Portion Capsule Non-Woven Filter for Clog-Resistant Beverage Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing portion capsules for beverage production face issues with screen blockages and increased production costs due to the use of plastic injection molding or thermoforming processes, which require additional material and complex manufacturing steps, leading to higher costs and inefficient liquid flow.
Innovation Solution
A portion capsule with a filter element made of non-woven material, such as fine plastic fibers or felt structures, which is directly supported on the capsule base, eliminating the need for complex manufacturing processes and providing improved liquid flow and resistance to blockage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screens are produced using plastic injection molding or thermoforming processes, then the screens can retain coffee particles, but the production costs rise and additional material is required
Solution Approach 1:
The patent employs a disposable paper filter instead of expensive reusable plastic screens. The paper filter is inexpensive, single-use, and disposed of after one brewing cycle, eliminating the need for costly injection molded or thermoformed plastic screens while maintaining particle retention functionality.
Solution Approach 2:
The patent uses a paper filter with controlled porosity to retain coffee particles while allowing liquid to pass through. The porous structure of the paper provides effective filtration without requiring the complex manufacturing processes needed for plastic screens with precisely controlled hole sizes.
2Strength
If supporting elements are added beneath screens to absorb brewing water pressures, then screen deformation is prevented, but additional material and production costs increase
Solution Approach 1:
The disposable paper filter is designed to withstand brewing pressures of up to 20 bar without requiring additional supporting elements. The filter's inherent strength is sufficient for single-use applications, eliminating the need for extra reinforcement structures and associated production costs.
Solution Approach 2:
The porous paper structure distributes brewing water pressure across its entire surface area, preventing localized deformation or failure. This natural pressure distribution mechanism eliminates the need for additional supporting elements that would be required with solid plastic screens.
3Reliability
If screens with small holes are used to retain particles, then coffee particles are retained, but liquid flow efficiency decreases
Solution Approach 1:
The paper filter's porous structure provides an optimal balance between particle retention and liquid flow efficiency. The interconnected porous network allows liquid to flow through rapidly while effectively capturing coffee particles, superior to plastic screens with small holes that create flow resistance.
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 non-woven filter element reduces production costs, prevents blockages, and ensures efficient liquid mixing and outflow, while maintaining the formation of 'crema' in beverages like espresso, with the added benefit of being resistant to high pressures and easy to integrate into the capsule design.
Implementation Method 1
a filter element being arranged between the beverage base and the capsule base, and with the filter element comprising a non-woven which is arranged in the region of the capsule base
Data Source
AI summary
A method for producing a beverage using a portion capsule is proposed. The portion capsule includes a capsule body with a capsule base and a cover, a cavity for accommodating a pulverulent or beverage base being formed between the capsule base and the cover, and a filter element being arranged between the beverage base and the capsule base. The filter element includes a non-woven having a felt structure such that no crema is formed on the beverage. The method includes providing the portion capsule in a first method step, perforating the capsule base by means of an external perforation means in a second method step, and at least partially spacing the filter element apart from the capsule base in a third method step.