U.S. patent application number 13/808776 was filed with the patent office on 2013-05-02 for method for producing a beverage-ingredient capsule for the preparation of a beverage and apparatus.
This patent application is currently assigned to NESTEC S.A.. The applicant listed for this patent is Guylann Collet, Alexandre Kollep. Invention is credited to Guylann Collet, Alexandre Kollep.
Application Number | 20130108752 13/808776 |
Document ID | / |
Family ID | 43332510 |
Filed Date | 2013-05-02 |
United States Patent
Application |
20130108752 |
Kind Code |
A1 |
Kollep; Alexandre ; et
al. |
May 2, 2013 |
METHOD FOR PRODUCING A BEVERAGE-INGREDIENT CAPSULE FOR THE
PREPARATION OF A BEVERAGE AND APPARATUS
Abstract
Method for producing a beverage-ingredient capsule (1) for the
preparation of a beverage; the method comprising the steps of:
providing a mould cavity (12), at least partially filling a mould
cavity with the beverage ingredient in powdered or particulate
form, compacting the powdered or particulate beverage ingredient in
the mould cavity to obtain a compacted mass of the beverage
ingredient, forming at least one recess (21) in the compacted mass
and, inserting a capsule identification insert (9) into the said
recess.
Inventors: |
Kollep; Alexandre; (Lutry,
CH) ; Collet; Guylann; (Orbe, CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kollep; Alexandre
Collet; Guylann |
Lutry
Orbe |
|
CH
CH |
|
|
Assignee: |
NESTEC S.A.
Vevey
CH
|
Family ID: |
43332510 |
Appl. No.: |
13/808776 |
Filed: |
June 23, 2011 |
PCT Filed: |
June 23, 2011 |
PCT NO: |
PCT/EP2011/060531 |
371 Date: |
January 7, 2013 |
Current U.S.
Class: |
426/394 ;
425/352; 426/420 |
Current CPC
Class: |
B65B 29/025 20170801;
B65B 61/20 20130101; B30B 11/08 20130101; B30B 15/065 20130101;
B65D 85/8046 20130101; B30B 11/085 20130101; B65B 63/022 20130101;
B30B 11/34 20130101; B65D 2203/10 20130101; B65B 29/06
20130101 |
Class at
Publication: |
426/394 ;
426/420; 425/352 |
International
Class: |
B65B 29/06 20060101
B65B029/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 7, 2010 |
EP |
10168672.3 |
Claims
1. Method for producing a beverage-ingredient capsule for the
preparation of a beverage comprising the steps of: providing a mold
cavity; at least partially filling the mold cavity with a beverage
ingredient in powdered or particulate form; compacting the powdered
or particulate beverage ingredient in the mold cavity to obtain a
compacted mass of the beverage ingredient; forming at least one
recess in the compacted mass; and inserting a capsule
identification insert into the recess.
2. Method according to claim 1, wherein the recess is formed while
the mass of powdered or particulate ingredient is being
compacted.
3. Method according to claim 1, wherein the step of insertion of
the insert is performed after the recess has been formed.
4. Method according to claim 1, wherein the recess is formed by
inserting the insert into the mass of powdered or particulate
beverage ingredient before the compaction step is finished.
5. Method according to claim 1, wherein the filling step is
performed in a single filling operation with the entire amount of
powdered or particulate beverage ingredient mass required for the
capsule.
6. Method according to claim 1, wherein the mold cavity is filled
with less than the entire amount of powdered or particulate
beverage ingredient required for the capsule before inserting the
insert and thereafter feeding into the mold cavity a remainder of
the required amount of powdered or particulate beverage ingredient
for the capsule and further compacting the mass.
7. Method according to claim 1, wherein the compacting step and the
recess forming step are effected by pressing an outer shape forming
surface and a recess forming surface against the mass of powdered
or particulate beverage ingredient.
8. Method according to claim 1, wherein the recess is formed in a
central region of the mass of powdered or particulate beverage
ingredient.
9. Method according to claim 1, wherein the recess is formed with a
flared opening.
10. Method according to claim 1, wherein the insert is an elongate
element.
