U.S. patent application number 14/411963 was filed with the patent office on 2015-08-13 for method and apparatus for fabricating a beverage capsule.
The applicant listed for this patent is Nestec S.A.. Invention is credited to Abdenour Djamer, Paul Eichler, Christian Guenat, Ulrich Kessler, Patricia Ann Mathias, Celine Sarrazin-Horisberger, Olivier Villain, Martin Von Blittersdorff.
Application Number | 20150225099 14/411963 |
Document ID | / |
Family ID | 48670587 |
Filed Date | 2015-08-13 |
United States Patent
Application |
20150225099 |
Kind Code |
A1 |
Villain; Olivier ; et
al. |
August 13, 2015 |
Method and Apparatus for Fabricating a Beverage Capsule
Abstract
A method for fabricating a beverage capsule comprises the steps
of providing a first wall member (103) delimiting a cavity (106)
and having a flange (109) disposed about an open end (108)
communicating with said cavity (106), providing a quantity of
edible granules (107) within said cavity (106), positioning a
second wall member (112) upon said flange (109) and said open end
(108) of said first wall member (103), attaching said second wall
member (112) to said flange (109) at at least two regions of said
flange (109) thereby dividing the flange (109) circumferentially
into at least two attached regions and at least two unattached
regions, applying a vacuum (119) between said first and second wall
members (103, 112) creating a vacuum (119) within said cavity
(106), and sealing said first and second wall members (103, 112)
along said flange (109), thereby maintaining said vacuum (119)
within said cavity (106).
Inventors: |
Villain; Olivier;
(Grandvaux, CH) ; Mathias; Patricia Ann; (Blonay,
CH) ; Eichler; Paul; (Arnex-sur-Orbe, CH) ;
Sarrazin-Horisberger; Celine; (Suchy, CH) ; Von
Blittersdorff; Martin; (Lausanne, CH) ; Djamer;
Abdenour; (Lausanne, CH) ; Kessler; Ulrich;
(Savigny, CH) ; Guenat; Christian; (L'Auberson,
CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nestec S.A. |
Vevey |
|
CH |
|
|
Family ID: |
48670587 |
Appl. No.: |
14/411963 |
Filed: |
June 25, 2013 |
PCT Filed: |
June 25, 2013 |
PCT NO: |
PCT/EP2013/063174 |
371 Date: |
December 30, 2014 |
Current U.S.
Class: |
426/115 ; 53/433;
53/511 |
Current CPC
Class: |
B65B 7/164 20130101;
B65B 29/022 20170801; B65B 31/04 20130101; B65D 85/8043
20130101 |
International
Class: |
B65B 31/04 20060101
B65B031/04; B65B 29/02 20060101 B65B029/02; B65B 1/04 20060101
B65B001/04; B65B 51/22 20060101 B65B051/22; B65D 85/804 20060101
B65D085/804; B65B 1/02 20060101 B65B001/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 4, 2012 |
EP |
12174912.1 |
Claims
1. A method for fabricating a beverage capsule, comprising the
steps of: providing a first wall member, said first wall member at
least partially delimiting a cavity and having a flange disposed
circumferentially about an open end communicating with said cavity;
providing a quantity of edible granules within said cavity of said
first wall member; positioning a second wall member upon said
flange and said open end of said first wall member; attaching said
second wall member to said flange at at least two regions of said
flange, thereby dividing the flange circumferentially into at least
two attached regions and at least two unattached regions; applying
a vacuum between said first and second wall members, thereby
evacuating the gas from within said cavity and said edible granules
through said at least two unattached regions of the flange and
creating a vacuum within said cavity; and sealing said first and
second wall members along said flange, thereby maintaining said
vacuum within said cavity.
2. The method of claim 1, wherein: the second wall member is
attached to said flange at a plurality of regions of said flange,
thereby dividing the flange circumferentially into a plurality of
attached regions and a plurality of unattached regions, and the
vacuum is applied between said first and second wall members,
thereby evacuating the gas from within said cavity and said edible
granules through said plurality of unattached regions of the
flange, thereby creating a vacuum in said cavity.
3. The method of claim 1, wherein said first wall member is a
self-supporting capsule body and said second wall member is a
flexible membrane.
4. The method of claim 1, wherein the steps for attaching and
sealing said second wall member onto said flange are performed by
heat sealing.
5. The method of claim 1, wherein the steps for attaching and
sealing said second wall member onto said flange are performed by
ultrasonic welding.
6. The method of claim 1, wherein the second wall member is
attached to said flange over an attachment area comprising between
25% and 90% of the total sealed surface of said flange of said
first wall member.
7. The method of claim 1, wherein the edible granules are provided
within the cavity in loose form.
8. The method of claim 1, wherein the application of vacuum and
sealing while maintaining the vacuum within the cavity are carried
out immediately after the attaching of the second wall member to
the flange and dividing the flange into the at least two or a
plurality of attached and unattached regions.
9. A beverage capsule fabricated by the method of claim 1.
10. An apparatus for the fabrication of a beverage capsule,
comprising: an attachment means, said attachment means being
configured to attach a first wall member to a second wall member at
a flange disposed circumferentially about an open end of said first
wall member, said attachment means being situated over at least two
regions of said flange and thereby dividing the flange into at
least two attached regions and at least two unattached regions,
said first wall member at least partially delimiting a cavity in
communication with said open end and being provided with a quantity
of edible granules within said cavity; a vacuum application means,
said vacuum application means being provided with a receptacle
adapted for airtight communication with said first and second wall
member, and being further configured to evacuate the gas from said
first wall member and edible granules through the at least two
unattached regions of the flange, thereby creating a vacuum within
said cavity; and a sealing means, said sealing means being
configured so as to create a seal between said first and second
wall members along said flange, thereby maintaining said vacuum
within said cavity.
11. The apparatus of claim 10, wherein: a. the attachment means
attaches said second wall member to said flange over a plurality of
regions of the flange, thereby dividing the flange into a plurality
of attached regions and a plurality of unattached regions; and b.
the vacuum application means is configured to evacuate the gas from
said first wall member and edible granules through the plurality of
unattached regions of the flange.
