US20240101340A1

US20240101340A1 - Single Serve Capsule For Preparing A Beverage In A Beverage Preparation Machine, And Method For Producing A Single Serve Capsule

Info

Publication number: US20240101340A1
Application number: US18/265,280
Authority: US
Inventors: Marc KRÜGER; Günter Empl
Original assignee: GCS German Capsule Solution GmbH
Current assignee: GCS German Capsule Solution GmbH
Priority date: 2020-12-07
Filing date: 2021-12-07
Publication date: 2024-03-28
Also published as: WO2022122718A2; AU2021393893A1; EP4255826B1; KR20230118157A; EP4255826C0; WO2022122718A3; EP4255826A2; EP4458727A2

Abstract

The invention relates to a single serve capsule for preparing a beverage in a brewing chamber of a beverage preparation machine, wherein the single serve capsule has a base element having a hollow space for receiving a beverage raw material, and a capsule cover that closes the hollow space, wherein the base element comprises a capsule bottom, a peripheral flange and a capsule wall that extends between the capsule bottom and the peripheral flange, wherein the flange has a sealing element which is integral with the flange and is in the form of a sealing bead oriented away from the capsule cover, wherein the sealing bead comprises an inner flank and an outer flank, wherein the flange has a first flange region between the capsule wall and the inner flank and a second flange region between the outer free end of the flange and the outer flank, and wherein the capsule cover is fastened along a first peripheral fastening face in the first flange region and along a second peripheral fastening face in the second flange region.

Description

PRIOR ART

The present invention proceeds from a single serve capsule for preparing a beverage in a brewing chamber of a beverage preparation machine, wherein the single serve capsule has a base element having a cavity for receiving a beverage raw material, and a capsule lid closing the cavity, wherein the base element comprises a capsule base, an encircling flange, and a capsule wall which extends between the capsule base and the encircling flange, wherein the flange has a sealing element which, in the form of a sealing crimp that points away from the capsule lid, is configured integrally with the flange, wherein the sealing crimp comprises an inner shoulder and an outer shoulder, wherein the flange between the capsule wall and the inner shoulder has a first flange region and between the outer free end of the flange and the outer shoulder has a second flange region.
Such single serve capsules are known from the prior art. For example, publication VO 2016/186,488 A1 discloses such a single serve capsule of the generic type. This single serve capsule is provided to be inserted into a brewing chamber in which the capsule base is perforated so as to direct pressurized brewing liquid in the form of hot water into the cavity. As a result, the pressure within the single serve capsule is increased, as a result of which the capsule lid is pressed against a relief or pyramid plate in the brewing chamber and, when reaching a predetermined pressure, is perforated or burst open at the contact points. The beverage created by the interaction between the inflowing water and the beverage raw material, in particular roasted and ground coffee, exits the single serve capsule through these perforated locations in the capsule lid. In other words, these single serve capsules are passed through by a flow of water or beverage running through the capsule base in the direction of the capsule lid. This single serve capsule of the generic type therefore has to be fundamentally differentiated from any other type of single serve capsules in which the flow takes place in the opposite direction, i.e. the water is incorporated into the single serve capsule through the capsule lid, and the beverage exits the single serve capsule through the capsule base.
It is common to all single serve capsules that sufficient sealing between the brewing chamber and the single serve capsule in the region of the flange is necessary so that the water within the brewing chamber for forming the beverage runs through the beverage raw material and does not bypass the beverage raw material outside the single serve capsule, thus between a wall of the brewing chamber and the external side of the capsule wall.
To this end, these types of single serve capsules in the region of the flange thereof have a sealing element which in the brewing chamber seals in relation to a brewing chamber element. It is desirable here that the sealing element is composed of the same material as the capsule body (also referred to as the base element) so as to keep the production costs for the single serve capsule low and to facilitate the disposal or recycling of single serve capsules already used.
