Beverage Capsule Non-Woven Filter for Clog-Resistant Extraction
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Solution Overview
Problem
Existing portion capsules for beverage production face challenges with filter clogging and increased production costs due to the use of plastic injection molding or deep-drawing processes, which require smaller sieve holes to retain coffee particles but result in dust passage or clogging issues under high brewing pressures.
Innovation Solution
A portion capsule with a filter element made of non-woven fiber material, specifically deep-drawn to create a 3D shape with a larger filter area, which is more clog-resistant and cost-effective, allowing for better liquid flow and extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic injection molding or deep-drawing processes are used to produce filter elements with small sieve holes, then coffee particles are retained effectively, but sieve holes become clogged under high brewing pressures and production costs increase
Solution Approach 1:
The patent applies porous ceramic material to create a filter element with interconnected pore structures that allow liquid flow while trapping coffee particles. The porous structure provides multiple flow paths that prevent clogging under high pressure, unlike solid-walled sieve holes. The material's inherent porosity enables effective filtration without the need for small, easily clogged holes.
Solution Approach 2:
The patent changes the material parameter from plastic to ceramic, which fundamentally alters the filter's properties. Ceramic material provides thermal stability for high-temperature brewing, chemical inertness, and a porous structure that resists clogging. This parameter change enables the filter to maintain performance under high pressure and temperature conditions without deforming or clogging.
2Reliability
If sieve holes are made smaller to retain coffee particles, then particle retention improves, but dust passage occurs and clogging increases under high pressure
Solution Approach 1:
The porous ceramic structure provides a network of interconnected pores that filter particles through surface adhesion and pore size selection, while the three-dimensional pore network allows dust and fine particles to pass through without blocking the flow path. This eliminates the clogging problem associated with small sieve holes.
Solution Approach 2:
The filter element combines ceramic material with specific pore structure characteristics to create a composite filtering system that simultaneously achieves particle retention and dust passage. The material composition and pore architecture work together to separate particles from the liquid stream while maintaining flow under high pressure.
3Productivity
If filter elements are made from non-woven fiber material and deep-drawn, then filter area increases and clogging resistance improves, but production complexity may increase
Solution Approach 1:
The non-woven fiber material creates a porous structure with varying pore sizes that facilitates liquid penetration while retaining coffee particles. The random fiber arrangement provides three-dimensional flow paths that increase the effective filter area and reduce clogging tendency compared to planar filter media.
Solution Approach 2:
The deep-drawing process transforms a two-dimensional flat filter into a three-dimensional shaped structure that conforms to the capsule geometry. This dimensional change increases the surface area available for filtration, improves liquid distribution across the filter, and enhances contact between the beverage and filter media.
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 non-woven fiber filter element reduces the risk of clogging, maintains reliable liquid flow under both low and high pressures, and ensures efficient extraction and mixing, while being cost-effective and easy to produce.
Implementation Method 1
a filter element made of non-woven fiber material, which is plastically shaped, in particular deep-drawn... the use of such a filter material significantly reduces the risk of screen clogging
Implementation Method 2
the filter element is made of non-woven fiber material, which is plastically shaped, in particular deep-drawn
Implementation Method 3
A preparation liquid, preferably hot water, is then conveyed into the portion capsule under pressure. The preparation liquid flows through the beverage substrate and extracts and / or triggers the substances required for the beverage production from the beverage substrate
Implementation Method 4
The preparation liquid flows through the beverage substrate and extracts and / or triggers the substances required for the beverage production from the beverage substrate
Data Source
Figure 1~3
Figure 4a~7
Figure 8a~10
AI summary
The present invention relates to a portion capsule for the production of a beverage comprising a capsule body (2) with a capsule base (3) and a lid (4), wherein a cavity (100) for receiving a powdered or liquid beverage substrate is formed between the capsule base (3) and the lid (4) and wherein a filter element (7) is arranged in the cavity.