12. The apparatus of claim 11, wherein said attachment means
comprises a plurality of faces disposed perpendicular to and in
radial symmetry about an axis of said attachment means, and which
are configured to attach said second wall member to said flange of
said first wall member over a plurality of regions corresponding to
said plurality of faces.
13. The apparatus of claim 10, wherein said vacuum-application
means and said sealing means are disposed coaxially about a
longitudinal axis, said vacuum-application means being adapted to
translate along said longitudinal axis relative to said sealing
means.
14. The apparatus of claim 10, further comprising a means for
cutting said second wall member to substantially match the outline
of said flange and open end of said first wall member.
15. The apparatus of claim 14, wherein said means for cutting said
second wall member is disposed about said attachment means, said
attachment means and means for cutting said second wall member
being coaxial about a longitudinal axis, and said means for cutting
said second wall member being adapted to translate along said
longitudinal axis relative to said attachment means.
Description
CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE
STATEMENT
[0001] This application is a US national stage application filed
under 35 USC .sctn.371 of International Application No.
PCT/EP2013/063174, filed Jun. 25, 2013; which claims benefit of EP
Application No. 12174912.1, filed Jul. 4, 2012. The entire contents
of the above-referenced applications are hereby expressly
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The presently disclosed and/or claimed inventive concept(s)
relates generally to a method for the fabrication of a beverage
capsule for use in a beverage machine. It also relates to an
apparatus for performing said method, as well as the beverage
capsules so produced. In particular, the presently disclosed and/or
claimed inventive concept(s) relates to such capsules as adapted
for coffee beverage.
BACKGROUND
[0003] It is known in the art to package perishable food products
in sealed packages or containers. This excludes air and moisture
from the unopened container, improving the shelf life and flavor of
the products within. This method is especially advantageous for
packaging roasted coffee.
[0004] The roasting process is what produces the characteristic
flavor of coffee by causing the green coffee beans to expand and to
change in color, aroma, and density. The oils and aromatic
volatiles contained and/or developed during roasting confer the
aroma and flavor of the coffee beverage produced therefrom, but are
also prone to degradation when exposed to the oxygen in the
surrounding air. Packaging coffee in sealed containers will protect
it from the surrounding air, resulting in greater shelf life and
optimal flavor and aroma during consumption.
[0005] Recently, it has been common to package coffee and other
such beverage ingredients in single-serving capsules, adapted for
use in a beverage system which prepares a beverage on demand from
such capsules. These capsules contain a pre-portioned amount of a
beverage ingredient or ingredients in the form of finely-textured
edible granules. Such beverage capsules may be hermetically-sealed,
preventing degradation of the beverage ingredient(s) within prior
to consumption.
[0006] While this document is primarily concerned with beverage
capsules containing roasted coffee, it is understood that other
alimentary substances may be used in such capsules. By way of
non-limiting example, such edible granules may comprise ground
roasted coffee, soluble coffee, powdered milk, powdered cocoa,
loose tea leaves and/or other herbs, broth, or any combination
thereof.
[0007] To prepare the beverage, the beverage capsule is placed into
the beverage production machine, which introduces hot water into
the beverage capsule and dispenses the resulting beverage into a
container for consumption. While this document refers to a
"capsule," it is understood that other terms, such as "pod,"
"cartridge," or "packet," may be employed instead.
[0008] To offer further protection of the edible granules from
degradation prior to consumption, it is also known to seal beverage
capsules under modified atmosphere (e.g. an atmosphere saturated
with nitrogen or carbon dioxide) or under vacuum. In particular, a
vacuum may be applied to the capsule when the capsule is filled
with a beverage ingredient to remove the air from within. The
beverage capsule is formed of gas-tight packaging materials and
hermetically sealed to preserve the vacuum therein. In this way,
any oxygen present in the capsule is removed prior to sealing and
the edible granules are thus protected from degradation prior to
consumption.
[0009] However, sealing a beverage capsule by vacuum-sealing
introduces additional complications. Since the edible granules are
generally of small size and light weight, the application of a
vacuum may suck them from the capsule. Such edible granules may be
aspirated into the vacuum-application means, causing damage to and
increasing maintenance costs of the vacuum-sealing apparatus.
[0010] The edible granules may also become entrained between the
sealing walls of the capsule, e.g. between the body and the capsule
sealing means, preventing the latter from being properly bonded to
the former. This compromises the strength and aesthetic quality of
the beverage capsule seal, and by extension the protection of the
edible granules within the seal of the beverage capsule.
[0011] The entrainment of edible granules may also result in
tearing of the seal of the beverage capsule due to the pressure
increase within the capsule during the beverage preparation
process. This can result in the rupture of the capsule and the
liberation of wet coffee powder through the broken seal, soiling
the beverage machine and producing a foul-tasting beverage.
[0012] The sealing of a beverage capsule under vacuum containing
ground coffee is known in the art, for example in the U.S. Pat. No.
5,472,719 and also in European patent EP 1 866 942. The latter
document discloses a beverage capsule containing a quantity of
coffee, which has been compressed into a tablet, reducing the size
of the capsule and obviating the need for a filter therein. A
vacuum is created within the capsule and the capsule is sealed by a
flexible lid, thereby preventing degradation of the coffee tablet
within.
[0013] WO2008129350 refers to a machine for packaging capsules also
in a vacuum and/or in a controlled atmosphere. After filling with
coffee, the capsules are partially closed by hermetic film. Then, a
vacuum is formed inside the capsules and sealed by a thermo-sealing
vacuum device.
[0014] U.S. Pat. No. 3,775,932 refers to a packaging apparatus for
making vacuum packages of a product by sealing of two superimposed
films together with the product contained therebetween. A vacuum is
drawn by a vacuum tube connection in the partially sealed package
whereby the edge of the packaging film is captured between the
sealing head and a resilient strip with the edge of the
superimposed film being free.
[0015] WO2010007633 refers to a machine for packaging products, in
particular capsules for machines for delivering infusion beverages.
A vacuum bell provides vacuum around each capsule to be welded. At
the same time, vacuum compensating means take care of inserting
gas, in particular nitrogen, inside each capsule in such a way to
compensate the presence of vacuum. Afterwards, the welding means
take care of welding the aluminium sheet onto the edge of the
respective capsule.
