Portion Capsule with Deep-Drawn Non-Woven Filter to Reduce Clogging
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Solution Overview
Problem
Existing portion capsules with filter elements produced by plastic injection moulding or deep drawing face issues such as clogging and high manufacturing costs due to the need for small sieve holes to retain coffee particles and additional support structures to prevent deformation under brewing pressure.
Innovation Solution
A portion capsule with a filter element made from deep-drawn non-woven plastic fabric, which provides a larger filter area, reduces clogging risk, and maintains liquid flow efficiency under both low and high pressures, using a mesh or felt structure with specific mass density and air permeability for optimal extraction and mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter elements are produced by plastic injection moulding or deep drawing with small sieve holes to retain coffee particles, then particle retention is improved, but clogging occurs and manufacturing cost increases
Solution Approach 1:
The patent employs a porous sintered plastic filter element instead of traditional injection-moulded or deep-drawn filters with small sieve holes. The sintered structure provides interconnected pores that allow liquid flow while retaining coffee particles, preventing clogging by maintaining open pathways for beverage extraction.
Solution Approach 2:
The filter element is made from composite material consisting of sintered plastic particles, combining the benefits of plastic durability with porous structure. This composite approach enables both particle retention and sustained liquid permeability without the clogging issues of conventional filters.
2Reliability
If small sieve holes are used in filter elements to retain coffee particles, then particle retention is improved, but manufacturing cost increases due to additional support structures
Solution Approach 1:
The sintered plastic filter element inherently provides structural support through its porous matrix, eliminating the need for additional support structures required by conventional filters with small sieve holes. This reduces manufacturing complexity and cost while maintaining particle retention capability.
Solution Approach 2:
The sintered composite structure integrates filtering and support functions into a single element, reducing the number of components and assembly steps required, thereby lowering manufacturing cost.
3Productivity
If filter area is increased to improve extraction efficiency, then beverage extraction is improved, but device complexity increases with additional support structures
Solution Approach 1:
The porous sintered filter element provides large surface area for extraction throughout its volume, not just at the surface. The three-dimensional porous structure allows simultaneous extraction across the entire filter area without requiring additional support structures.
Solution Approach 2:
The filter element transitions from a two-dimensional surface filter to a three-dimensional porous structure, increasing the effective filter area and extraction surface without adding structural complexity. The porous volume provides extensive extraction surface area within the same footprint.
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 deep-drawn non-woven filter element is cost-effective, clog-resistant, and ensures efficient beverage extraction and mixing while maintaining aroma-tight sealing, reducing manufacturing costs and improving brewing efficiency.
Implementation Method 1
a filter element (7) which is made from non-woven fibre material... the filter element is deep-drawn... ensures efficient beverage extraction and mixing while maintaining aroma-tight sealing
Data Source
AI summary
A portion capsule for producing a beverage. The portion capsule includes a capsule body that has a collar edge and a capsule bottom; a filter element located inside of the capsule body, the filter element is elastic, the filter element has a flange that is attached to the collar edge of the capsule body, the filter element has a bottom; and a cover attached to the capsule body. The bottom of the filter element is spaced apart from the capsule bottom such that a free space remains between the filter element and the capsule bottom. The filter element is spaced apart from the capsule bottom in such a manner that only before a liquid is applied to a beverage substrate, does the filter element not touch the capsule bottom.