Beverage Capsule Filter Permeability for Gas Exchange
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Solution Overview
Problem
Conventional multi-chamber beverage capsules, such as the Keurig K-cup, face manufacturing inefficiencies and prolonged brewing cycles due to air evacuation and inert gas replacement challenges, as well as restricted air flow rates caused by filter designs, leading to increased nitrogen usage and prolonged manufacturing lead times.
Innovation Solution
A beverage capsule design featuring a filter with high air flow permeability (at least 400 L/s·m2) and air flow channels in the body, along with a vent region between the ingredients and extraction chambers, allows for efficient air evacuation and inert gas replacement, improving production rates and reducing manufacturing inefficiencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional filter design is used in multi-chamber beverage capsules, then the capsule structure is simple and easy to manufacture, but the air flow rate is restricted which significantly impacts production rate
Solution Approach 1:
The patent employs a porous filter material with optimized pore structure to achieve high air flow permeability (at least 400 L/s·m2). This porous design allows rapid air evacuation and inert gas replacement during modified atmosphere packaging while maintaining the filter's function of separating ingredients from the extraction chamber. The porous structure inherently provides high permeability without requiring complex geometric features.
Solution Approach 2:
The patent changes the key parameter of air flow permeability by specifying a minimum value of 400 L/s·m2. This parameter change transforms the filter from a flow-restricting component to a high-performance air permeable barrier. The specification of this critical parameter directly addresses the production rate bottleneck by ensuring sufficient gas exchange during manufacturing while maintaining structural simplicity.
2Loss of time
If conventional multi-chamber capsules are manufactured with standard filtration, then manufacturing equipment is simple, but large volumes of nitrogen are required and lead time is prolonged
Solution Approach 1:
The high permeability porous filter enables rapid air evacuation and inert gas replacement during modified atmosphere packaging. This reduces the time required for atmosphere replacement and decreases the total volume of nitrogen needed to achieve proper gas exchange, directly addressing both the lead time and nitrogen consumption issues.
Solution Approach 2:
The patent implements a process where air is rapidly evacuated and inert gas is quickly introduced through the high permeability filter. This rushing through the gas exchange process minimizes the time the manufacturing chamber must remain under modified atmosphere conditions, thereby reducing both lead time and nitrogen consumption.
3Duration of action of moving object
If conventional filter designs are used, then manufacturing is efficient, but the brewing cycle is prolonged due to delayed pressure differential balancing
Solution Approach 1:
The high permeability porous filter enables rapid pressure equalization between chambers during brewing. As hot water is injected into the ingredients chamber, pressure builds quickly and is efficiently balanced with the extraction chamber through the permeable filter, preventing delays in the brewing cycle and improving overall brewing efficiency.
4Productivity
If a filter with high air flow permeability is used, then air evacuation and inert gas replacement is efficient, but the filter structure becomes more complex
Solution Approach 1:
The patent achieves high air evacuation rates through the inherent properties of porous materials rather than complex structural designs. The porous structure with optimized pore size, distribution, and connectivity provides high permeability (at least 400 L/s·m2) while maintaining a relatively simple filter construction that can be integrated into conventional capsule manufacturing.
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 improved design enhances the rate of production by efficiently evacuating and replacing air within the capsule, reducing manufacturing lead times and shortening brewing cycles, while allowing for a higher volume of ingredients and improved fluid flow.
Implementation Method 1
said filter having an air flow permeability of at least 400 L/s·m2
Data Source
AI summary
A beverage capsule is provided for use in a beverage preparing machine. A system and process for making the beverage capsule is also provided. The beverage capsule includes a body defining an interior space having an opening. A filter is disposed in the body to define an ingredients chamber and an extraction chamber. The filter has an air flow permeability of at least 400 L/s·m2. Ingredients are disposed in the ingredients chamber and a cover is dispensed over the opening to seal the interior space. The filter includes a vent region between the top surface of the ingredients and the bottom surface of cover for venting gas through said filter between said ingredients chamber and said extraction chamber. An alternate embodiment includes air flow channels defined in a side wall of body.