[0016] U.S. Pat. No. 4,069,349 refers to a process for vacuum
packaging of roasted ground coffee in pouches. The pouches are
partially sealed, with a tortuous unsealed passage, and then stored
for a predetermined period of time to permit the gases to evolve
from the pouches and then sealing the pouches to prevent further
gaseous passage to and from the product.
[0017] The prior art references do not, however, resolve the
problem of aspiration and entrainment of the edible granules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] This is advantageous in that the two means may be disposed
so that the attachment means is within the means for cutting the
second wall member. This conserves space in the apparatus,
effectively placing the two components in the space of one. The
vacuum application and sealing means may be adapted to act upon the
first and second wall members simultaneously, thereby reducing the
time required to carry out the attachment and cutting steps. This
feature will thereby improve the output and efficiency of the
apparatus, while simultaneously making it more compact and
space-efficient.
[0019] Other particularities and advantages of the presently
disclosed and/or claimed inventive concept(s) will also emerge from
the following description.
[0020] In the accompanying drawings, given by way of non-limiting
examples:
[0021] FIG. 1 is a series of orthogonal section views depicting an
attachment means, a cutting means, a vacuum-application means, and
a sealing means;
[0022] FIG. 2 is a series of views of attachment apparatuses in
four different configurations; and
[0023] FIG. 3 is a flowchart depicting the method of the presently
disclosed and/or claimed inventive concept(s) as integrated into a
process for the fabrication of beverage capsules, said process
comprising a series of steps.
DETAILED DESCRIPTION
[0024] Therefore, the presently disclosed and/or claimed inventive
concept(s) includes a method for the fabrication of beverage
capsules in which edible granules may be sealed under vacuum within
a beverage capsule, while reducing or eliminating the aspiration of
such edible granules and thereby producing a seal of high
integrity.
[0025] According, therefore, a first aspect of the presently
disclosed and/or claimed inventive concept(s) is directed to a
method for fabricating a beverage capsule, comprising the steps of
providing a first wall member, said first wall member at least
partially delimiting a cavity and having a flange disposed
circumferentially about an open end communicating with said cavity;
providing a quantity of edible granules within said cavity of said
first wall member; positioning a second wall member upon said
flange and said open end of said first wall member; attaching said
second wall member to said flange at at least two regions of said
flange, thereby dividing the flange circumferentially into at least
two attached regions and at least two unattached regions; applying
a vacuum between said first and second wall members, thereby
evacuating the gas from within said cavity and said edible granules
through said at least two unattached regions of the flange and
creating a vacuum within said cavity; and sealing said first and
second wall members along said flange, thereby maintaining said
vacuum within said cavity.
[0026] The attachment of the second wall member to the flange of
the first wall member along at least two regions prevents the
second wall member from moving in any direction along the flange
when a vacuum is applied. This is advantageous because the
attachment of the second wall member to at least two regions of the
flange of the first wall member will reduce or eliminate the
aspiration of edible granules during the application of the vacuum.
This also prevents the second wall member from being displaced
(e.g. moved off-center), deformed, or folded prior to the sealing
step, preventing the formation of wrinkles, creases, plies, or
other undesirable forms in the second wall member. As a result, it
is possible to produce capsules at a faster pace on the production
line while guaranteeing the quality with a high vacuum level.
[0027] According to a feature, the second wall member is attached
to said flange at a plurality of regions of said flange, thereby
dividing the flange circumferentially into a plurality of attached
regions and a plurality of unattached regions; and the vacuum is
applied between said first and second wall members, thereby
evacuating the gas from within said cavity and said edible granules
through said plurality of unattached regions of the flange, thereby
creating a vacuum in said cavity.
[0028] The term "plurality" in the present context means more than
two.
[0029] This is advantageous because the attachment of the second
wall member to a plurality of regions of the flange of the first
wall member will reduce or eliminate the aspiration of edible
granules during the application of the vacuum. Particularly, the
attached regions prevent the edible granules from leaving the
capsule. However, the gas within the cavity and edible granules may
still be removed, as it may still flow through the spaces between
the flange and the second wall member at the unattached
regions.
[0030] Thus, since the edible granules may be confined to the first
wall member during the application of the vacuum, the quantity of
such edible granules which are aspirated into the vacuum-sealing
apparatus is greatly reduced. The amount of damage the edible
granules cause to the sealing and vacuum means of the apparatus,
and the consequent maintenance and repair costs, are reduced or
eliminated. The performance of this method is thereby rendered more
cost-effective and reliable, while the quality of the beverage
capsules so produced is simultaneously improved.
[0031] The entrainment of edible granules between the second wall
member and the flange of the first wall member is similarly reduced
or eliminated. Since the edible granules no longer interfere with
the interface between the wall members, the strength and aesthetic
quality of the seal between the two are improved. The physical
properties of the beverage capsule are thus optimized, providing
more effective protection to the edible granules and better
preserving the flavor and aroma of the beverage produced from
them.
[0032] Finally, the method permits the above-mentioned advantages
to be realized while providing vacuum and sealing the beverage
capsules individually. The attachment of the second wall member to
the flange of the first wall member prior to the application of a
vacuum and the sealing of the beverage capsule permits a vacuum to
be rapidly applied while still maintaining a high level of strength
and aesthetic quality in the sealed beverage capsules. Since the
vacuum is applied only to one beverage capsule at a time, the
sealing of each beverage capsule may be individually monitored and
controlled. The sealing process may thus be made adaptable so that
each capsule is given a seal of the highest possible quality. In
this way, the efficiency of the method is maximized while
simultaneously ensuring that the beverage capsules so fabricated
are of the highest possible quality.
[0033] According to another feature, the method is characterized in
that said first wall member is a self-supporting capsule body and
said second wall member is a flexible membrane.
[0034] This is advantageous in that first and second wall members
in the form of a self-supporting capsule body and a flexible
membrane facilitate the provision of coffee within the capsule body
and the sealing of the membrane upon the flange. Also, a
self-supporting capsule body will give structural strength to the
unsealed beverage capsule, facilitating handling during the
manufacturing process. The advantages of the presently disclosed
and/or claimed inventive concept(s) may be realized with a minimum
of effort and expense.
[0035] According to another feature, the steps for attaching and
sealing said second wall member onto said flange are performed by
heat sealing.
