Capsule and manufacturing process for said capsule
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Solution Overview
Problem
Existing beverage capsules fail to effectively produce crema-free coffee while maintaining the sensory characteristics of filter coffee and ensuring ergonomic use and in-cup results.
Innovation Solution
A capsule design featuring a rigid body with a circumferential sidewall, a base wall, a flange, and a lid with a filter element and carrier disk, where the carrier disk has preformed outlet openings and is retained by mechanical deformations at the junction of the flange and sidewall, preventing crema formation and ensuring the beverage's integrity during extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetically closed capsule is used to maintain beverage ingredient freshness, then storage stability is improved, but crema formation cannot be prevented during extraction
Solution Approach 1:
The capsule is divided into two functional parts: a hermetically sealed body for maintaining ingredient freshness during storage, and a removable lid with filter element that is opened during extraction to prevent crema formation. This segmentation allows the capsule to achieve both storage stability and crema-free extraction.
2Object-generated harmful factors
If a filter element is added to prevent crema formation, then crema-free beverage is achieved, but device complexity increases
Solution Approach 1:
The filter element is merged with the removable lid structure, combining the filtration function with the lid's structural role. This integration reduces overall device complexity compared to having a separate filter component, while still achieving crema-free beverage extraction.
3Object-generated harmful factors
If a removable lid is used to enable crema-free extraction, then crema formation is prevented, but ease of operation is reduced
Solution Approach 1:
The lid is pre-attached to the capsule body during manufacturing, creating a pre-assembled unit that requires minimal manipulation during use. The user simply needs to peel back the lid rather than assemble separate components, significantly improving ease of operation while maintaining crema-free extraction capability.
4Reliability
If mechanical deformations are added to retain carrier disk, then beverage integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The mechanical deformations on the capsule body's internal surface automatically retain the carrier disk through friction and geometric interlocking, without requiring additional fastening mechanisms or complex assembly steps. The capsule structure itself provides the retention function, simplifying manufacturing while ensuring beverage integrity during extraction.
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~4B
AI summary
The invention related to a capsule for preparing a beverage comprising - a substantially rigid capsule body having a circumferential sidewall extending around an inner space of the capsule, said inner space being at least partially filled with a beverage ingredient suitable for preparing the beverage, - a base wall covering the inner space at a first end of the sidewall, - a flange arranged circumferentially around an open side of the capsule at a second end of the sidewall of the base body opposite the base wall, - a lid covering the inner space and the open side of the capsule at the second end of the sidewall opposite the base wall and tightly closing the capsule, the lid being removably attached to the flange of the capsule, - a filter element positioned in the inner space of the capsule between the beverage ingredient and the lid; and - a carrier disk provided in the inner space of the capsule between the lid and the filter, said carrier disk comprising multiple preformed outlet openings suitable for draining the prepared beverage from the inner space outside of the capsule when the capsule is used in the beverage preparation device. According to the invention, the capsule comprises at least one mechanical deformation at the junction or in the vicinity of the junction of the flange and side wall of the capsule, said mechanical deformation retaining the carrier disk inside the inner space of the capsule. The invention also relates to a manufacturing method for manufacturing said capsule and to the use of said capsule.