Single serve capsules having sealing elements of this type are disclosed, for example, in publications VO 2016/186 488 A1 and WO 2016/041,596 A1. The single serve capsules disclosed therein have an embossed sealing crimp in their flange. The sealing effect between the sealing crimp and the brewing chamber element is to be achieved by a simple deformation of the sealing crimp. A further single serve capsule having an encircling sealing element is known to the person skilled in the art from publication EP 2 872 421 A1.
It is common to all aforementioned single serve capsules that the sealing effect of their sealing elements is in each case based on a severe deformation of said sealing elements per se. To this end, inner shoulders having an ideally flat angle are used, so that the brewing chamber element can act on the shoulder when the brewing chamber is closed, this thus leading to a slight deformation of the sealing element.
In a sealing solution which is based on deforming the sealing element it is disadvantageous that significantly higher forces are required for dosing the brewing chamber as a result. The ease of operation and the durability of the beverage preparation machine are in this way significantly increased. Moreover, the sealing elements known from the prior art are of an asymmetrical design. Therefore, these sealing elements tilt laterally away during deformation. As a result, an increased sealing effect is indeed achieved, but the lateral tilting of the sealing elements typically poses the issue that the brewing chamber element is jammed by the sealing element in such a manner that the single serve capsule can no longer be separated from the brewing chamber element without an increased effort in force after the brewing procedure. The ejection of the single serve capsule used from the brewing chamber is thus significantly impeded and seriously compromises the ease of operation.
An alternative would be separate sealing elements made from a sealing material as are known from publications EP 1 654 966 A1 and EP 1 839 543 A1. However, such sealing elements have the disadvantage already mentioned above that the production costs for the single serve capsules are significantly higher owing to the use of separate materials, on the one hand, and the disposal or recycling of already used single serve capsules is more difficult because the different materials have to be separated from one another, on the other hand.
A further issue in the known single serve capsules lies in the fastening of the capsule lid to the flange. Capsule lids of this type typically are at least partially composed of aluminum and are usually sealed to the flange along an encircling sealing face. This is in particular not problematic in single serve capsules with a continuous flange, in which the capsule lid can be fastened across the entire area or at least without problems by way of a sufficiently large sealing face.
This is a different matter in single serve capsules which, as described above, have a sealing crimp which is configured integrally with the flange. In this case, the flat face of the flange that is available for sealing is limited, and it is difficult to achieve reliable sealing. Liquid can escape through the capsule lid even if the seal of the capsule lid has only a few defective spots.
Furthermore, when sealing the lid to a region of the flange that lies radially outside the sealing crimp, as is the case in previously mentioned VO 2016/041,596 A1, for example, liquid can flow into the cavity of the sealing crimp and remain therein as a dead volume. This quantity of liquid is absent in the desired total volume of the beverage, on the one hand, and the liquid can also leak from the sealing crimp after the brewing procedure and thus cause undesirable dripping from the single serve capsule, on the other hand.

DISCLOSURE OF THE INVENTION

It is an object of the present invention to make available a single serve capsule of the type mentioned at the outset, which does not have the issues outlined in the context of the prior art. A single serve capsule which guarantees reliable fastening of the capsule lid even when the single serve capsule has a sealing crimp is to be provided in particular. Furthermore to be made available is a method for producing such a single serve capsule, and an installation for producing such a single serve capsule.
The object of the present invention is achieved by a single serve capsule for preparing a beverage in a brewing chamber of a beverage preparation machine, wherein the single serve capsule has a base element having a cavity for receiving a beverage raw material, and a capsule lid closing the cavity, wherein the base element comprises a capsule base, an encircling flange, and a capsule wall which extends between the capsule base and the encircling flange, wherein the flange has a sealing element which, in the form of a sealing crimp that points away from the capsule lid, is configured integrally with the flange, wherein the sealing crimp comprises an inner shoulder and an outer shoulder, wherein the flange between the capsule wall and the inner shoulder has a first flange region and between the outer free end of the flange and the outer shoulder has a second flange region, wherein the capsule lid along a first encircling fastening face is fastened in the first flange region, and along a second encircling fastening face is fastened in the second flange region. The first and/or the second fastening face are/is preferably a flat plane. The first and/or the second fastening face are/is particularly preferably configured annularly, wherein the first fastening face and the second fastening face have in particular substantially the same radial extent.