[0036] This is advantageous in that heat sealing processes can
rapidly produce seals which are generally airtight, durable,
flexible, and sanitary. Heat-sealing means may also be integrated
into an apparatus embodying this method, such as by the
incorporation of hot air jets, electric resistance heaters, or the
like. Heat sealing processes may also be adapted to work with a
variety of materials, improving the compatibility of this
method.
[0037] Furthermore, the bonds created between the second wall
member and the flange of the first wall member during the
attachment step will be substantially identical to the seal created
during the sealing step. This results in a seal which is uniform
across its entire surface, without any areas of diminished strength
or other undesirable variations. Moreover, this feature is
advantageous in that the first and second wall members need only be
suitable for a single type of bonding process rather than two
types, increasing the selection of possible materials for the
components of the beverage capsule. This feature, therefore, makes
the presently disclosed and/or claimed inventive concept(s) simpler
and easier to practice while producing improved results.
[0038] In a possible alternative, the steps for attaching and
sealing of said second wall member onto said flange are performed
by ultrasonic welding.
[0039] This is advantageous in that, as with heat sealing,
ultrasonic welding can rapidly produce seals which are generally
airtight, durable, flexible, and sanitary. Ultrasonic welding is
also advantageous in that it does not require the first and second
wall members to be heated in order to create the seal, permitting
these components to be fabricated from materials which may not be
suitable for heat sealing. The versatility of the presently
disclosed and/or claimed inventive concept(s) is thereby
improved.
[0040] According to still another feature, the second wall member
is attached to said flange over an area comprising between 25% and
90%, such as but not limited to, between 30% and 75% of the total
sealed surface of said flange of said first wall member.
[0041] This is advantageous in that attaching the second wall
member to the flange over the ranges given above will permit the
vacuum to be applied with maximum speed and minimal aspiration of
the edible granules within the beverage capsule. As a result, the
efficiency and cost-effectiveness of the method are improved.
[0042] According to still another feature, the edible granules are
provided within the cavity in loose form.
[0043] This is advantageous in that providing the edible granules
in this way eliminates the need for compacting the edible granules
within the beverage capsule. Instead, the edible granules are
simply inserted into the cavity and sealed therein, without
requiring any time for compacting them or additional apparatus for
doing so. In this way, the process is rendered faster, more
efficient, and more economical
[0044] According to still another feature, the application of
vacuum and sealing while maintaining the vacuum within the cavity
are carried out immediately after the attaching of the second wall
member to the flange and dividing the flange into the at least two
or a plurality of attached and unattached regions. By
"immediately", it is meant that there is no pause higher than a few
seconds allowing the edible granule to significantly loose gas and
consequently aroma.
[0045] According to a second aspect, the presently disclosed and/or
claimed inventive concept(s) is directed to a beverage capsule
fabricated as described above.
[0046] This is advantageous in that a beverage capsule so
fabricated will embody the advantages of the presently disclosed
and/or claimed inventive concept(s) as detailed above.
[0047] According to a third aspect, the presently disclosed and/or
claimed inventive concept(s) is directed to an apparatus for the
fabrication of a beverage capsule, comprising an attachment means,
said attachment means being configured to attach a first wall
member to a second wall member at a flange disposed
circumferentially about an open end of said first wall member, said
attachment being situated over at least two regions of said flange
and thereby dividing the flange into at least two attached regions
and at least two unattached regions, said first wall member at
least partially delimiting a cavity in communication with said open
end and being provided with a quantity of edible granules within
said cavity; a vacuum application means, said vacuum application
means being provided with a receptacle adapted for airtight
communication with said first and second wall members, and being
further configured to evacuate the gas from said first wall member
and edible granules through the at least two unattached regions of
the flange, thereby creating a vacuum within said cavity; and a
sealing means, said sealing means being configured so as to create
a seal between said first and second wall members along said
flange, thereby maintaining said vacuum within said cavity.
[0048] This is advantageous in that such an apparatus embodies the
method for fabricating a beverage capsule described above. The
advantages of the presently disclosed and/or claimed inventive
concept(s) are thereby embodied in beverage capsules whose
production is rendered more efficient, adaptive, consistent, and
economical.
[0049] In a particular, non-limiting embodiment, the first wall
member is a self-supporting capsule body defining said cavity and
said flange and the second wall member is a flexible membrane. The
membrane may have a thickness comprised between 10 and 250 microns,
such as but not limited to, between 30 and 100 microns. The
membrane contains at least one layer fabricated from a material
having gas barrier properties, such as aluminum. In particular,
non-limiting embodiments, the membrane also comprises a sealant
layer comprised of a material such as polypropylene.
[0050] According to a feature, the apparatus is characterized in
that the attachment means attaches said second wall member to said
flange over a plurality of regions of the flange, thereby dividing
the flange into a plurality of attached regions and a plurality of
unattached regions and the vacuum application means is configured
to evacuate the gas from said first wall member and edible granules
through the at least one unattached region of the flange.
[0051] The term "plurality" in the present context means more than
two.
[0052] This is advantageous in that it permits one to optimize the
attachment and vacuum-application means, as described above.
[0053] According to another feature, the attachment means comprises
a plurality of faces disposed perpendicular to and in radial
symmetry about an axis of said attachment means, and which are
configured to attach said second wall member to said flange of said
first wall member over a plurality of regions corresponding to said
plurality of faces.
[0054] This is advantageous in that such an attachment means will
attach the second wall member to the flange of the first wall
member over a uniform, symmetric pattern, thereby providing a
plurality of equally symmetric and uniform unattached regions. The
resulting attachment will be thus rendered more uniform and
reliable. This further reduces the aspiration and entrainment of
the edible granules during the application of the vacuum, and
produces beverage capsules having further improved seal quality.
The efficiency and cost-effectiveness of the apparatus are thereby
improved.
[0055] According to another feature, said vacuum-application means
and said sealing means are disposed coaxially about a longitudinal
axis, said vacuum-generating means being adapted to translate along
said longitudinal axis relative to said sealing means.
[0056] This is advantageous in that the sealing means may be
disposed within the vacuum application means. This conserves space
in the apparatus, effectively placing the two means in the space of
one. This is also advantageous in that the steps for vacuum
application and sealing may be performed simultaneously as
described above. This feature will thereby improve the output and
efficiency of the apparatus, while simultaneously making it more
compact and space-efficient.
