused or dissolved contained inside the capsule
Implementation Method 2
the flow of hot water, delivered by an extraction machine, passes through the essence to be infused or dissolved contained inside the capsule
Implementation Method 3
activated by increasing the pressure within the cup so as to allow the inner sealing disc to detach
Implementation Method 4
antidrip means in the form of a labyrinth
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A single-material capsule (1) for the preparation of soluble or infusion beverages, according to the present invention, is characterized in that it is made of at least 90% polyethylene terephthalate, or polyethylene terephthalate combined with a material that is similar to polyethylene terephthalate and recyclable together with polyethylene terephthalate. Advantageously, with respect to known capsules composed of different plastics materials or paper or aluminum-coupled materials, which are very difficult to separate from each other at the time of collecting waste, the capsule that is the subject matter of the present invention is easily recyclable both for the final consumer and for those industries that decide to invest in green solutions. A capsule made of a plastics single-material that is not coupled to other elements is easier to recycle and may be converted into good quality material that may even be reused to create new packaging.