The single serve capsule according to the invention, in comparison to the prior art, has the advantage that by fastening the capsule lid in at least two mutually disparate regions, pressure-resistant and reliable fastening of the capsule lid takes place. Particularly advantageously, no liquid can make its way into the cavity formed by the sealing crimp either. It was surprising and unexpected to the person skilled in the art that reliable fastening to two different faces which, when viewed individually, are in each case small faces, is also possible.
Advantageous design embodiments and refinements of the invention can be derived from the dependent claims and from the following description with reference to the drawings. These advantageous design embodiments and refinements also relate to the further subjects according to the invention and vice versa.
According to a preferred embodiment of the present invention it is provided that the base element is integrally made of aluminum. The person skilled in the art understands that the sealing element, which according to the invention is provided so as to be integral with the flange, in this case is likewise made of aluminum. In the context of this invention, aluminum is also to comprise aluminum laminates and other materials which at least contain aluminum. Materials which additionally also have varnishes and/or coatings are in particular also to be included, wherein said materials may also comprise plastics materials, for example. Aluminum is the preferred material for the single serve capsule according to the invention; however, the base element can alternatively also be made from a plastics material and/or a biodegradable material. It is crucial that the sealing element as a sealing crimp is configured integrally with the flange and that reliable fastening of the capsule lid to the first flange region and the second flange region is possible. The base element is preferably produced by cold forming or hot forming, in particular deep drawing, in which the sealing crimp is embossed integrally into the flange. The single serve capsule is preferably embodied so as to be frustoconical or cylindrical.
According to a preferred embodiment of the present invention it is provided that the capsule lid has an aluminum foil. Here too, an aluminum foil is also to be understood to be a foil of aluminum laminate, and/or an aluminum foil having a coating and/or varnish on one or two sides. The capsule lid can be provided with one or two tiers and in particular also comprise a layer construction.
The beverage raw material, which is provided in the cavity that is formed by the base element and is, in particular hermetically, closed by the capsule lid, preferably comprises roasted coffee granules, instant coffee, chocolate powder, blended tea, milk powder and/or the like.
According to a preferred embodiment of the present invention it is provided that the outer free end of the flange is rolled up, in particular flared, in such a manner that said outer free end forms an encircling bead, wherein the bead relative to the flange preferably has a vertical extent of more than zero, particularly preferably on both sides of the flange, wherein the vertical extent of the bead on that side of the flange that faces away from the capsule lid is very particularly preferably less than the vertical extent of the sealing crimp, and/or wherein the vertical extent of the bead on that side of the flange that faces the capsule lid is less than on that side of the flange that faces away from the capsule lid. In other words, it is preferably provided that the bead is smaller than the sealing crimp, particularly preferably on both sides of the flange. Most particularly preferably the bead is configured so as to be substantially and in particular in terms of the vertical extent thereof symmetrical in relation to the flange. Alternatively, it is also possible that the vertical extent of the bead on that side of the flange that faces away from the capsule lid is greater than the vertical extent of the sealing crimp, and/or wherein the vertical extent of the bead on that side of the flange that faces the capsule lid is greater than on that side of the flange that faces away from the capsule lid. The bead is most particularly preferably provided in such a manner that no sealing effect is created during the preparation of the beverage. A bead of this type advantageously protects a user from unintentional injury, in particular if the base element is made of aluminum. However, the outer free end of the flange can also be of a sharp configuration and/or have production-related defective spots which result in a risk of injury to the user in single serve capsules made of plastics materials. This is particularly advantageously avoided by providing a bead, thus effectively a radiused outer free end of the flange. The bead is in particular formed by rolling the flange periphery, wherein the flange periphery is preferably rolled inward in the direction of the capsule base.