11. Method according to claim 10, wherein the insert has a
cross-section which is slightly larger than a cross-section of the
recess.
12. Method according to claim 1, wherein the mass of powdered or
particulate beverage ingredient is compacted and formed in the
molding cavity to define two main opposed convex surfaces and a
truncated peripheral edge.
13. Method according to claim 12, wherein after the steps of
compacting, forming the recess and inserting the insert are
completed, the compacted mass is removed from the mold cavity and
loaded into a package comprising a first and second foils covering
the respective main surfaces and the foils are sealed at a
peripheral seam adjacent to the truncated peripheral edge.
14. Method according to claim 13, wherein the package forms a
gas-tight enclosure.
15. Apparatus for implementing a method for preparing a
beverage-ingredient capsule comprising a first mold part and a
second mold part in opposed relation and relatively moveable toward
and away of each other, at least one of the mold parts comprising a
recess-forming member for forming at least one recess in a mass of
powdered or particulate beverage ingredient while the mass is
compacted between the mold parts; and a recess member for
positioning an insert in a recess thus formed in the compacted mass
of powdered or particulate beverage ingredient.
16. Apparatus according to claim 15, comprising another mold part
received around the first and second mold parts for defining a
truncated peripheral edge of the compacted mass of powdered or
particulate beverage ingredient.
Description
[0001] The present invention relates to the manufacturing of a
beverage-ingredient capsule used for preparing a beverage in a
beverage producing device, such as a coffee machine. The method
also relates to an apparatus for implementing the method.
[0002] Beverage producing systems have been developed for many
years on the basis of portioned beverages, in particular, capsules
containing a predetermined dose of beverage ingredient such as
coffee, tea, milk powder and the like. The numerous advantages of
such systems have been widely recognized, in particular, their
convenience of use, clean operations and better controlled quality
of the brewed beverage delivered.
[0003] The term "capsule" is here used to designate packets, pods
or cartridges as well, comprising in general a mass of ingredient
and an outer (removable or non-removable) package.
[0004] Capsules such as coffee pods, wherein the ingredient is
compacted therein, are known, for example, in EP0602203B1. The
capsule can take the form of a flexible sachet containing
individual portions of ingredient powder, e.g., coffee, tea,
soluble coffee, etc. The ingredient powder is compacted to form a
solid cake of powder. The compacted cake of powder is sealed in a
gastight package formed of two flexible foils of circular, oval or
polygonal shape. When hot water is injected through one of the two
foils, the opposite foil is opened under the effect of the increase
of the fluid pressure inside the capsule, such as against
perforating elements of a capsule holder of the beverage
preparation device. Other extraction principles also encompass
capsules which open solely under the effect of inside pressure or
pre-opened before insertion in the device.
[0005] A capsule with a cake of compacted ingredients therein
provides advantages over a capsule with loose ingredients therein.
In particular, a smaller capsule can be produced for providing a
similar quality of beverage, e.g., liquid coffee extract.
Therefore, the capsule uses less packaging material and provides a
reduced volume of waste after brewing. They can be more
conveniently and more economically packaged in large packs, e.g.,
in cardboard containers or flow wrap bags, to reduce shipment costs
and storage space.
[0006] Co-pending European patent application No. 09164590.3
relates to a capsule for the preparation of a beverage comprising a
first and second covering wall (e.g., foil) connected at a
peripheral seam for forming an internal cavity containing a
beverage ingredient and a contactless identifying element for
identifying the capsule by detecting means of a beverage producing
device, wherein the identifying element is placed inside the
ingredient powder. In particular, the identifying element can be an
insert embedding glass-coated metal-alloy wire(s) providing
magnetic characteristics. This invention proposes a capsule
detecting solution, e.g., that provides more freedom on the design
of the capsule, ensures a more reliable signal detection and is
less prone to damage or deterioration of the identifier, e.g.,
during handling of the capsule.
[0007] Another co-pending European patent application No.
09164586.1 relates to a capsule wherein the identifying insert is
oriented along its longest dimension substantially orthogonally
relative to the transversal plane passing along the seam of the
capsule.
