Open Pore Foam Filter for Coffee Capsule Injection Molding
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Solution Overview
Problem
Existing coffee capsule systems with filter elements are complex and costly to produce, requiring significant polymer material and energy, and often result in undesired coffee grounds entering the beverage due to design complexities.
Innovation Solution
A portion capsule design featuring a base element and cover element with an open pore foam filter element made from biodegradable materials like polypropylene or bio-plastics, which simplifies production, reduces weight, and allows for direct contact with the capsule base or cover, eliminating the need for a separate joint product region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional filter elements are used in injection molded capsules, then filtering function is achieved, but production complexity and polymer material consumption increase
Solution Approach 1:
The filter element is integrated directly into the capsule structure during injection molding, merging the filtering function with the capsule body. This eliminates separate filter components and reduces overall design complexity while maintaining effective coffee grounds separation.
Solution Approach 2:
The patent employs porous polymer materials with controlled pore sizes that provide effective filtration of coffee grounds while allowing liquid passage. The porous structure achieves filtering functionality inherently within the capsule material itself, reducing the need for additional filter components.
2Loss of energy
If traditional filter elements are used in injection molded capsules, then filtering function is achieved, but energy consumption and weight increase
Solution Approach 1:
The injection molded capsule utilizes porous polymer structures that provide filtering capability without requiring excessive material. The controlled porosity allows liquid flow while blocking coffee grounds, reducing overall polymer consumption compared to traditional solid filter elements.
Solution Approach 2:
The patent optimizes the pore size distribution, wall thickness, and material density parameters of the injection molded capsule to achieve effective filtration with minimal material usage. By carefully controlling these parameters, energy consumption during production and final capsule weight are reduced.
3Reliability
If joint product region is added to protect piercing tips, then piercing tip damage is prevented, but capsule complexity increases
Solution Approach 1:
The protective function for piercing tips is integrated into the main capsule body structure through the injection molded design. The capsule base and cover are formed as unified structures that inherently guide and protect the piercing tips during insertion, eliminating the need for separate joint product regions.
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 use of open pore foam filter elements in coffee capsules results in a more environmentally friendly, lightweight, and cost-effective solution that prevents coffee grounds from entering the beverage while enabling efficient recycling and biodegradability, with improved brewing efficiency and reduced energy consumption.
Implementation Method 1
A filter element is placed in the interior space. The filter element separates the extraction material region from the capsule base or from a capsule cover formed by the cover element. The filter element is formed of an open pore foam material.
Implementation Method 2
Open pore or open cell foam materials refers here to foam materials wherein the walls between the pores are at least partially not completely closed, so that the foam material can receive and release liquid.
Data Source
AI summary
A portion capsule includes a base element, for example like a cup, having a capsule base and a circumferential side wall. A cover element is attached to the base element and forms together with the same an interior space having an extraction material region filled with an extraction material. A filter element is placed in the interior space. The filter element separates the extraction material region from the capsule base or from a capsule cover formed by the cover element. The filter element is formed of an open pore foam material.