Calendered Fiber Filter for Single-Serve Capsules Under Pressure
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Solution Overview
Problem
Existing portion capsules for beverage production face challenges with complex and costly filter element production, low mechanical stability, and risk of clogging, especially under high pressure.
Innovation Solution
A portion capsule with a filter element made from point and/or structure calendered fiber material, such as felt or fleece, which provides high mechanical stability, reduced clogging risk, and enhanced liquid flow characteristics, eliminating the need for complex production processes and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional injection-moulded or deep-drawn plastic filter elements are used, then mechanical stability is improved, but production complexity and cost increase
Solution Approach 1:
The patent changes the material parameter from thermoplastic material to fibrous material (fleece or felt), and applies calendering treatment to modify the physical state of the fibers. This creates a mechanically stable filter element through fiber matting and calendering rather than through complex molding processes, thereby reducing production complexity while maintaining mechanical stability
Solution Approach 2:
The filter element is designed as a disposable component made from inexpensive fibrous material that can be produced through simple calendering of fleece or felt. This eliminates the need for expensive, complex injection molding or deep-drawing processes, making the filter element cost-effective for single-use portion capsules
2Strength
If traditional plastic filter elements are used, then structural integrity is improved, but liquid entry surface area decreases
Solution Approach 1:
The patent employs porous fibrous material (fleece or felt) as the filter element, which naturally provides high porosity and large internal surface area. The calendering process creates a compressed fiber mat with numerous interconnected pores, enabling extensive liquid entry surface while maintaining structural integrity through the dense fiber network
3Reliability
If dense filter elements are used to prevent clogging, then filtration performance is improved, but liquid flow under pressure decreases
Solution Approach 1:
The calendering process creates local variations in fiber density and pore structure within the filter element. The compression creates regions of different porosity that balance filtration capability with flow permeability, allowing the filter to resist clogging while maintaining adequate liquid flow under brewing pressure
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 fiber-based filter element ensures reliable extraction and mixing with reduced clogging, maintaining liquid flow even under high pressure, and is cost-effective to produce, with improved mechanical stability and drainage behavior.
Implementation Method 1
the filter element comprises a point and/or structure calendered material made from fibers
Implementation Method 2
point and/or structure calendered material made from fibers
Implementation Method 3
a filter element being arranged between the beverage substrate and the capsule base
Implementation Method 4
a liquid transverse flow (parallel to the main plane of extension of the filter plane) is made possible
Implementation Method 5
a liquid transverse flow (parallel to the main plane of extension of the filter plane) is made possible
Data Source
Figure 1~3
Figure 4~6
Figure 7~9c
AI summary
The invention relates to a single serve capsule (1) for producing a drink, comprising a capsule body (2) with a capsule base (3) and a filling side (4). A cavity (100) for accommodating a powdered or liquid drink substrate is formed between the capsule base (3) and the filling side (4), a filter element (7) is arranged between the drink substrate and the capsule base, and said filter element (7) is made from a fibrous material having a point and/or calendered structure.