[0008] Therefore, there is a need for producing a capsule with an
insert, such as an identification element, precisely and reliably
positioned in the compacted mass of ingredient.
[0009] There is also a need for producing the capsule, in
particular, the compacted mass or cake, at quick pace on the
manufacturing line. One problem of positioning an insert in a
compacted mass of powder comes from the ability to place the insert
in a precisely defined position but also the ability to maintain
this insert in this position during all the steps of production.
Furthermore, the insert should not move in the capsule after its
manufacturing, i.e., before or during its use in the beverage
machine. In case the insert would be an identification element as
in co-pending patent applications No. 09164590.3 and No.
09164586.1, a deviation of the position of the insert in the
capsule would potentially lead to problems of detection of the
insert by the detecting means of the beverage producing device or
other control devices.
[0010] The present invention now fulfils these needs and resolves
essentially all these problems.
[0011] For this, the invention relates to a method according to the
appended independent claim(s). Additional characteristics of the
method and apparatus are present in the appended dependent
claims.
[0012] More particularly, the invention relates to a method for
producing a beverage-ingredient capsule for the preparation of a
beverage; the method comprising the steps of: [0013] providing a
mould cavity, [0014] at least partially filling a mould cavity with
the beverage ingredient in powdered or particulate form, [0015]
compacting the powdered or particulate beverage ingredient in the
mould cavity to obtain a compacted mass of the beverage ingredient,
forming at least one recess in the compacted mass and, inserting a
capsule identification insert into the said recess.
[0016] In a mode, the recess is formed while the mass of powdered
or particulate beverage ingredient is being compacted.
[0017] According to the method of the invention, the forming of the
recess is facilitated. Also the dimensions and shape of the recess
are better geometrically defined. Also, the walls of the recess
become more compact, thereby more solid and less crumbly. As a
result, the insert can be well positioned and its position is more
reliable and less subject to deviation or alteration during placing
and/or once the insert is in place.
[0018] In an embodiment, the filling step is carried out in a
single filling operation with the entire amount of powdered or
particulate beverage ingredient mass required for the capsule.
[0019] The filling of the mould cavity can be done in more than one
operation.
[0020] In another mode, the mould cavity is filled with less than
the entire amount of powdered or particulate beverage ingredient
required for the capsule before inserting the insert and thereafter
feeding into the mould cavity the remainder of the required amount
of powdered or particulate beverage ingredient for the capsule and
further compacting the mass. In this embodiment, the mould cavity
is filled with a partial mass of powdered or particulate ingredient
before insertion of the insert and the mould cavity is filled with
the remainder mass after insertion of the insert.
[0021] In a mode, the step of insertion of the insert is carried
out after a recess dedicated for the insert has been formed. For
example, once the compaction of the ingredient powder is finished,
a recess is left open in the compacted mass which enables placement
of the insert therein. Since the mass is compacted, the recess has
walls, e.g., bottom end and tubular sidewalls that offer a
relatively solid support for the insert thereby ensuring a correct
and reliable position.
[0022] In another mode, the recess is formed by the insert itself
preferably during its insertion in the mass of powdered or
particulate ingredient. In this mode, the operation is simplified
by the use of the insert for forming the recess. Furthermore, the
operation can also comprise leaving the insert in place in the
recess once it is formed by the insert.
[0023] In a method, the compacting step and the recess forming step
are effected by pressing an outer shape forming surface and a
recess forming surface against the mass of powdered or particulate
beverage ingredient.
[0024] More preferably, the outer shape forming surface and the
recess forming surfaces are both part of a portion of a mould,
e.g., a half-mould; such that both surfaces are connected in such a
manner that the two operations applied on the mass of powdered or
particulate ingredient are carried out substantially during a
single pressing stroke applied by the portion of mould, e.g.,
half-mould, onto the powder.
[0025] In a preferred mode, the recess is formed in the central
region of the mass of powdered or particulate beverage ingredient.
The central location of the recess is preferred for many different
reasons. The recess in the centre of the mass provides reduced
risks of damaging the mass and a potentially stronger recess for
receiving the insert. The insert is also better protected in the
centre of the capsule inasmuch as potentially a greater mass of
powdered or particulate ingredient surrounds the insert and
prevents it from moving in the mass when compacted.
