Three-Ply Nonwoven Filter Capsule for Particle and Foam Control
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Solution Overview
Problem
Existing portion capsules for beverage production often result in undesirable foam formation, such as crema, during the extraction process, particularly for beverages like classic filter coffee, due to the sudden loss of pressure on the filter medium, which contaminates the beverage with fine particles.
Innovation Solution
A portion capsule with a filter element comprising three layers, including a fibrous layer produced by hot air spinning, provides high mechanical stability and air permeability, preventing fine particles from entering the beverage while allowing effective extraction, and is designed to minimize foam formation by maintaining a sealed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a filter medium is used in conventional portion capsules, then beverage substrate particles are filtered, but foam formation occurs due to sudden pressure loss
Solution Approach 1:
The filter element is constructed as a three-ply composite structure combining different nonwoven fabric layers (spunbond and/or meltblown materials) with distinct properties. The outer layers provide mechanical stability and filtration, while the inner layer controls pressure distribution to prevent foam formation, achieving both filtration and foam suppression through material composition
2Object-affected harmful factors
If a filter medium with small pore size is used, then fine particles are filtered effectively, but mechanical stability decreases
Solution Approach 1:
The three-ply composite structure combines layers with different pore sizes and mechanical properties. The outer spunbond layers provide mechanical strength and stability, while the inner meltblown layer with smaller pores provides fine particle filtration. This composite approach allows each layer to fulfill its specific function without compromising the other
Solution Approach 2:
Different regions of the filter element have different properties optimized for their specific functions. The outer layers have larger pores and higher mechanical strength for structural support, while the inner layer has smaller pores for fine particle filtration. This local differentiation allows simultaneous achievement of mechanical stability and effective filtration
3Productivity
If a filter element with high air permeability is used, then extraction efficiency improves, but foam formation increases
Solution Approach 1:
The composite three-ply structure creates a balanced pressure distribution across the filter element. The inner layer with controlled permeability moderates the pressure drop, preventing sudden pressure loss that causes foaming, while the overall structure maintains sufficient air permeability for efficient extraction of beverage substances
Data Source
AI summary
The invention relates to a portion capsule for producing a beverage, having a capsule body with a capsule base and a filling side. A cavity for receiving a pulverulent or liquid beverage substrate is formed between the capsule base and the filling side, and a filter element is arranged between the beverage substrate and the capsule base. The filter element comprises an open-pore felt and/or nonwoven fabric, and the felt and/or nonwoven fabric has a first average pore size in a first region facing the beverage substrate and a second average pore size in a second region facing the capsule base, said first pore size being smaller than the second pore size.