Process for manufacture of a dispensing capsule and apparatus for carrying out the process
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Solution Overview
Problem
Current coffee capsules made from plastics and aluminum pose significant recycling challenges due to mixed materials and resource inefficiency, and existing pulp fibre technologies are too slow and expensive to produce sustainable, recyclable capsules that match the performance and volume of traditional capsules.
Innovation Solution
A high-speed process using moulded pulp fibres to create capsules with a frustroconical shape, involving a continuous feed belt with articulated mesh toolsets, vacuum formation, and secondary tooling for deformation and drying, allowing for the production of pulp fibre capsules that are dimensionally compatible with existing coffee machines and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional plastics and aluminium are used to manufacture capsules, then manufacturing ease and oxygen barrier performance are improved, but recycling difficulty and environmental sustainability worsen
Solution Approach 1:
The patent changes the material parameter from traditional plastics and aluminium to moulded pulp fibre, transforming the capsule from non-recyclable to fully recyclable and compostable while maintaining manufacturing feasibility through high-speed continuous production processes
Solution Approach 2:
The patent enables recovery and recycling of pulp fibre capsules through composting and industrial recycling processes, converting the previously discarded single-use plastic and aluminium capsules into recoverable organic material that can be returned to the production cycle
2Object-generated harmful factors
If existing pulp fibre technologies are used to produce capsules, then sustainability and recyclability are improved, but production speed and economic viability worsen
Solution Approach 1:
The patent implements a continuous production process where pulp fibre is continuously formed, molded, and dried on an endless conveyor belt system, eliminating batch processing interruptions and achieving production speeds comparable to traditional plastic and aluminium capsule manufacturing
Solution Approach 2:
The patent replaces slow, labor-intensive traditional pulp molding methods with a mechanized high-speed continuous forming system using vacuum conveyance and automated molding, dramatically increasing production efficiency while maintaining sustainability
3Productivity
If high-speed continuous production is implemented for pulp fibre capsules, then productivity and economic viability are improved, but manufacturing complexity and process difficulty worsen
Solution Approach 1:
The patent divides the continuous production process into distinct functional zones (forming zone, molding zone, drying zone, collection zone) along the conveyor belt, allowing each segment to be optimized independently while maintaining overall high-speed continuous operation
Solution Approach 2:
The patent designs a multi-functional production line where a single continuous conveyor belt system performs multiple operations (forming, molding, drying, and collection), reducing the need for separate processing equipment and simplifying the overall manufacturing infrastructure
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 process enables the production of pulp fibre capsules that are economically viable, recyclable, and sustainable, maintaining performance and volume compatibility with traditional capsules, thus addressing recycling issues and environmental concerns while ensuring consistent quality and ease of use.
Implementation Method 1
a vacuum source is drawn without disruption through a tank containing a suspension that includes water and pulp fibres... applying a vacuum to the mesh tool sets so as to draw pulp fibres from the suspension onto the plurality of mesh tool sets
Data Source
Figure 1A~1C
Figure 2
Figure 3A~3B
AI summary
An apparatus for high speed continuous thermoforming of pulp materials into pulp based products including a beverage dispensing capsule comprising a body having a side wall and a base formed entirely of moulded pulp fibres, said apparatus comprising a holding tank for water and pulp fibres in suspension, a continuous feed belt of articulated mesh toolsets contoured to the preform shape of said products, said belt being inclined to allow partial immersion and partial withdrawal from said suspension by continuous rotation of said belt, vacuum means applied to said mesh toolsets to draw said pulp fibres onto said mesh toolsets immersed in said suspension to form a preform pulp mat of said product.