[0026] In a particular mode, the outer shape forming surface and
recess forming surface are formed in an upper mould part. The upper
mould part is preferably moved relatively to a lower mould part
containing the powder mass, in the manner of a piston stroke, for
providing powder compaction and for forming the recess at the same
time. The external form, e.g. of the upper mould part,
complementary fits in the cavity of the lower mould part causing
the reduction of the size of the cavity during the stroke and
consequently, compaction of the mass of powder contained
therein.
[0027] The control of the compaction of the powder mass is
generally made by determining the quantity of powdered or
particulate ingredient filled in the cavity and by controlling the
reduced size of the cavity left by the stroke between the two mould
parts. Therefore, a constant compaction is generally obtained by
maintaining the quantity of powder and reduced size of the cavity
constant; all other possible relevant parameters (e.g., powder
grind size, type of powder, etc.) being equal.
[0028] Preferably, no subsequent compacting step is necessary after
said stroke. However, it can also be possible that a later
compacting step of the mass of powdered or particulate ingredient
and/or of capsule itself containing said ingredient, is carried out
by a second stroke to complete the compaction desired or when an
additional filling operation is necessary to complete the content
of the final mass of powder desired for the capsule.
[0029] The compaction of the (partial or full) mass of powder is
usually such that the powdered or particulate ingredient, e.g.,
coffee cake, forms a relatively handleable and solid piece with
limited crumbliness.
[0030] The recess can be formed in any suitable location(s) of the
mass of powdered or particulate beverage ingredient. Also more than
one recess can be formed at the same time in different locations of
the mass. More preferably, the recess is formed in the central
region of the mass of powdered or particulate beverage
ingredient.
[0031] In the preferred method, the recess is formed with a flared
opening. Such opening configuration of the recess takes into
account the tolerance of positioning of the insert by the insert
positioning device (at the operational positioning speed), e.g., an
insert feeder.
[0032] Preferably, the insert is an elongate element. The insert
can be an elongate element which ratio of length-to-diameter is
comprised between 50:1 and 3:1. Preferably, the element is
cylindrical or parallelepiped. More preferably, the insert is an
identification element such as a magnetically responsive, inductive
element or RFID element.
[0033] The insert has a cross-section which is substantially
complementary to the cross-section of the recess. However, slight
cross-sectional variation between the insert and the recess are
tolerated such as if they can help anchoring the insert in the
powder.
[0034] The cross-section of the insert is preferably slightly
larger than the cross section of the recess for tightening the
insert in the recess and therefore avoiding the insert to move
during the subsequent manufacturing operations of the capsule and
during all subsequent handling and use of the capsule. This size
differential is also useful for taking into account the tolerances
between the dimensions of the insert and the dimensions of the
formed recess. For example, the element can be a small rigid stick
of about 5-20 mm long and 0.5-3 mm large with its diameter being
larger by about 0.01 to 0.5 mm the diameter of the recess.
[0035] In a specific mode, the mass of powdered or particulate
beverage ingredient is compacted and formed in the moulding cavity
to define two main opposed convex surfaces and a truncated
peripheral edge.
[0036] After the steps of compacting, forming the recess and
inserting the insert are completed, the compacted mass is removed
from the mould cavity and loaded into a package comprising a first
and second foils covering the respective main surfaces and the
foils are sealed at a peripheral seam adjacent to the truncated
peripheral edge.
[0037] The invention also relates to an apparatus for implementing
the method, as aforementioned, comprising at least a first mould
part and at least a second mould part in opposed relation and
relatively moveable toward and away of each other, at least one of
said mould parts comprising recess-forming means for forming at
least one recess in the mass of powdered or particulate beverage
ingredient while the mass is compacted between the mould parts;
said apparatus comprising recess means for positioning an insert in
the recess thus formed in the compacted mass of powdered or
particulate beverage ingredient.
[0038] The apparatus may further comprise another mould part
received around the first and second mould parts for defining a
truncated peripheral edge of the compacted mass of powdered or
particulate beverage ingredient.
