Portion capsule for preparing a beverage
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Solution Overview
Problem
Existing portion capsules with filter elements produced by injection moulding or deep drawing face issues such as clogging due to screen holes being either too large or too small, leading to increased manufacturing costs and inefficient extraction processes.
Innovation Solution
A portion capsule with a filter element made from deep-drawn non-woven plastic fabric, providing a larger filter area and improved liquid inflow, which reduces clogging risk and maintains efficient extraction under varying pressures, and is hermetically sealed to preserve aroma.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If screen holes are made larger to prevent clogging, then liquid flow is improved, but coffee particles pass through the screen
Solution Approach 1:
The foam support structure contains pores that are larger than the screen holes, allowing efficient liquid flow through the support layer. The fine mesh screen layer with smaller apertures sits on top of this porous support, providing the necessary particle retention while the foam beneath maintains open flow pathways.
Solution Approach 2:
The filter assembly is divided into distinct functional layers: a fine mesh screen layer for particle retention and a porous foam support layer for structural support and flow management. This segmentation allows each layer to be optimized independently - the screen for retention and the foam for flow - without compromising either function.
2Stability of the object's composition
If support elements are added between the screen and capsule bottom to prevent deformation, then structural stability is improved, but manufacturing cost increases due to additional materials
Solution Approach 1:
The support function and the structural body are merged into a single integrated foam support structure. Rather than adding separate support elements to a flat screen, the foam material forms an inherent three-dimensional support architecture that provides both mechanical stability and flow pathways, eliminating the need for additional discrete support components.
Solution Approach 2:
The porous foam material provides structural stability through its three-dimensional cellular architecture, which inherently resists deformation under pressure. The foam's open-cell structure distributes mechanical loads across its volume, providing rigidity and support without requiring additional solid support elements that would increase material usage and manufacturing complexity.
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 deep-drawn non-woven filter element enhances extraction efficiency, reduces clogging, and maintains efficient liquid flow, while being cost-effective and capable of withstanding high pressures, ensuring optimal beverage preparation without foam formation.
Implementation Method 1
a preparation liquid, preferably hot water, is conveyed under pressure into the portion capsule. The preparation liquid flows through the substrate, and extracts and/or dissolves the substances required for the preparation of the beverage from the beverage substrate
Implementation Method 2
The preparation liquid flows through the substrate, and extracts and/or dissolves the substances required for the preparation of the beverage from the beverage substrate
Implementation Method 3
The filter element is preferably situated between the beverage substrate and the capsule base and is supported on this. These filter elements prevent particles from the beverage substrate from entering the beverage being made
Implementation Method 4
A portion capsule with a filter element made from deep-drawn non-woven plastic fabric, providing a larger filter area and improved liquid inflow, which reduces clogging risk and maintains efficient extraction under varying pressures
Data Source
AI summary
A portion capsule for producing a beverage. The portion capsule includes a capsule body that has a collar edge and a capsule bottom; a filter element located inside of the capsule body, the filter element is elastic, the filter element has a flange that is attached to the collar edge of the capsule body, the filter element has a bottom; and a cover attached to the capsule body. The bottom of the filter element is spaced apart from the capsule bottom such that a free space remains between the filter element and the capsule bottom. The filter element is spaced apart from the capsule bottom in such a manner that only before a liquid is applied to a beverage substrate, does the filter element not touch the capsule bottom.