Universal Coffee Capsule with Non-Woven Filter
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Solution Overview
Problem
Current coffee capsules are not compatible with multiple dispensing machines, as they require specific filters for different products (coffee powder, soluble, and leaf products), leading to issues like residue release, filter breakage, and maintenance challenges, making it costly to produce and maintain filters for each type.
Innovation Solution
A single-body coffee capsule with a non-woven fabric filter, supported by evenly distributed spacers, which is compatible with various machines and maintains filter integrity under pressure, ensuring effective dissolution of soluble products and prevention of residue release, while maintaining high tensile strength and resistance to flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single filter design is used for all products (coffee powder, soluble, leaf products), then manufacturing cost is reduced, but product performance deteriorates because each product type requires specific filter characteristics
Solution Approach 1:
The patent applies universality by designing a single filter structure that can handle multiple product types (coffee powder, soluble products, and leaf products). The filter comprises a support layer and a filtering layer with specific permeability characteristics that work effectively for all three product types, eliminating the need for separate filter designs for each product category.
Solution Approach 2:
The patent utilizes parameter changes by carefully selecting the permeability coefficient of the filtering layer (between 10^-10 and 10^-12 m²) and the thickness ratio between support layer and filtering layer (between 0.1 and 0.5). These parameter optimizations allow the single filter design to achieve satisfactory performance across different product types while maintaining manufacturing simplicity.
2Ease of manufacture
If the filter is placed close to the bottom for easy manufacturing, then manufacturing simplicity increases, but the filter breaks under flow pressure causing product release
Solution Approach 1:
The patent applies dimensionality change by introducing a two-layer filter structure with different functional layers. The support layer provides mechanical strength while the filtering layer provides filtration function. This dimensional separation of functions allows the filter to maintain structural integrity under flow pressure while remaining manufacturable.
Solution Approach 2:
The patent uses composite materials by combining a support layer (made of thermoplastic resin) with a filtering layer (made of porous material). This composite structure provides both the mechanical strength needed to resist flow pressure and the filtration capability required for product performance, solving the contradiction between manufacturability and structural integrity.
3Ease of operation
If opening devices penetrate deeply to open the capsule, then opening effectiveness improves, but the filter is damaged and product is released
Solution Approach 1:
The patent applies the nested doll principle by creating a stepped structure where the filter assembly is nested within the capsule body at a specific height. The filter support layer extends upward to form a protective barrier that prevents opening devices from directly contacting and damaging the filtering layer, while still allowing effective capsule opening.
Solution Approach 2:
The patent implements beforehand cushioning by designing the filter support layer to protrude above the bottom surface of the capsule. This protruding support structure acts as a protective cushion that intercepts opening devices before they can reach and damage the filtering layer, ensuring filter integrity while maintaining opening effectiveness.
4Productivity
If the filter has high permeability for fast flow, then dispensing speed improves, but the filter breaks under pressure
Solution Approach 1:
The patent applies segmentation by dividing the filter into two distinct layers: a support layer that provides mechanical strength and a filtering layer that provides filtration and controlled permeability. The support layer bears the mechanical load from flow pressure while the filtering layer maintains the desired permeability for fast dispensing, allowing both high productivity and filter strength to be achieved simultaneously.
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 capsule achieves compatibility with multiple machines, reduces maintenance costs, and ensures consistent performance across different coffee types, maintaining high outlet temperature and preventing uncontrolled spurts, with a filter that resists breakage and maintains permeability even under high pressures.
Implementation Method 1
the material the filter is made of is a material which has a tensile strength higher than that of the usual filter paper with the same grammage
Implementation Method 2
said filter is distanced from the bottom by a series of evenly distanced spacers
Implementation Method 3
whose permeability is between 250 and 1500 l/m²/h
Implementation Method 4
a non-woven fabric filter on the inside of the capsule near the bottom, whose grammage is between 40 and 200 gr/sq.m and whose thickness is between 0.1 and 0.9 mm
Implementation Method 5
provides, right from the first supply (and especially of Italian coffee, namely coffee delivered in 30-40 seconds), a high outlet temperature
Data Source
AI summary
The capsule that is the object of this invention is, because of its configuration with an outlet opening for the product exposed beyond the bottom and because of the way it is made with a specific non-woven fabric filter with special characteristics, a capsule that adapts well to coffee, soluble products and leaf products, and which is also compatible with numerous dispensing machines.