Thin-Walled Beverage Capsule with Protected Internal Filtration
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Solution Overview
Problem
Existing beverage capsules face issues with high wall thickness due to pressure resistance requirements, leading to increased costs, reduced chamber size, limited manufacturing methods, uneven water distribution, and contamination risks from needle interaction with filters.
Innovation Solution
A capsule design with a thin frustum-shaped body made of compostable plastic, featuring a smooth side wall, internal circumferential reinforcement, and a filter structure that prevents needle contact with the filter, ensuring uniform water distribution and contamination prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wall thickness of the cup-shaped body is increased to withstand pressurized water, then the capsule can resist pressure stresses, but the cost increases and the chamber dimensions are reduced
Solution Approach 1:
The patent applies local quality by implementing circumferential reinforcement ribs at specific locations on the cup-shaped body where pressure stress is highest, rather than uniformly thickening the entire wall. This allows the chamber to maintain its volume while providing targeted strength enhancement at critical stress points.
Solution Approach 2:
The patent uses composite materials by combining a thin-walled cup-shaped body made from cost-effective material with reinforcing elements (ribs or internal structures) that provide additional strength. This composite approach allows the main body to remain thin and economical while the reinforcement elements provide the necessary pressure resistance.
2Strength
If the wall thickness is increased to withstand pressure, then the capsule can resist stress, but the manufacturing methods are limited
Solution Approach 1:
The patent segments the cup-shaped body into a main thin-walled portion and separate reinforcement elements (circumferential ribs). This segmentation allows the main body to be manufactured using flexible thin-wall techniques while the reinforcement elements can be added through separate manufacturing steps or molding processes, thus maintaining manufacturing flexibility.
Solution Approach 2:
By localizing reinforcement to specific circumferential regions rather than uniformly thickening the entire wall, the patent maintains compatibility with various manufacturing methods including injection molding and thermoforming, which struggle with uniformly thick walls. The localized ribs can be integrated into molds without requiring complex thickness control throughout the entire part.
3Power
If injection needles pierce the blind bottom to inject water, then water can be injected under pressure, but preferential channels form causing uneven water distribution
Solution Approach 1:
The patent segments the water injection process by providing multiple injection needles distributed around the circumference of the blind bottom, rather than a single needle. This segmentation of injection points creates multiple flow paths that distribute water more uniformly across the chamber, preventing the formation of preferential channels.
Solution Approach 2:
The patent transitions from a single-point (0D) or linear (1D) injection approach to a distributed circumferential (2D) injection pattern. By arranging multiple injection needles around the circumference, the water distribution moves from concentrated flow paths to a more uniform two-dimensional distribution pattern.
4Reliability
If the filter is placed at the blind bottom near injection needles, then filtration is achieved, but the needle may contact and pierce or displace the filter causing contamination
Solution Approach 1:
The patent introduces an intermediary structure (such as a filter holder or positioning element) between the injection needle and the filter. This intermediary component maintains the filter in its correct position and prevents direct contact between the needle and filter, thereby preventing needle displacement or piercing of the filter while maintaining filtration functionality.
Solution Approach 2:
The patent segments the filter assembly from the blind bottom by providing a separate filter holder or mounting structure. This segmentation allows the filter to be positioned and secured independently, preventing it from being displaced by needle insertion while maintaining its filtration function.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A capsule (1) for preparing a beverage by injection, within said capsule, of a fluid under pressure, comprising: a cup-shaped body (2), which in turn comprises a side wall (3) which is substantially frustum-shaped and delimits an opening (6) and a blind bottom (4), and a membrane for closing the opening (6) of the cup-shaped body (2) in order to delimit a containment chamber (7) configured to contain a food substance for preparing the beverage; an internal filter (17) being proximate to the blind bottom (4), the internal filter (17) comprising a bottom wall (18) which comprises a substantially circular central region (18A), the central region (18A) being arranged in contact with the blind bottom (4) of the capsule and being surrounded by a circumferential distribution groove (19) which is open toward the blind bottom (4).