Multilayer Pulp Capsule Liner for Delamination-Free Piercing
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Solution Overview
Problem
Beverage capsules made of moulded pulp with a barrier liner face delamination issues during water injection, causing the liner to be dragged inside without piercing, leading to blockage and preventing beverage flow.
Innovation Solution
A multilayer liner with specific polymer layers is used, where the outermost layer has a low melting point for cohesion with pulp, the innermost layer has a high melting point for adherence, and intermediate layers provide adhesion, ensuring the liner is securely attached to the pulp body and can be easily pierced by blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a barrier liner is adhered to the internal surface of the pulp body to prevent delamination, then the liner attachment strength is improved, but the elasticity of the liner causes it to be dragged inside without piercing during water injection
Solution Approach 1:
The patent changes the physical parameters of the liner by controlling its elasticity to be lower than that of the pulp body. This parameter adjustment allows the liner to remain securely attached during water injection while enabling the piercing blades to effectively pierce through both the liner and pulp body without the liner being dragged inside.
2Reliability
If the liner elasticity is increased to maintain liner integrity, then the barrier protection is improved, but the delamination effect is reinforced during water injection
Solution Approach 1:
The patent adjusts the elasticity parameter of the liner to be lower than that of the pulp body, creating an optimal balance. This ensures the liner maintains sufficient integrity to provide barrier protection while preventing the delamination effect that occurs when liner elasticity exceeds pulp elasticity during water injection.
3Strength
If the liner is made tightly adhered to the pulp body, then the attachment strength is improved, but water injection is blocked when the liner is dragged inside
Solution Approach 1:
The patent optimizes the attachment strength parameter by ensuring the liner is tightly adhered to the pulp body with controlled elasticity. This allows the liner to remain in place during water injection, preventing blockage and ensuring proper beverage flow while maintaining the necessary attachment strength.
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 prevents delamination, ensuring effective water injection and beverage flow by maintaining the integrity of the liner with the pulp body, enhancing recyclability and environmental sustainability.
Implementation Method 1
the outermost layer has a low melting point for cohesion with pulp
Implementation Method 2
intermediate layers provide adhesion
Implementation Method 3
the innermost layer has a high melting point for adherence
Data Source
Figure 1~3A
Figure 3B~5
AI summary
Capsule (1) for beverage preparation, comprising a cup-shaped body (2) of moulded cellulose pulp and a closing membrane (5) attached to said body (2), further comprising a multilayer polymeric liner (3) attached to the inner surface of the cellulose pulp body (2), said liner comprising: (i) an outermost polymeric layer (7) having an elongation at break between 10% and 800%, a melt flow rate (MFR) between 2 and 4, and a melting point temperature below 80°C, (ii) a first tie layer (8), (iii) a barrier layer (9), (iv) a second tie layer (10), (v) an innermost polymeric layer (11) comprising a biodegradable polymer, said innermost layer having a thickness between 10 and 100 µm, and said innermost layer having an elongation at break between 10% and 1000%, a melt flow rate (MFR) comprised between 4 and 10, and a melting point temperature between 110°C and 180°C.