Beverage Capsule Filter Element with Cut-Out to Reduce Pressure Loss
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Solution Overview
Problem
Existing portion capsules for beverage production have high pressure loss, complex production processes, and high weight, particularly due to the filter element, which requires substantial pump pressure and is difficult to manufacture.
Innovation Solution
A portion capsule with a filter element featuring a cut-out without filtering material, made from fiber material, is designed to reduce pressure loss and weight, and is produced using vacuum-formed plastic or injection molding, with the filter element being tack-welded to the capsule body to enhance alignment and prevent contact with broaching members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter element is provided in the portion capsule, then beverage substrate is filtered from the prepared beverage, but pressure loss increases and pump pressure must be substantially higher than 2 bar
Solution Approach 1:
A cut-out is provided in the filter element through which no filtering material is present, allowing beverage to pass through without filtration. This extracts the non-essential filtering function from part of the filter element, reducing pressure loss while maintaining filtration where needed.
Solution Approach 2:
The filter element has different properties in different regions: the peripheral region provides filtration, while the central cut-out region allows free flow without filtration. This local differentiation optimizes both filtration performance and pressure characteristics.
2Reliability
If a filter element is provided in the portion capsule, then beverage substrate is filtered, but production complexity increases
Solution Approach 1:
The filter element is made from a non-woven fiber material that naturally provides filtration through its porous structure. This eliminates the need for additional filtering components and simplifies production while maintaining effective filtration.
3Reliability
If a filter element is provided in the portion capsule, then beverage substrate is filtered, but weight increases
Solution Approach 1:
The cut-out removes filtering material from the central region of the filter element, eliminating unnecessary weight while preserving filtration functionality in the peripheral region where it is most needed.
4Reliability
If filter element is made from fiber material, then filtration is provided, but pressure loss increases
Solution Approach 1:
The filter element is segmented into a peripheral filtering region and a central non-filtering cut-out region. This segmentation allows beverage to bypass the high-resistance fiber material through the cut-out, reducing overall pressure loss while maintaining filtration capability.
Data Source
AI summary
The invention relates to a single serve capsule (1) for producing a beverage, comprising a capsule body (2). Said capsule body has a capsule bottom (3), a sidewall (22), a collar edge (5), and a cover (6). A cavity (100) for accommodating a beverage substrate in the form of a powder, granules, cut leaves or liquid is formed between the capsule bottom and the cover. A filter element (7) is arranged in the cavity, and the filter element is produced of non-woven fiber material. The filter element has a cut-out in which no filtering material is provided. The present invention also relates to a method for producing a single serve capsule.