Metal Foil Filter Plate Openings for Recyclable Beverage Capsules
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Solution Overview
Problem
Existing beverage capsules face challenges in recyclability due to mixed materials and the difficulty in separating components, particularly the filter paper, which affects the quality of recyclable materials.
Innovation Solution
A method for manufacturing a punctured filter plate using metal foil with small openings, achieved through piercing and subsequent stamping or tearing techniques, allowing for the creation of a filter plate that can be integrated into a metal beverage capsule, eliminating the need for filter paper and improving recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter paper is used in beverage capsules, then filtration function is achieved, but recyclability is reduced due to mixed materials
Solution Approach 1:
The patent merges the filtration function with the filter plate structure by integrating a filter layer directly onto the filter plate. This combination eliminates the need for separate filter paper components, allowing the entire capsule including filtration elements to be made from recyclable materials such as aluminum, thereby resolving the contradiction between achieving filtration function and maintaining recyclability
Solution Approach 2:
The patent employs composite material structures where a filter layer (which can be made from recyclable materials) is integrated with the filter plate. This composite approach enables the filtration function to be achieved while using materials that are compatible with recycling streams, thus resolving the contradiction between filtration performance and recyclability
2Reliability
If filter paper is used to filter beverage, then beverage quality is improved, but separation of components becomes difficult
Solution Approach 1:
By integrating the filter layer directly onto the filter plate structure, the patent creates a unified component that performs both filtration and structural functions. This integration eliminates the need to separate filter paper from other capsule components during recycling, thus resolving the contradiction between achieving beverage quality through filtration and simplifying component separation
Solution Approach 2:
The integrated filter plate structure serves multiple functions: it provides structural support, enables filtration through the integrated filter layer, and facilitates recycling by eliminating separate filter paper components. This multi-functionality resolves the contradiction by making the filtration component itself recyclable rather than requiring separation
3Ease of manufacture
If metal foil with small openings is manufactured by piercing, then openings are created, but opening size precision is insufficient
Solution Approach 1:
The patent applies a preliminary stamping action to the metal foil after piercing to precisely control the final opening dimensions. The stamping process pre-defines the exact size and shape of openings, ensuring manufacturing precision while maintaining the ease of creating multiple openings through the initial piercing step
Solution Approach 2:
The patent replaces purely mechanical piercing with a combination of mechanical piercing and stamping processes. The stamping process provides precise dimensional control by applying controlled mechanical deformation to define exact opening sizes, thus resolving the contradiction between ease of creating openings and achieving precise opening dimensions
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 method enables the production of punctured filter plates with precise small openings, enhancing the filtration efficiency while facilitating the recyclability of beverage capsules by eliminating the need for separate filter paper components.
Implementation Method 1
piercing the metal foil to obtain a plurality of openings
Implementation Method 2
stamping at least an area around each opening to reduce the smallest dimension thereof
Implementation Method 3
the punctured filter plate is located at a distance from said base which is equal or larger than a piercing height of the draining member... and wherein said beverage is able to pass through the punctured filter plate
Data Source
Figure 1~2
Figure 3~5
Figure 6~7B
AI summary
A method (100) for manufacturing a punctured filter plate (20) for use in a beverage capsule (10), the method comprising: a) providing (110) a metal foil (30) having a thickness (To ) between 100 µm and 400 pm; b1) piercing (120) the metal foil to obtain a plurality of openings (24) each having a smallest dimension (Dhi ) between 300 µm and 1,5 mm and stamping (135; 140) at least an area around each opening to reduce the smallest dimension thereof to between 25 µm and 300 pm; and c) cutting (130; 145) the metal foil along a predetermined two-dimensional contour to obtain the punctured filter plate.