[0057] According to still another feature, the apparatus further
comprises a means for cutting said second wall member to
substantially match the outline of said flange and open end of said
first wall member.
[0058] This is advantageous in that it permits the material from
which the second wall member is fabricated to be provided in bulk
form, such as a sheet or ribbon, thereby facilitating the handling
of said second wall member and reducing the overall complexity of
the apparatus. Furthermore, cutting said second wall member to
substantially match the outline of said flange and open end of said
first wall member will result in a second wall member which does
not have to be trimmed after the fabrication of the beverage
capsule. This eliminates the need for additional means for
trimming. In this way, the efficiency and speed of the presently
disclosed and/or claimed inventive concept(s) may be improved.
[0059] According to still another feature, said means for cutting
said second wall member is disposed about said attachment means,
said attachment means and means for cutting said second wall member
being coaxial about a longitudinal axis, and said cutting means
being adapted to translate along said longitudinal axis relative to
said sealing means.
[0060] The following description will be given with reference to
the above-mentioned figures.
[0061] FIG. 1 is a sequence of section views depicting the sealing
of a beverage capsule according to the presently disclosed and/or
claimed inventive concept(s). FIG. 1 depicts the attachment and
cutting steps in views A through D, and the vacuum application and
sealing steps in views E through H. Portions of the apparatus are
omitted from each of these views for purposes of clarity.
[0062] View A depicts an attachment means 100 and a cutting means
101 disposed in a first position, prior to the start of an
attachment step. The attachment means 100 and the cutting means 101
are generally tubular and coaxial about the first longitudinal axis
102. In particular, non-limiting embodiments, the cutting means 101
will be disposed around and capable of translation relative to the
attachment means 100, as depicted here.
[0063] A capsule body 103 is positioned within the base plate 104,
which is provided with a capsule seat 105 in which the capsule body
103 is positioned. In particular, non-limiting embodiments, the
base plate 104 is configured to be mobile, facilitating a high rate
of production of beverage capsules. This mobile configuration may
comprise such means as a conveyor belt system or rotating turret,
for example. In a particular, non-limiting embodiment, the capsule
body 103 is positioned beneath the attachment means 100 and cutting
means 101 so as to be coaxial with them about the first
longitudinal axis 102.
[0064] The capsule body 103 defines a cavity 106, in which a
predetermined quantity of ground coffee powder 107 is provided. The
capsule body 103 is substantially cup-shaped, and is provided with
an open end 108 communicating with said cavity 106. The capsule
body 103 is further provided with a flange 109, disposed about the
circumference of the capsule body 103 at the open end 108.
[0065] In particular, non-limiting embodiments, the capsule body
103 is fabricated from a formable material such as aluminum,
plastic, starch, cardboard, or combination thereof. Where the
capsule body itself is not gas-impermeable, a gas barrier layer may
be incorporated therein to prevent the entry of oxygen. The gas
barrier may comprise a coating, film, or layer of aluminum,
ethylene vinyl alcohol, polyamide, oxides of aluminum or silicon,
or combinations thereof.
[0066] For example, in one embodiment, the capsule body 103 is
formed of deep-drawn aluminum. In another embodiment, the capsule
body 103 is formed of deep-drawn polypropylene and aluminum. In a
third embodiment, the capsule body 103 is thermoformed from a
combination of polypropylene, ethylene vinyl alcohol, and
polyethylene terephthalate.
[0067] In a particular, non-limiting embodiment, the flange 109 and
the capsule seat 105 are configured so that the capsule body 103
protrudes through the base plate 104, with the flange 109 resting
directly on the base plate 104 and substantially the entire
beverage capsule 103 being disposed beneath the base plate 104. In
an alternate configuration, the capsule seat may be configured as a
cup, in which the capsule body is seated.
[0068] A portion of membrane material 110 is disposed between the
cutting means 101 and the base plate 104. In particular,
non-limiting embodiments, said membrane material 110 is provided in
the form of a continuous sheet or web, which may be fed into the
apparatus by techniques adapted from those known in the art of
materials handling. In particular, non-limiting embodiments, the
membrane material 110 is flexible, permitting moderate elastic
deformation. The membrane material 110 may have a thickness between
10 and 250 microns, such as but not limited to, between 30 and 100
microns.
[0069] In a particular, non-limiting embodiment, the membrane
material 110 comprises at least a base layer fabricated of
aluminum, polyester (e.g. PET or PLA), polyolefin(s), polyamide,
starch, paper, or any combination thereof. In particular,
non-limiting embodiments, the base layer is formed of a laminate
comprising two or more sub-layers of these materials. The base
layer may comprise a sub-layer which acts as a gas barrier, if none
of the other sub-layers are of a material which is impermeable to
gas. The gas barrier sub-layer is fabricated from a gas-impermeable
material such as aluminum, ethylene vinyl alcohol, polyamide,
oxides of aluminum or silicon, or combinations thereof. In
particular, non-limiting embodiments, the membrane material 110
also comprises a sealant layer, e.g. polypropylene, disposed to
create a seal with the capsule body 103.
[0070] For example, in one embodiment the membrane material 110 is
an aluminum layer between 25 and 40 microns. In another embodiment,
the membrane material 110 comprises a base layer with two
sub-layers: an external sub-layer made of PET and an internal
sub-layer made of aluminum. The aluminum sub-layer serves the
function of preventing undesirable transmission of light, moisture,
and oxygen. In another embodiment, the membrane material 110
comprises three sub-layers: an external sub-layer of PET 5 to 50
microns thick, a middle sub-layer of aluminum 5 to 20 microns
thick, and an internal sub-layer of cast polypropylene 5 to 50
microns thick.
[0071] View B depicts the apparatus in a second position, during a
cutting step. The cutting means 101 is advanced downward along the
first longitudinal axis 102 into the membrane material 110. In a
particular, non-limiting embodiment, the cutting means 101 is
sharpened along its peripheral edge 111 so as to cut the membrane
material 110 when pressed into it. However, alternate
configurations, such as a hot-knife apparatus, may be preferable
for certain compositions of heat-sensitive membrane material. The
cutting means 101 is advanced through the membrane material 110,
cutting a membrane 112 from the membrane material 110.