According to a preferred embodiment of the present invention it is provided that the inner shoulder and the outer shoulder are configured so as to be mutually symmetrical. In particular, said shoulders have the same angles and/or the same material thicknesses. As a result, the effect according to the invention of stable and reliable sealing is advantageously reinforced.
According to a preferred embodiment of the present invention it is provided that the outer shoulder as well as the inner shoulder in relation to a horizontal plane running through the first flange region and through the second flange region are aligned at an angle of more than 80 to less than 90 degrees, preferably of 81 to 89 degrees, particularly preferably of 83 to 87 degrees, most particularly preferably of 84 to 86 degrees, and in particular of substantially 85 degrees. The person skilled in the art understands that, in the context of the present invention, horizontal is to be understood in particular in relation to a customary arrangement of the capsule in which the central longitudinal axis of the capsule, preferably of a rotationally symmetrical configuration, is disposed vertically, and the first and/or the second flange region are/is disposed perpendicularly to this capsule axis. The horizontal extent of the first and/or the second flange region particularly preferably coincides with a horizontal extent of the first and/or the second fastening face. It has been demonstrated that in this angular range the deformation of the sealing crimp can be reduced firstly and the stiffness of the sealing crimp increased because the angle is ideally steep and the sealing crimp in this way guarantees a high level of stability in relation to forces which act on the sealing crimp perpendicularly to the first and/or the second fastening face (also referred to as the vertical direction and thus in particular parallel to the central longitudinal axis of the single serve capsule), and simple and cost-effective production of the single serve capsule is made possible because the angle is at all times more acute than a right angle, on the other hand. In the case of a right angle on both shoulders of the sealing crimp, the inner shoulder and the outer shoulder, the demolding of the single serve capsule from the mold, or the embossing tool, respectively, during production of the single serve capsule would be significantly more difficult.
According to a preferred embodiment of the present invention it is provided that the sealing crimp is configured in such a manner that said sealing crimp when closing the brewing chamber is deformed only by at most 30%, preferably by at most 20%, particularly preferably by at most 10%, and most particularly preferably by at most 5%, of its overall height perpendicular to the first and/or the second flange region, or to the first and/or the second fastening face, respectively. The sealing crimp is in particular configured in such a manner that said sealing crimp, when impinged with a force of up to 100 N acting on the sealing crimp perpendicularly to the first and/or the second fastening face, is deformed only by at most 30%, preferably by at most 20%, particularly preferably by at most 10%, and most particularly preferably by at most 5% of its height perpendicular to the first and/or the second fastening face.
According to a preferred embodiment of the present invention it is provided that the sealing crimp is configured in such a manner that said sealing crimp when closing the brewing chamber is deformed parallel to the first and/or the second fastening face only to the extent that the radius of said sealing crimp relative to a central center longitudinal axis (about which the flange is disposed so as to be rotationally symmetrical) of the single serve capsule is displaced only by at most 10%, preferably by at most 8%, particularly preferably by at most 5%, and most particularly preferably by at most 4%, parallel to the first and/or the second fastening face. As a result, jamming of the brewing chamber element by the laterally tilting sealing crimp is advantageously prevented so that the brewed single serve capsule can at all times be removed from the brewing chamber again in a simple manner and without an increased effort in terms of force.
The sealing crimp is thus in particular configured to be stiff and stable in such a manner that a reduced deformation of the sealing crimp takes place in the event of a force impingement by a force of in particular up to 100 N, which acts perpendicularly to the first and/or the second fastening face, thus along the vertical direction, parallel to the central longitudinal axis of the single serve capsule, centrally on the sealing crimp, said force acting in particular in a planar manner on the tip of the sealing crimp or on the inner and/or the outer shoulder of the sealing crimp, or on a planar transition plane of the sealing crimp. In the process, the sealing crimp in terms of the height thereof is to be variable in particular by at most 30%, preferably by at most 20%, particularly preferably by at most 10%, and most particularly preferably by at most 5%. It is furthermore conceivable that only a reduced lateral displacement or deformation along a direction parallel to the first and/or the second fastening face, thus in particular when viewed in the radial direction R from the central longitudinal axis of the concentrically configured single serve capsule, takes place. It is provided here too that the tip of the sealing crimp, thus the transition region of the sealing crimp, is displaced or deformed from the central center longitudinal axis of the single serve capsule by at most 10%, preferably by at most 8%, particularly preferably by at most 5%, and most particularly preferably by at most 4% of the total radius of said sealing crimp. The radius proceeding from the center of the sealing crimp can be considered to be the total radius here, for example.
