Capsule with a sealed filter element
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Solution Overview
Problem
Existing portion capsules require precise positioning of the filter element during manufacturing due to a seal seam close to the outer edge, making them more complex and costly to produce without ensuring beverage quality.
Innovation Solution
A portion capsule design with a seal seam outer diameter of 60-70% of the filter element's diameter, allowing for easier manufacturing and eliminating the need for precise positioning, while maintaining a sufficient active filter area for high-quality drink production, using either fleece or felt filter elements with specific diameter and thickness specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the seal seam is positioned close to the outer edge of the filter element (84-94% of diameter), then foam formation is reduced, but manufacturing precision requirements increase and device complexity increases
Solution Approach 1:
The patent changes the critical parameter from seal seam outer diameter (84-94% in prior art) to seal seam inner diameter (45-65% of filter element diameter). This parameter shift moves the sealing function inward, creating a tolerance buffer zone that eliminates the need for precise filter element positioning while maintaining effective filtration area.
Solution Approach 2:
The patent introduces an intermediary zone between the seal seam and the outer edge of the filter element. This intermediate annular region (comprising the seal seam itself and the area between inner and outer diameters) serves as a buffer that absorbs positioning variations, allowing the seal to remain effective even when the filter element is not precisely positioned.
2Ease of manufacture
If the seal seam outer diameter is reduced to 60-70% of filter element diameter, then manufacturing becomes easier and less precise positioning is needed, but the active filter area is reduced
Solution Approach 1:
The patent redefines the critical dimension from outer diameter to inner diameter of the seal seam. By specifying inner diameter at 45-65% of filter element diameter, the patent ensures sufficient active filter area remains in the central region, while the reduced outer diameter (60-70%) provides manufacturing tolerance and ease of production.
Solution Approach 2:
The patent segments the filter element area into distinct functional zones: a central active filtration zone (within the inner diameter of the seal seam) and an outer annular zone (between inner and outer diameters of the seal seam). This segmentation allows the inner zone to provide sufficient filtration area while the outer zone accommodates sealing variations and manufacturing tolerances.
3Device complexity
If the seal seam outer diameter is reduced from 84-94% to 60-70% of filter element diameter, then device complexity and manufacturing cost are reduced, but filtering performance may be impaired
Solution Approach 1:
The patent changes the defining parameter from outer diameter to inner diameter of the seal seam, and optimizes it to 45-65% of filter element diameter. This ensures that the central active filtration area is sufficient for maintaining beverage quality, while the reduced overall seal diameter simplifies manufacturing and reduces device complexity.
Solution Approach 2:
The patent design预先 establishes the seal seam inner diameter within the optimal range (45-65%) during the manufacturing process, ensuring that sufficient active filter area is preserved before any operational variations occur. This preliminary design choice guarantees reliable beverage quality without requiring complex quality control during operation.
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 design simplifies and cost-reduces the production of portion capsules without compromising beverage quality, ensuring effective extraction and minimizing foam formation.
Implementation Method 1
The seal seam, which connects the filter element to the bottom of the portion capsule, is preferably attached by ultrasonic welding.
Data Source
Figure 1a~1b
Figure 2
AI summary
The present invention relates to a single serve capsule for preparing a beverage, comprising a side wall and a bottom, which together define a space, a filter element being sealed to the bottom within said space.