[0039] The invention will be described in more detail in the
description of the figures that follows.
[0040] FIG. 1 is a cross-section view of a capsule for the
preparation of a beverage including an ingredient-powder cake and
an identification insert embedded therein;
[0041] FIG. 2 is a schematic view of an apparatus for producing the
ingredient-powder cake of the capsule of FIG. 1;
[0042] FIGS. 3 to 9 illustrate a first embodiment of the process of
forming the powder cake and placing the insert therein;
[0043] FIG. 3 show the beginning of filling the lower mould portion
with ingredient powder;
[0044] FIG. 4 shows the mould portion when filled with loose
ingredient powder before compaction;
[0045] FIG. 5 shows the punching step in the mould during the
stroke;
[0046] FIG. 6 shows the powder cake with its recess after the
punching step;
[0047] FIG. 7 shows the handling of the insert in the apparatus for
positioning it within the compacted cake;
[0048] FIG. 8 shows the positioning of the insert in the compacted
cake;
[0049] FIG. 9 shows the compacted cake with its insert being
properly placed;
[0050] FIGS. 10 to 17 illustrate a second embodiment of the process
of forming the powder cake and placing the insert therein;
[0051] FIG. 10 shows the beginning of the powder filling operation
with a partial mass of powder in a lower mould portion with
ingredient powder;
[0052] FIG. 11 shows the mould portion when filled with the partial
mass of loose powder just before compaction;
[0053] FIG. 12 shows the compacted partial mass of powder after a
first compaction stroke,
[0054] FIG. 13 shows the positioning of the insert in the partial
compacted mass;
[0055] FIG. 14 shows the second filling operation of the mould
portion with the remaining mass of loose powder to complete the
production of the powder cake;
[0056] FIG. 15 shows the mould portion full with powder and an
insert therein just before compaction;
[0057] FIG. 16 shows the end of the second compaction of the mass
of powder with the insert fully embedded therein during the second
compaction stroke;
[0058] FIG. 17 shows the removal of the capsule from the lower
mould.
[0059] In reference to FIG. 1, the capsule 1 of the invention forms
a package containing ingredient-powder such as roast and ground
coffee powder. The capsule can be sized with powder suitable for
preparing a beverage single or multi-serving. The capsule can be
formed of a first foil 2 and a second foil 3 connected at a
peripheral seam 4 and delimiting an internal cavity filled with
ingredient. The capsule can (but not necessarily) be designed
symmetrically along a plane passing through seam 4. The two foils
may be permeable or impermeable to the liquid. If impermeable to
liquid, the foils 2, 3 can be opened, such as by perforating them,
before or at the time of use in the beverage producing device or
removed before insertion in the device. The foils may further be
impermeable to gas when a gas barrier layer is present, e.g., a
layer of thin aluminium and/or EVOH. The container may further
comprise one or more internal filter layer(s) such as paper
filter(s) for instance. The two foils may also be formed entirely
of filter layers such as a porous paper, porous plastic, porous
aluminium and combinations thereof.
[0060] The two foils 2, 3 connect together at a seam 4 along a
median transversal plane P. The seam can be produced by welding the
two foils together in this region. In a preferred mode, the seam is
preferably resistant to tearing and may be reinforced by additional
layers such as cellulose (e.g. paper), polymeric fibres, plastic,
rubber and the like. The foils can be flexible for facilitating
forming during manufacturing and reducing the amount of packaging
material. The foils can have an inner layer made of a layer
compatible to sealing such as oriented polypropylene (OPP). The
foil may also contain a decorative layer. In a preferred packaging
configuration, each foil is formed of a multi-layer comprising the
following layers (from exterior to interior): PET/decorative
layer/Adhesive/Aluminium/Adhesive/OPP. The aluminium layer has
preferably a thickness between 10 and 100 microns. The OPP (i.e.,
oriented polypropylene) layer has a thickness of between 5 to 50
microns and the PET layer has a thickness of between 5 and 50
microns. The foils could also be formed of filter paper and a
welding layer for the seam or a combination of aluminium, filter
paper and/or plastic.