It is preferably provided that the angle between the inner and the outer shoulder is preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees, and most particularly preferably substantially 10 degrees.
According to a preferred embodiment of the present invention it is provided that the first fastening face and the second fastening face each have a substantially horizontal extent. The extent of the first and/or of the second fastening face particularly preferably coincides with the extent of the first or the second flange region in the region of the respective fastening face, respectively. This means, in particular, that it is preferable for the first fastening face to correspond to an, in particular horizontal, surface portion of the first flange region on that side of the flange that faces the capsule lid and/or for the second fastening face to correspond to an, in particular horizontal, surface portion of the second flange region on that side of the flange that faces the capsule lid. As a result of a horizontal extent of the fastening face, a conventional fastening by sealing by means of a flat sonotrode is made possible in a particularly advantageous manner.
According to a preferred embodiment of the present invention it is provided that the base element has a, preferably constant, but at least mean material thickness between 0.05 mm and 0.3 mm, preferably between 0.08 mm and 1.8 mm, particularly preferably between 0.09 mm and 1.5 mm, and most particularly preferably of substantially 0.11 mm. The base element preferably has the above-mentioned material thickness at least in the region of the sealing crimp, the capsule wall, the capsule base and/or the flange, in particular the first and/or the second flange region.
According to a preferred embodiment of the present invention it is provided that the first fastening face and the second fastening face are vertically spaced apart from one another, wherein the first fastening face preferably has a smaller vertical spacing from the capsule base than the second fastening face. Particularly preferably, this applies accordingly also to the first and the second flange region. Provided in this way is a single serve capsule of which the flange has two, in particular horizontal, portions at different heights. This is particularly advantageous because a minimal offset between the first flange region and the second flange region often cannot be avoided for production reasons. It was extremely amazing and unexpected to the person skilled in the art that reliable fastening of the capsule lid is also possible in two regions which are at different heights relative to the central longitudinal axis. In particular, the available first fastening face of the first flange region is very minor so that reliable fastening was not to be expected. Alternatively, the first flange region and the second flange region are at the same height. This has the advantage that no indirect repositioning or deformation of the sealing crimp arises when closing the brewing chamber, in that the first flange region and the second flange region are deformed or repositioned relative to one another in the vertical direction. Instead, both flange regions can be supported on the closure element of the brewing chamber and thus build up a suitable counterforce for avoiding any notable deformation of the sealing crimp.
According to a preferred embodiment of the present invention it is provided that the vertical spacing between the fastening faces and/or the first and the second flange region is less than three times the thickness of the flange in the region of the first and/or the second fastening face, or the first and/or the second flange region, respectively, preferably less than 0.035 mm, particularly preferably less than 0.030 mm, in particular at most 0.025 mm. The vertical offset is most particularly preferably less than twice the material thickness, and even more preferably less than one material thickness. The material thickness in this case is in particular the material thickness of the base element in the region of the first and/or the second flange region, in particular measured vertically to the extent in the aforementioned region. As a result it is in particular made possible in an advantageous manner that there is a certain tolerance in terms of the heights of the flange regions for production reasons, and reliable and tight fastening of the capsule lid is nevertheless ensured.
According to a preferred embodiment of the present invention it is provided that the first fastening face and the second fastening face are provided in such a manner that there is no fluid connection between the cavity of the single serve capsule and the cavity present between the capsule lid and the sealing crimp. This means that in particular the fastening of the capsule lid in the first flange region by way of the first fastening face is configured in a fluid-tight manner. As a result, a water-tight and air-tight single serve capsule is advantageously provided.
