Beverage Container Filter Back-Injection Molding
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Solution Overview
Problem
Existing storage and process containers for beverage machines, such as coffee machines, lack a secure and permanent connection between the filter part and the plastic injection-molded parts, which can lead to instability during the brewing process and limited material choices for the filter part.
Innovation Solution
The filter part is connected directly to the inner or outer part via back-injection molding, ensuring a secure, permanent connection and a larger material selection by gripping the filter part radially with connecting webs, creating a stable and extensive filter surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to connect the filter part to the plastic injection-molded part, then the connection is achieved, but the material choice for the filter part is limited and the connection may break during the brewing process
Solution Approach 1:
The filter part is integrated directly into the injection-molded plastic part through back-injection molding, merging two previously separate components (filter and container) into a single unified structure. This eliminates the need for separate connection processes like ultrasonic welding and allows diverse material choices for the filter while maintaining a permanent, reliable connection that cannot break during brewing.
Solution Approach 2:
The invention uses composite construction by combining the filter part (which can be made from various materials including paper, fleece, or non-woven fabric) with the plastic injection-molded part. The back-injection process creates a composite structure where different materials are permanently bonded together, achieving both connection reliability and material versatility.
2Ease of manufacture
If the filter part is connected using conventional techniques, then the manufacturing process is simple, but the connection is not secure and may break during brewing
Solution Approach 1:
The back-injection molding process combines the filtering of plastic material with the connection process itself. The plastic is injected through the filter part, which is held in place by closing elements, and the filter becomes permanently integrated into the plastic structure. This merging of processes achieves both manufacturing efficiency and secure, permanent connection.
3Reliability
If back-injection molding is used to connect the filter part, then a secure permanent connection is achieved with greater material choice, but the manufacturing process becomes more complex
Solution Approach 1:
The injection process is segmented into two distinct phases: first injecting the plastic material to form the container structure, then back-injecting additional plastic through the filter part to create the permanent connection. This segmentation allows each phase to be optimized independently while maintaining overall process efficiency and achieving reliable connections.
4Area of stationary object
If the filter part is made very thin to increase filter surface area, then the filter efficiency improves, but the connection strength may be reduced
Solution Approach 1:
The back-injection process merges the filter part with the plastic structure, creating a composite where the plastic penetrates and bonds with the thin filter material. This merging provides mechanical reinforcement to thin filter parts, allowing them to maintain high surface area while achieving sufficient connection strength through the integrated plastic-filler structure.
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
This configuration provides a stable connection that withstands the brewing process and allows for a broader range of material options for the filter part, enhancing the manufacturing technology and performance of the container.
Implementation Method 1
the filter part is connected directly to the inner part or the outer part by back-injection molding on one side
Data Source
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AI summary
The invention relates to a storage and process container (1) which is made up of an inner part (I) and an outer part (A) and is intended for a drinks machine, a filter part (8) being arranged between the inner part (I) and the outer part (A). In order further to improve the quality of a container of the type in question, it is proposed that the filter part (8) be connected to the inner part (I) or to the outer part (A) directly by in-mould lamination.