[0061] The connected foils 2, 3 delimit an internal cavity 5 which
can be at least partially occupied by a powder cake 6 formed of
compacted beverage ingredient. The beverage ingredient can be
ground coffee, soluble coffee, leaf tea, soluble tea, cocoa, milk,
chicory, herbal tea, an infant formula, culinary powder and
combinations thereof. In a preferred embodiment, the ingredient
contains essentially roast and ground coffee powder.
[0062] The beverage ingredient is in compacted form such as
resulting in a solid powder cake. The cake may form a lenticular
section with a truncated peripheral edge 7 substantially axially
oriented. As a result of the edge 7 being present, an annular void
8 is created between the powder and the seam of the outer package.
Such shape is less fragile after compaction and it facilitates
welding of the foils at the seam. Eventually, the cavity may be
placed under partial vacuum before sealing at the seam for
preventing the walls to deform outwardly due to gas release (e.g.,
CO.sub.2) from coffee powder. The resulting general form of the
capsule can be a symmetrical lenticular container of substantially
convex surface on both sides. Of course, other shapes of capsule
can be envisaged which are not symmetrical. For instance, the outer
package of the capsule can comprise a cup-shaped body with a flange
and a membrane connected (e.g., welded) to the flange of the
body.
[0063] An insert 9 is embedded, at least partially in the compacted
cake. By "partially embedded", it is meant that more than 50% of
the surface of the insert is directly in contact or in close
vicinity with the powder without separation by the outer packaging
material (e.g., foils). More preferably, the insert 9 is
substantially fully embedded in the beverage ingredient. By
substantially fully embedded, it means that at least about 90% of
the surface of the insert is directly in contact or in close
vicinity with the powder without separation by the outer packaging
material (e.g., foils). The insert can be an identifying element
which is sensitive to physical excitation by or from an outside
detecting device and/or providing a signal to an outside detecting
device such as by magnetic effect, inductive effect or radio-waves.
In a preferred mode, the identifying element is designed for
enabling detection of the capsule in presence of a magnetic field
produced by a magnetic-field producing device. By
"magnetically-responsive", it is here meant that, in a general
manner, the identifying element (or also referred in short as:
"identifier") has magnetic or ferromagnetic characteristics
corresponding to its specific composition and identifiable, or at
least discriminable, compared to another composition under the
effect of magnetic flux provided by electromagnetic detecting means
(not shown). More particularly, the insert 9 comprises a protective
sheath including one or more glass-coated metallic wires such as
described in co-pending European patent application No.
09164590.3.
[0064] FIG. 2 illustrates an apparatus for producing the
ingredient-powder cake 6. The apparatus comprises a press 10 with a
circular plate 11 including a series of mould portions 12 arranged
in a circumferential pattern in the plate. The press is designed to
produce a plurality of powder cakes at quick pace. The plate is
controlled by a control and driving unit (not shown) to turn
stepwise or in a continuous motion (in rotational direction A). The
press further comprises a series of upper mould portions 13 wherein
each mould portion is arranged to reciprocate up and down relative
to a lower mould portion (along axial direction B) and to engage in
the lower mould portion 12 for compaction of a powder cake.
Preferably, each lower mould portion 12 is thus associated with an
upper mould portion 13 such that the upper and lower mould portions
12, 13 are axially aligned (along axis D) and turn together along a
circular path around a median vertical axis I of the plate and in
direction of rotation A shown. In a known manner `per se`, the
relative axial movement of the upper mould portions 13 is
controlled by a cam path (not illustrated) forcing the portions up
and down as they turn along axis I. As a possible alternative, the
axial movement of the mould portions 13 could also driven by a
mechanism using hydraulic pistons. The press further comprises a
powder feeder 14 for feeding the lower mould portions 12 with
powder as the plate turns. The powder feeder extends across a
portion of the plate 11 in intersection of the lower moulds 12 and
it is arranged to continuously feed the lower mould portions moving
below it with powder. The press further comprises an insert feeder
15 for placing at least one insert in each of the powder cake after
compaction.
