Multilayer frustoconical filter structure

A reusable multilayer filter for use with a beverage brewing apparatus, said multilayer filter comprising:

• a frustoconically shaped foraminous support layer, said foraminous support layer having an inside surface, an outside surface and a multiplicity of spaced apart bores extending from said inside surface to said outside surface;
• a porous mesh layer overlying said inside surface of said frustoconicaly shaped foraminous support layer, said porous mesh layer being attached to said foraminous support layer in areas surrounding said bores, said foraminous support layer having a multiplicity of pores extending therethrough, said pores in said porous mesh layer having a smaller diameter than said bores in said foraminous support layer for retaining materials having dimensions larger than said pores;
• and
• a multiplicity of dimples in said porous mesh layer, each of said dimples being disposed within a corresponding area defined by a perimeter of a corresponding one of said bores of said foraminous layer, said dimples projecting inwardly into said bores of said foraminous support layer for increasing the effective internal surface area of said multilayer filter.

A method of forming a reusable multilayer filter for use with a beverage brewing apparatus, said method comprising the steps of:

• providing a support layer and a mesh layer;
• forming a multiplicity of spaced part bores through said support layer;
• positioning said mesh layer over said support layer;
• attaching said mesh layer to one side of said support layer;
• deforming said support layer and attached mesh layer for forming a concave body of a desired filter shape with said mesh layer attached to an inside surface of said support layer and for forming dimples in said mesh material in areas defined by a perimeter of said spaced apart bores, said dimples effectively increasing the internal surface area of said concave multilayer filter.