[0072] View C depicts the apparatus in a third position, during an
attachment step. At the lower end 113 of the attachment means 100
are disposed a plurality of faces disposed substantially
perpendicular to the longitudinal axis 102, which are pressed into
the membrane 112. The attachment means 100 is advanced so that the
lower end 113 presses the membrane 112 into the flange 109 over a
plurality of regions corresponding to the aforementioned faces.
[0073] The attachment means 100 is configured to attach the
membrane 112 to the flange 109 over the regions where the faces of
the lower end 113 press said membrane 112 into the flange 109 of
the capsule body 103. In the present embodiment, the attachment of
the membrane 112 to the flange 109 of the capsule body 103 is
achieved by heat-sealing; though in other, non-limiting
embodiments, alternate techniques such as ultrasonic welding may be
preferred.
[0074] In particular, non-limiting embodiments, the attachment
means 100 is therefore furnished with appropriate means for
attaching the membrane 112 to the flange 109 during the attachment
step. For example, such means may comprise an electrical resistance
heater, hot air jet, or ultrasonic welding horn. This will make the
apparatus more compact and space-efficient.
[0075] Said regions of the flange 109 corresponding to the faces of
the lower end 113 of the attachment means 100 will comprise a
portion of the total surface of the flange 109. The cavity 106 of
the capsule body 103 thereby remains in communication with the
surrounding atmosphere, via the spaces between the flange 109 and
the membrane 112 where the membrane 112 remains unattached to the
flange 109.
[0076] View D depicts the apparatus in a fourth position, after the
completion of the attachment step. The attachment means 100 and
cutting means 101 are withdrawn from the capsule body 103 and
membrane 112. The scrap membrane material 110 may be removed, while
the base plate 104 is advanced in direction 114 to both place the
current beverage capsule in position for vacuum sealing and bring
the next beverage capsule into position for the attachment and
cutting steps.
[0077] In particular, non-limiting embodiments, the step for
cutting the membrane 112 as depicted in View B and the step for
attaching said membrane 112 to the flange 109 as depicted in View C
are performed sequentially but in a continuous movement of descent
of the cutting and attachment means 101, 100. A slight vacuum is
further applied through the attachment means to maintain the
membrane 112 in coaxial position in axis 102 during the cutting and
attachment steps. This is advantageous, in that it minimizes the
time to fabricate a capsule and thus increases the rate at which
capsules are produced.
[0078] View E depicts the apparatus in a fifth position, prior to
the start of a sealing step. The cutting and attachment means
depicted in the previous steps are omitted here for clarity;
however, the cutting and attachment means are ideally disposed
adjacent or in close proximity to the vacuum-application means 115
and sealing means 116, making the apparatus more compact and
space-efficient.
[0079] In a particular, non-limiting embodiment, the
vacuum-application means 115 and the sealing means 116 are tubular
and disposed coaxially about the second longitudinal axis 117. The
sealing means 116 is in the form of a hollow cylinder, of
approximately the same width and diameter of the flange 109 of the
beverage capsule 103. The vacuum-application means 115 is also in
the form of a hollow cylinder, and is provided with a means for
creating a vacuum within. In particular, non-limiting embodiments,
the vacuum-application means 115 is configured so as to be capable
of translation relative to the sealing means 116 along their shared
second longitudinal axis 117.
[0080] The base plate 104 is advanced in the direction 114 until
the capsule body 103 and membrane 112 are also coaxial with the
vacuum-application means 115 and the sealing means 116 about the
second longitudinal axis 117. The capsule body 103 and membrane 112
are thus positioned in a centered position directly below the
vacuum-application means 115 and sealing means 116.
[0081] View F depicts the apparatus in a sixth position, during a
vacuum-application step. The vacuum-application means 115 have been
advanced so as to create an airtight seal between the mouth 118 of
the vacuum-application means 115 and the flange 109 of the capsule
body 103. A vacuum 119 is applied to the capsule body 103 through
the vacuum-application means 115, reducing the pressure in the
cavity 106 of the capsule body 103 below atmospheric pressure.
[0082] The vacuum 119 causes the gas within the cavity 106 of the
capsule body 103 to be drawn out through the plurality of spaces
between the flange 109 and the membrane 112, which are defined by
the regions where said membrane 112 remains unattached to said
flange 109. The gas can be air or any inert gas, such as nitrogen,
CO.sub.2, or any combination thereof. In this way, the cavity 106
of the capsule body 107 is voided of gas and a vacuum created
within it.
[0083] In particular, non-limiting embodiments, the
vacuum-application step is configured so that the vacuum may be
rapidly applied to the capsule body 103 while avoiding sucking the
coffee powder 107 from the cavity 106. It is known that the rapid
application of a vacuum to a beverage capsule may cause some of the
coffee powder within to be sucked out, which may result in damage
to the apparatus from aspirated coffee powder. The coffee powder
may also become entrained between the sealing surfaces of the
beverage capsule, weakening the seal and diminishing its aesthetic
properties. The application of vacuum may also cause the sealing
means to move, further compromising seal integrity.
[0084] Here, the attachment of the membrane 112 to the flange 109
of the capsule body 103 over a plurality of regions will prevents
the aspiration and entrainment of the coffee powder 107 between the
flange 109 and the membrane 112, as well as prevent the
displacement of the membrane relative to the capsule body during
the application of the vacuum 119. The integrity of the beverage
capsule seal and the reliability of the sealing apparatus are thus
preserved even when the vacuum is applied very rapidly, permitting
higher-quality beverage capsules to be produced at a faster
rate.
[0085] In particular, non-limiting embodiments, the
vacuum-application step is also configured to enable the conditions
within the capsule to be monitored as the vacuum 119 is applied.
Specifically, the vacuum-application means permits the rapid
application of the vacuum 119 to a single capsule body 103, rather
than the slower application of a vacuum to a group of capsule
bodies in a vacuum chamber. Thus, by use of data collection and/or
control-loop methods known in the art, one may continually adapt
the parameters of the vacuum-sealing process to optimize the
sealing of each capsule while still maintaining an overall high
rate of production.