[0065] FIG. 3 shows, in cross section, a detail of the press 10
during feeding of powder in the lower mould 12. As the plate 11
moves (e.g., turns) relative to the powder feeder 14, powder 16
falls into the mould portion 12 and progressively fills it. The
cavity 17 is sized to be able to receive a predetermined quantity
of powder (e.g., ground coffee powder) corresponding to the desired
ingredient quantity in the final capsule. When the mould 12 has
passed the powder feeder 14, its cavity is filled with the proper
quantity of powder as illustrated in FIG. 4. The powder is loose in
the cavity and its upper surface has been scraped by the front
surface of the feeder by virtue of the relative movement of the
mould portion relative to the powder feeding portion 14. It should
be noted by the way that the press could move in a linear relative
fashion rather than in a rotary relative fashion as illustrated as
a matter of example.
[0066] As shown in FIG. 5 in the next operation, the powder is
compacted by the upper mould portion 13 lowering and engaging in
the lower mould portion 12 in the manner of a piston-type press.
The upper mould portion comprises an outer forming surface 18 that
is designed to press one of the two extended sides of the compacted
cake whereas the lower mould portion 12 comprises an outer forming
surface 19 designed to press the other extended side. The surfaces
18 and 19 can also be of substantially cup shape. The surfaces 18
or 19 can be of relatively identical design when the resulting
capsule is symmetrical. The degree of compaction of the powder cake
is determined by controlling the relative constant cavity's height,
e.g., "D", between the two moulds. In general, the volume of the
powder is reduced between 10 and 80% of its initial volume in loose
form in the mould. While the compact powder cake is being formed,
at least one recess is being also formed by a recess forming
surface 20 of the mould portion protruding downwards from the upper
mould portion 13, i.e., from its forming surface 18. The recess
forming surface thus forms, in general, at least one protrusion
extending from the outer forming surface 18. For example, the
protrusion 20 extends vertically along the median axis of the
cavity to provide a recess within the mass of powder in a position
aligned with the centre I of the capsule (FIG. 1). Thereby, as the
upper mould portion lowers in the cavity of the lower mould
portion, the recess in the coffee powder is created while the
coffee remains sufficiently loose, so that the mass of powder is
still relatively soft to be introduced by the protrusion.
Furthermore, the compaction by the upper mould 13 on the powder is
exerted while the protrusion 20 remains in place in the coffee
powder thereby solidifying the powder by compaction effect around
the puncher. As a result, the recess is well dimensionally defined
and the walls and edges delimiting the recess become relatively
solid.
[0067] In an alternative, the recess can be formed by a recess
forming means protruding from the lower mould portion 12. In this
case, the upper forming mould portion 13 can be formed as a concave
forming surface 18 without the protrusion 20. The protrusion is
thus affixed to the lower mould portion 12 and protrudes upwardly.
In this case, the protrusion is preferably designed to produce a
through-hole in the mass of powder to ensure an opening on the
upper surface of the compacted mass enabling the insertion of the
insert in the subsequent step. It can also be possible that both
the upper and lower mould portions have a part of the
protrusion.
[0068] As illustrated in FIG. 6 after compaction, the upper mould
portion 13 is disengaged from the lower mould portion 12 thereby
leaving a recess 21 in the compacted cake. The recess 21 may be
formed with a flared opening portion 22 of a few degrees relative
to the median axis I to take into account the precision tolerance
when inserting the insert in the cake in the next operation of
insertion. Preferably, the angle of the opening portion is of about
5-30 degrees relative to median axis I, more preferably of about 10
degrees. The recess may also be formed by a main portion 23 of
tubular or slightly conical shape (e.g., 1-7 degrees relative to
median axis I) to prevent risks of breakage. Furthermore, the
recess is preferably slightly longer than the length of the insert
to be received in or at least of equal length. Also, the main
portion 23 is preferably of slightly smaller cross-section than the
insert to ensure a certain blocking effect on the insert and
consequently prevent risk of variation of its localization once in
place.
