Portion capsule for the praparation of a beverage and process to produce such a beverage by using said capsule
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Solution Overview
Problem
Existing portion capsules with sieve arrangements face challenges such as increased manufacturing costs, clogging issues due to small sieve holes, and the need for additional support elements to handle high brewing pressures.
Innovation Solution
The use of a simple and cost-effective filter fleece or felt as the filter screen, which eliminates the need for complex plastic injection molding processes and support structures, while providing a larger liquid inlet surface and enabling transverse liquid flow for better mixing and drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small sieve holes are used to retain coffee particles, then particle retention is improved, but the sieve becomes clogged at high pressures
Solution Approach 1:
The patent applies porous materials by using a filter fleece with controlled pore structure instead of traditional solid sieves with small holes. The porous nature of the fleece allows it to retain coffee particles while maintaining open pathways for liquid flow, preventing clogging even at high brewing pressures up to 20 bar.
Solution Approach 2:
The patent uses composite materials by combining the filter fleece with a support structure (such as a mesh or grid) that provides mechanical strength. This composite arrangement allows the fleece to perform filtration while the support structure prevents deformation and maintains stability under high pressure conditions.
2Manufacturing precision
If small sieve holes are used to retain coffee particles, then particle retention is improved, but manufacturing costs increase due to complex injection molding processes
Solution Approach 1:
The patent applies disposable objects by using a filter fleece that can be easily manufactured and disposed of after single use. The fleece is made from inexpensive materials and can be produced through simple cutting or forming processes rather than complex injection molding, significantly reducing manufacturing costs while maintaining adequate filtration performance.
Solution Approach 2:
The patent applies parameter changes by transitioning from solid sieve materials with small holes to fibrous fleece materials with controlled pore sizes. This change in material parameters allows for simpler manufacturing processes while achieving the required particle retention through the natural pore structure of the fleece rather than precisely molded holes.
3Manufacturing precision
If traditional sieves are used, then particle retention is achieved, but additional support elements are required to handle high brewing pressures
Solution Approach 1:
The patent applies flexible shells and thin films by using a filter fleece that is both flexible and structurally sound. The fleece can conform to the capsule base shape while maintaining its filtration function, and when combined with a lightweight support mesh, it provides sufficient structural integrity to handle high brewing pressures without requiring bulky support elements.
4Manufacturing precision
If sieve arrangements with small holes are used, then particle retention is improved, but the liquid inlet surface area is reduced
Solution Approach 1:
The patent applies porous materials by using a filter fleece with high porosity that allows large portions of the surface area to remain open for liquid flow. The porous structure provides numerous small pathways distributed across the entire surface, maintaining both particle retention and adequate liquid inlet surface area, unlike solid sieves that block large portions of the surface.
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 filter fleece significantly reduces manufacturing costs, prevents clogging, maintains reliable cross-flow of liquids, and forms a crema on beverages like espresso, while ensuring the beverage substrate is well retained during preparation.
Implementation Method 1
a filter element is arranged between the beverage substrate and the capsule base
Implementation Method 2
the preparation liquid flows through the beverage substrate and extracts and/or dissolves the substances required for beverage production from the beverage substrate
Implementation Method 3
the preparation liquid flows through the beverage substrate and extracts and/or dissolves the substances required for beverage production from the beverage substrate
Implementation Method 4
a brewing water pressure of up to 20 bar acts on the coffee powder to extract the essential oils. This pressure also acts on the particle sieve located between the coffee powder and the capsule base
Data Source
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Figure 8~9
AI summary
Disclosed is a single-serve capsule for preparing a beverage, comprising a capsule member that includes a capsule bottom and a filling end, a cavity being formed between the capsule bottom and the filling end for holding a powdery or liquid beverage substrate. A filter element is placed between the beverage substrate and the capsule bottom, said filter element comprising a nonwoven fabric which is placed in the region of the capsule bottom.