Foldable Coffee Filter Flap for Spill-Free Filling
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Solution Overview
Problem
Existing coffee filters with protruding filling funnels are difficult to fill and prone to spilling ground coffee, due to small filling openings, which negatively impacts user acceptance.
Innovation Solution
A filter design where a first filter layer is connected to a second layer only over part of the circumference, forming a foldable flap that can be inserted into a pocket on the second layer, creating a large filling opening that can be easily closed by loosely inserting the flap, ensuring no coffee escapes during brewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protruding filling funnel is used to close the filling opening, then the filling opening can be easily closed, but the filling process becomes difficult and ground coffee can be spilled
Solution Approach 1:
The filling flap is designed to be movable and foldable, transitioning between a flat state during filling (providing large access) and a folded state during brewing (providing closure). This dynamic element resolves the contradiction by allowing the same structure to serve two opposing functions at different stages of use.
Solution Approach 2:
The filter is divided into multiple layers (first filter layer, second filter layer) with the filling flap formed from the first layer and inserted into a pocket of the second layer. This segmentation allows the filling mechanism to be integrated into the filter structure itself, providing both large filling access and effective closure without requiring a separate protruding funnel.
2Ease of operation
If a large filling opening is provided, then filling is easier and less coffee is spilled, but the filter becomes harder to close securely
Solution Approach 1:
The filling flap is nested within a pocket formed in the second filter layer. During filling, the flap is folded back to provide large access. During brewing, the flap is inserted into the pocket where it is held securely by the pocket walls, preventing coffee from escaping. The nesting structure provides both large opening capability and secure closure.
3Strength
If the connecting seam extends over the entire circumference, then the filter layers are securely connected, but no foldable flap can be formed for filling
Solution Approach 1:
The connecting seam is segmented rather than continuous, extending only over a portion of the circumference. This leaves a gap where the filling flap can be formed by folding the first filter layer. The segmented connection maintains structural integrity while enabling the dynamic filling mechanism.
Solution Approach 2:
The filter structure has different properties in different locations: the connecting seam provides strong fixed connections over most of the circumference, while the local area with the filling flap provides flexible, movable access. This local variation in structural quality allows both secure connection and easy filling.
Data Source
Figure 1~2
AI summary
A filter (1) for the preparation of tea or coffee consists of two filter layers forming an essentially disc-shaped void to be filled with coffee grains or tea leaves. The first filter layer (2) is joined only along part of its periphery to the neighboring second layer, thereby forming a folding flap (8). The flap tucks into a pocket against the second filter layer.