[0069] In the next operation shown in FIG. 7, the lower mould
portion 12 is uncovered thereby showing the compacted cake apparent
with its empty recess 21. The insert 9 intended to be placed in the
cake, is handled by a pair of jaws 24 of the insert feeder 15. The
insert is lowered relatively to the compacted cake in axial
direction C causing the insert to be introduced in the recess. The
jaws handle the insert such that a sufficient free length "1" of
the insert can be inserted in the recess while the remaining length
of the insert is firmly held or pinched by the jaws. Preferably,
the free length "1" represents at least 50%, preferably at least
80% of the total length of the insert.
[0070] In the next step as shown in FIG. 8, the insert 9 is pushed
in the recess to take its final position by a pusher 25 that exerts
a pushing action at the opposite end of the insert, e.g., an
axially and downwardly oriented pushing action. During the pushing
action, the insert may still be pinched by the jaws 24 or may be
disengaged from the jaws (as illustrated).
[0071] After this operation, the compacted cake 6 is ejected from
the press by a central part 26 of the lower mould portion moving
upwardly relative to the outer part of the portion to force the
compacted cake out of the mould portion 12 (FIG. 9).
[0072] The compacted cake including the insert is then sealingly
packed between the two foils 2, 3 which are sealed at the
peripheral seam (not shown).
[0073] A second embodiment of the process of the invention is
illustrated in relation to FIGS. 10 to 17. In order to avoid undue
repetitions, only the main differences compared to the first
embodiment will be described whereas the other characteristics and
features of the method and/or apparatus will appear to the skilled
person as applicable to this embodiment For this also, the same
numerical references are used to designate the same or similar
technical means, axis, planes and directions.
[0074] As shown in FIG. 10, in this second embodiment, the press 10
comprises a lower mould portion 12 which is filled with a partial
mass of powder 16 by the powder feeder 14. By "partial mass of
powder" it is meant here that only a part of the total
predetermined amount of powder due for making the final capsule is
filled in a preliminary filling operation. For this, the size of
the cavity 17 of the mould portion 12 is adapted to receive the
partial mass of powder. The size of the cavity can be reduced
compared to the size of the cavity which would be necessary for
receiving the total amount of powder due to produce the final
powder cake. The size reduction of the cavity can be obtained by
different means. In the illustrated example, it is obtained by
providing a size adjustable part 27 of the lower mould portion. The
part 27 can be a central part which is moved relative to a
circumferential part 28 of the lower mould portion until the proper
size of reduced cavity is obtained.
[0075] Once the partial mass of powder is filled as illustrated in
FIG. 11, an upper mould portion 13 is lowered relative to the lower
mould portion 12 to compact the partial mass. The upper mould
portion 13 may not necessarily comprise a recess forming surface
but can simply comprise the outer shape forming surface 18, i.e., a
convex surface, to form one extended side of a partial powder cake.
After this first stroke (FIG. 12), a partial compacted cake of
powder 29 is obtained. The size of the cake is reduced compared to
the final compacted cake to be produced for the capsule.
[0076] In the next operation, the insert is used to provide a
recess in the partial compacted mass. The insert 9 is placed by
means of the insert feeder 15 in this partial compacted cake. It
results that the insert engages only partially in the partial
compacted cake while a portion of the insert remains outside of the
cake 29. As a possible variant, the recess could also be made by a
recess forming surface or protrusion protruding from the surface of
the upper mould portion 13.
[0077] In the next operation, a second powder filling operation
takes place (FIG. 14). The same powder feeder 14 can be used to
complete the filling of the cavity. The cavity can be re-sized to
accommodate the second desired amount of powder necessary to
complete the mass of powder. Then, a second stroke is carried out
by the upper mould portion 13 or another mould portion to form the
outer shape of the final compacted cake (FIGS. 15 and 16). In the
next operation, the final compacted cake 30 is removed, e.g., by
moving the central part 27 upwardly or axial direction A until to
eliminate or reduce the size of the cavity (FIG. 17).
[0078] As discussed, the rotary press described in relation to the
figures is presented as a preferred example, but it could be
replaced by another type of press in which the powder is fed into
the mould portions by effect of a linear movement relative of the
mould portions (or plate containing them) and the powder
feeder.
* * * * *