[0086] View G depicts the apparatus in a seventh position, during a
sealing step. The mouth 118 of the vacuum-application means 115 is
kept in contact with the flange 109 of the capsule body 103, such
that the vacuum within the cavity 106 of the capsule body 103 is
maintained.
[0087] In particular, non-limiting embodiments, the sealing means
116 is provided with a means for creating a seal between the
membrane 119 and the flange 109 of the capsule body 103, similar to
the attachment means as discussed above. As with the attachment
means, this may comprise such means as an electrical resistance
heater, hot-air jets, or ultrasonic welding horn.
[0088] The sealing means 116 is advanced into contact with the
membrane 112, pressing into it along the sealing edge 120 disposed
at an end of said sealing means 116. The membrane 112 is pressed
into the flange 109 by the sealing means 116, thereby bonding the
remaining unattached regions of the membrane 112 to the surface of
the flange 109 and sealing the cavity 106 of the capsule body 103.
While the remaining unattached regions of the membrane are bonded,
the bond of the attached regions created during the attachment step
may be renewed. The air-tight hermetic seal created between the
flange 109 and the membrane 112 will thereby preserve the vacuum in
the cavity 106 of the capsule body 103, protecting the coffee
powder 107 from exposure to air and subsequent loss of flavor and
aroma.
[0089] View H depicts the sealed beverage capsule after the
completion of the sealing step. The sealing means 116 is withdrawn
to allow the bond to solidify. Then the vacuum is stopped in the
vacuum means, exposing the capsule body 103 and membrane 112 to
atmospheric pressure and causing the membrane 112 to take a concave
form as depicted. Finally, the vacuum-application means 115 is
withdrawn. The vacuum which was applied to the capsule body 103 in
an earlier step is preserved therein by the seal between the flange
109 and the membrane 112. The base plate 104 is then moved off in
direction 114, removing the capsule to be packaged and distributed
and bringing the next capsule into position for vacuum sealing.
[0090] In addition to the benefits realized by the presently
disclosed and/or claimed inventive concept(s) as discussed above,
an additional benefit is realized when, as in this embodiment, the
edible granules are of a substance that tends to evolve a gas. Such
substances notably include roasted coffee, especially ground
roasted coffee powder as described here.
[0091] As a result of chemical processes triggered by the roasting
process, the coffee powder 107 will evolve gas for a period of time
after the roasting process is completed, a process known in the art
as "degassing." As the coffee powder 107 within the beverage
capsule degasses, the gases which are evolved are kept within the
cavity 106 of the beverage capsule by the membrane 112, the capsule
body 103, and the hermetic seal between them.
[0092] This accumulation of evolved gases will cause the pressure
within the beverage capsule to increase until equilibrium pressure
is reached. At equilibrium, there will be a positive pressure
within the beverage capsule, i.e. a pressure above the atmospheric
pressure, causing the membrane 112 to be deflected outwardly.
[0093] The vacuum which is sealed into the beverage capsule thus
partially offsets the pressure generated by the gases evolved from
the coffee powder 107. The degree to which the vacuum offsets the
evolved gases may vary from embodiment to embodiment, depending on
the volume of the beverage capsule, the mass of coffee provided
within, and the type and degree of roast of the coffee powder
itself. In any case, the vacuum within the beverage capsule
compensates for the degassing at least to the extent that the
evolved gas is prevented from compromising the structural integrity
of the beverage capsule and its hermetic properties.
[0094] In a particular, non-limiting embodiment, the initial vacuum
pressure of the capsule immediately after the sealing step will be
between 300 and 600 mbar, such as but not limited to, between 400
and 500 mbar. After the beverage capsule is sealed, the gases
evolved by the coffee powder during degassing will continue to
accumulate in the cavity 106 of the beverage capsule, causing the
internal pressure of the beverage capsule to rise above atmospheric
pressure in approximately 5 hours and reach equilibrium at between
1050 and 1600 mbar, such as but not limited to, between 1050 and
1350 mbar, in approximately 72 hours.
[0095] Additionally, the method may be configured so that all, or
substantially all, of the degassing occurs within the beverage
capsule after it has been sealed. While the pressure within the
beverage capsule will be negative at time of sealing, the evolved
gases will rapidly increase the pressure within the capsules. In a
particular, non-limiting embodiment, the capsule will rise above
atmospheric pressure in less than 5 hours and stabilize in
approximately 72 hours.
[0096] FIG. 2 is a series of views depicting several configurations
for the attachment means. As discussed above, the attachment means
comprises at its bottom end a plurality of faces, which are pressed
into the membrane to attach it to the flange of the capsule body
over a plurality of regions corresponding to said faces.
[0097] FIG. 2A and 2B depict an orthogonal view and a perspective
view, respectively, of an attachment means 200. As previously
discussed, the attachment means 200 is substantially in the form of
a hollow cylinder. Two slots 201 have been provided in the
attachment means 200, with the result that the end of the
attachment means 200 is divided into two faces 202 and two voids
203.
[0098] When pressed into a membrane during the attachment step as
described above, the membrane will be attached to a flange of a
capsule body over the portion of the surface of the flange
corresponding to the faces 202 of a first kind. The membrane will
remain unattached and permit fluid communication between the cavity
of the capsule body and the surrounding atmosphere through the
unattached regions between the membrane and flange defined by the
voids 203 of a first kind.
[0099] FIG. 2C depicts an orthogonal view of an alternate
configuration for the attachment means, comprising four faces 204
of a second kind and four voids 205 of a second kind. Such an
attachment means will attach a membrane to a flange of a capsule
body over a plurality of regions corresponding to each of the four
faces 204 of a second kind, while leaving the regions of the
membrane corresponding to the four voids 205 of a second kind
unattached.
[0100] FIG. 2D depicts an orthogonal view of another alternate
configuration for the attachment means, provided with eight faces
206 of a third kind and separated by eight voids 207 of a third
kind. As above, the faces 206 of a third kind will define the
region over which a membrane is attached to the flange of a capsule
body, and the voids 207 of a third kind defining where it is
unattached.