According to a preferred embodiment of the present invention it is provided that a transition region extends between the inner shoulder and the outer shoulder, wherein the transition region is preferably configured so as to be curved, or has a transition plane which extends parallel to the first flange region and/or to the second flange region. The transition plane is in particular configured so as to be horizontal. The curved configuration of the transition region has the advantage that the sealing crimp gains stability, deformation being able to be even more effectively prevented in this way. In contrast, the flat configuration of the transition region has the advantage that the sealing crimp is flatter and as a result engages into the depression of the sealing contour of the receptacle element of the brewing chamber to a lesser extent such that less force is exerted on the sealing crimp when dosing the brewing chamber. Moreover, the risk of jamming the brewing chamber part is less in the case of the flat sealing crimp.
According to a preferred embodiment of the present invention it is provided that the transition region in the radial direction has an extent of 0.05 mm to 0.20 mm, preferably of 0.07 mm to 0.17 mm, particularly preferably of 0.10 mm to 0.14 mm, in particular of 0.12 mm. This means in particular that the transition region in the radial cross section of the encircling sealing crimp has a rectilinear connecting region which has a width of between 0.05 mm to 0.20 mm, preferably of 0.07 mm to 0.17 mm, particularly preferably of 0.10 mm to 0.14 mm, and in particular of 0.12 mm.
According to a preferred embodiment of the present invention it is provided that the single serve capsule in the transition from the outer shoulder to the second flange region and/or in the transition from the inner shoulder to the first flange region has a radius of 0.03 mm to 0.20 mm, preferably of 0.06 mm to 0.15 mm, and particularly preferably of 0.09 mm to 0.13 mm, in particular of 0.11 mm. The above-described preferred dimension of the sealing crimp leads to the sealing crimp having sufficient stability so that no deformation of the latter takes place while closing the brewing chamber and/or brewing the capsule in the brewing chamber.
The inner shoulder as well as the outer shoulder in the radial cross section of the encircling sealing crimp each preferably have a rectilinear contact region which extends between the flange and the transition region. The wording “in the radial cross section” means that the flange contour is viewed in a sectional illustration along the circumferential direction of the encircling flange contour. Accordingly, the plane of the sectional illustration is defined by the vertical direction and the radial direction, as illustrated in FIGS. 3 to 5 .
According to a preferred embodiment of the present invention it is provided that the rectilinear contact region has a length of 0.1 mm to 1.5 mm, particularly of 0.3 mm to 1.3 mm, particularly preferably of 0.5 mm to 1.0 mm, and most particularly preferably of 0.7 mm to 0.9 mm. It has been demonstrated in simulations and experiments that optimal sealing between the sealing contour of the brewing chamber element and the flange can be achieved in the case of a rectilinear contact region of the lengths mentioned. In other words: it suffices that the inner shoulder bears in a planar manner with a form fit and a force fit on a sealing projection shoulder of the sealing contour of the brewing chamber element over a length of 0.1 mm to 1.5 mm, preferably of 0.3 mm to 1.3 mm, particularly preferably of 0.5 mm to 1.0 mm, and most particularly preferably of 0.7 mm to 0.9 mm, in order to achieve a sufficient sealing effect (in the region of the inner shoulder) without an intense deformation of the sealing crimp by the sealing contour being required.
According to a preferred embodiment of the present invention it is provided that the single serve capsule in the transition from the rectilinear contact region to the transition region on that side that faces the capsule lid has a radius of 0.05 mm to 0.35 mm, preferably of 0.10 mm to 0.30 mm, and particularly preferably of 0.21 mm. According to a preferred embodiment of the present invention it is provided that the single serve capsule in the transition from the outer shoulder to the transition region on that side that faces the capsule lid has a radius of 0.05 mm to 0.35 mm, preferably of 0.10 mm to 0.30 mm, and particularly preferably of 0.21 mm. According to a preferred embodiment of the present invention it is provided that the height of the sealing crimp perpendicular to the sealing plane comprises between 0.6 mm and 1.3 mm, preferably between 0.3 mm and 0.6 mm, and particularly preferably between 0.9 and 1.0 millimeters. The above-described preferred dimension of the sealing crimp leads to the sealing crimp having sufficient stability so that no intense deformation of the latter takes place while dosing the brewing chamber and/or brewing the capsule in the brewing chamber.
