Portion Capsule Flange Bead Sealing for Secure Lid Attachment
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Solution Overview
Problem
Existing portion capsule manufacturing methods face challenges in achieving a secure and cost-effective sealing mechanism that prevents preparation liquid from entering the brewing chamber, particularly when using aluminum or aluminum mixtures, and in securely fastening the capsule lid due to gas pressure from the beverage raw material.
Innovation Solution
A method involving the production of a portion capsule with a base element and a flange that includes a bead stamped into the flange after filling, which forms a continuous groove for a liquid-tight seal, allowing the capsule lid to be securely attached, thereby preventing liquid penetration into the brewing chamber and accommodating materials like aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressed-in groove or zigzag structure is used for sealing, then sealing capability is improved, but the attachment of the capsule lid becomes problematic due to insufficient mounting surface area
Solution Approach 1:
The sealing function and lid attachment function are segmented into two distinct structural elements: a pressed-in groove for sealing and a separate annular flange providing a mounting surface for the capsule lid. This segmentation allows each element to optimize its specific function without compromise.
Solution Approach 2:
The solution extends the sealing structure into a third dimension by creating an annular flange that protrudes from the base element surface. This dimensional extension provides additional surface area for lid attachment while maintaining the effectiveness of the pressed-in groove sealing mechanism.
2Reliability
If material thickening during forming is attempted for aluminum alloys, then sealing sensitivity to counter-surface irregularities is reduced, but the forming process becomes difficult or impossible
Solution Approach 1:
The sealing groove is pressed into the flange after the base element is formed and after the capsule interior is filled with beverage raw material. This preliminary action sequence allows the use of aluminum alloys without requiring material thickening during the forming process, as the groove is created in the already-formed flange structure.
3Strength
If the capsule lid is securely fastened to withstand gas pressure, then capsule integrity is improved, but the sealing mechanism becomes more complex
Solution Approach 1:
The solution merges the sealing groove and lid mounting surface into a single integrated annular flange structure. This combination provides both the pressed-in groove for sealing and the annular surface for secure lid attachment, simplifying the overall mechanism while achieving both sealing and structural integrity functions.
Data Source
Figure 1~2(h)
Figure 3~4
Figure 5(a)~5(c)
AI summary
A method for producing a portion capsule (1) is proposed, wherein, in a first step, a base element (2) , having a capsule bottom (2''), a capsule wall (2') encircling the capsule bottom (2''), and a flange (5) encircling the capsule wall (2') are produced in a forming process, wherein, in a second step, a beverage raw material is filled into a capsule interior (3) bordered by the capsule bottom (2'') and the capsule wall (2'), and wherein, in a third step, a capsule cover (4), closing the capsule interior (3), is fastened to the flange (5), characterized in that, after the third step, a bead (6) encircling the capsule wall (2') is impressed into the flange (5),