[0101] FIG. 2E depicts an orthogonal view of another alternate
configuration for the attachment means, provided with eight faces
208 of a fourth kind which are separated by eight voids 209 of a
fourth kind. Compared to the attachment means depicted in FIG. 2D,
the faces 208 of a fourth kind are much smaller than the faces 206
of a third kind, while the voids 209 of a fourth kind are much
larger than the voids 207 of a third kind. As a result, the
proportion of the flange of a capsule body to which a membrane will
be attached by the attachment device in FIG. 2E is much lower than
would be achieved by the attachment device of FIG. 2D, with a
corresponding increase in the size of the regions of the flange to
which the membrane remains unattached.
[0102] The attachment devices may in this way be configured to best
suit the particular application in which the attachment device is
to be employed. In the foregoing embodiments the attachment devices
are altered by adjusting their number and size; however, in other
embodiments it may be advantageous to modify other elements of
their form and geometry such as shape, thickness, or placement
about the lower end of the attachment means.
[0103] In this way, one may configure the attachment means to
reduce the time required to apply the vacuum to the capsule body
while still minimizing the aspiration and entrainment of the coffee
powder or other edible granules contained within the capsule body.
The sealing of the beverage capsules may thus be optimized to
achieve a maximum output at a minimum cost.
[0104] FIG. 3 is a flowchart depicting a process for the
fabrication of beverage capsules, said operation comprising a
series of elements. The first step of the operation is Capsule Body
Destacking 300. The empty capsule bodies are generally stored
stacked atop each other when stored before use, and so must be
separated before they can be further processed. In the step for
Capsule Body Destacking 300, the capsule bodies are separated from
each other and placed in the proper orientation to continue in the
process.
[0105] Simultaneously, the Coffee Preparation Process 301 furnishes
a supply of coffee powder for packaging within the beverage
capsules. In the Coffee Preparation Process 301, coffee beans are
roasted to the desired degree of roasting and then ground to the
desired degree of fineness.
[0106] As discussed above, the gases generated within the coffee
beans during roasting are evolved from the coffee. Some degassing
will occur between the roasting of the coffee and the sealing of
the beverage capsule. In certain particular, non-limiting
embodiments, it is preferable, however, to configure the process
for fabrication of beverage capsules to minimize degassing outside
of the capsule, so that the degassing essentially occurs after the
beverage capsule has been sealed. In a particular, non-limiting
embodiment, the duration between the grinding of the coffee and its
provision within the beverage capsule is less than ten minutes; in
this way the flavor and aroma of the beverage ultimately produced
from the beverage capsule is best preserved.
[0107] Furthermore, since the coffee is not degassed before the
sealing process, the infrastructure required to degas the coffee
beforehand is no longer necessary. This renders the beverage
capsule sealing operation more compact, economical, and
flexible.
[0108] During Product Filling & Densifying 302, a portion of
the coffee powder provided by the Coffee Preparation Process 301 is
placed within the capsule body and densified, so that the coffee is
settled within the capsule body and the amount of gas therein is so
minimized. In an alternate embodiment, the beverage powder may be
compacted into a tablet during the Coffee Preparation Process 301
step, which is then positioned in the capsule body during the step
of Product Filling & Densifying 302.
[0109] Ideally, each element of the operation is linked by a step
for Transport 303, where the capsule body is transferred between
the devices for carrying out each element of the operation. In
addition, it is understood that the elements for carrying out each
of the elements of the process may be located in proximity to each
other, or even integrated into each other, so that the time
required for transporting the beverage capsule between elements is
minimized. The process is thereby rendered more space-efficient and
economical.
[0110] After this is Membrane Attachment and Cutting 305, as
depicted in Views A-D of FIG. 1. In this step, the membrane is
attached to the flange of the capsule body at a plurality of
regions of the flange, leaving a plurality of unsealed regions on
said flange as well. The membrane is also cut to a size which will
cover the flange and open end of the capsule body.
[0111] Following Membrane Attachment & Cutting 305 is Vacuum
Application & Sealing 306, depicted in FIG. 1, Views E-H. A
vacuum is applied to the capsule body, removing the gas from within
through the plurality of unsealed regions of the flange. The
membrane is then sealed over the entirety of the surface of the
flange, preserving the vacuum within the capsule.
[0112] In beverage capsules containing roasted, ground coffee as
shown here, it is particularly advantageous that the vacuum within
the capsule is a reduction of pressure high enough to offset the
pressure generated by the gases evolved by the coffee as it
degasses in the capsule. A normally configured beverage capsule
will so resist the pressure accumulated within the sealed capsule
as a result of the evolved gases.
[0113] Finally, the capsule is transferred to Distribution 308,
where it may be packaged in a box, sleeve, bag, or the like and
distributed for sale.
[0114] Of course, the presently disclosed and/or claimed inventive
concept(s) is not limited to the embodiments described above and in
the accompanying drawings. Modifications remain possible,
particularly as to the construction of the various elements or by
substitution of technical equivalents, without thereby departing
from the scope of protection of the presently disclosed and/or
claimed inventive concept(s).
[0115] In particular, it should be understood that the presently
disclosed and/or claimed inventive concept(s) may be adapted to
fabricate beverage capsules for the preparation of various kinds of
alimentary substances, for example broth, cocoa, coffee, infant
formula, milk, tea, tisane or any combination thereof. It should
also be understood that the edible granules comprising said
alimentary substances may be provided in various forms and sizes,
such as flakes, grains, granules, pellets, powders, shreds, or any
combination thereof. While the particular embodiment of the
preceding description is directed to a beverage capsule containing
a quantity of roasted, powdered coffee, it should not be construed
as limiting the scope of the presently disclosed and/or claimed
inventive concept(s) to beverage capsules so configured.
[0116] Furthermore, while the embodiments depicted in the
accompanying figures depict an attachment means which is configured
to attach a membrane to a flange of a capsule body over a plurality
of regions, it should be understood that an attachment device which
does so over only one region of the flange of the capsule body may
equally be feasible.
[0117] The exact configuration and operation of the presently
disclosed and/or claimed inventive concept(s) as practiced may thus
vary from the foregoing description without departing from the
inventive principle described therein. Accordingly, the scope of
this disclosure is intended to be exemplary rather than limiting,
and the scope of this presently disclosed and/or claimed inventive
concept(s) is defined by any claims that stem at least in part from
it.
* * * * *