According to a preferred embodiment of the present invention it is provided that the single serve capsule on the capsule wall thereof, in particular on the external side of the capsule wall, has one or a plurality of, preferably two, three, four, five, six, seven or eight, concentrically encircling grooves. The grooves here may be configured as depressions and/or elevations which are directed inward or outward. Grooves of this type are advantageously used for stiffening and/or reinforcing the capsule wall so that the single serve capsule withstands the pressures arising during the preparation of the beverage.
According to a preferred embodiment of the present invention it is provided that the single serve capsule has a filter in the region of the capsule base. The filter particularly preferably comprises a non-woven material and/or a felt material. The filter is very particularly preferably configured with one or a plurality of plies. The filter is preferably configured so as to be disk-shaped, in particular round. Alternatively, the filter is configured so as to be angular, for example rectangular, hexagonal, octagonal, or decagonal. It is preferably provided that the filter is disposed in the region of the base. Most particularly preferably, the filter in the region of the capsule base is in portions or in an encircling manner fastened, in particular sealed, to the latter and/or to the capsule wall and/or in a transition region between the capsule base and the capsule wall.
A further subject matter of the present invention is a system for preparing a beverage, having a beverage preparation machine and a single serve capsule according to the invention, wherein the beverage preparation machine has a brewing unit having a first brewing chamber part and a second brewing chamber part, wherein the first and/or the second brewing chamber part are/is movable relative to the other brewing chamber part between a converged position, in which the first and the second brewing chamber part form a closed brewing chamber, and an open position, in which the first and the second brewing chamber part are mutually spaced apart for inserting or ejecting a single serve capsule, wherein the first brewing chamber part comprises a receptacle element for at least partially receiving the single serve capsule, and the second brewing chamber part comprises a closure element for the receptacle element, wherein in the closed position the flange of the single serve capsule is received in a form-fitting and sealing manner between a peripheral region of the receptacle element and the closure element.
The single serve capsule according to the invention is part of the system according to the invention, which is why all advantages and refinements discussed in the context of the single serve capsule also apply in an analogous manner to the system according to the invention—and to the further subjects of the present invention—and vice versa.
According to a preferred embodiment of the present invention it is provided that a sealing contour for engaging in a sealing manner with the sealing crimp is configured in the peripheral region of the receptacle element, wherein the sealing contour comprises an encircling depression and, configured adjacent to the depression, an encircling sealing projection, wherein the depression in the radial direction is preferably disposed outside the sealing projection, and wherein an outer sealing projection shoulder forms an inner wall of the depression, and/or wherein in the dosed position the sealing projection engages in the first flange region and the sealing crimp engages in the depression in such a manner that the sealing projection shoulder conjointly with the inner shoulder in the radial cross section configure a linear contact. A configuration of the brewing chamber part of this type is particularly advantageous because an improvement in terms of the tightness of the system is achieved in this way. In particular, it is achieved that the path for potentially invading water is lengthened.
According to a preferred embodiment of the present invention it is provided that, in the dosed position, the sealing crimp is deformed by the sealing contour only by at most 30%, preferably by at most 20%, particularly preferably by at most 10%, and most particularly preferably by at most 5%, of the height of said sealing crimp perpendicular to the first and/or the second fastening face. The acting forces are advantageously delimited as a result, and the risk of damage to the beverage preparation machine and/or to the single serve capsule is minimized in this way.
According to a preferred embodiment of the present invention it is provided that the sealing contour has a further encircling sealing projection, wherein the depression in the radial direction is disposed between the sealing projection and the further sealing projection, wherein the sealing projection is configured so as to be longer than the further sealing projection and wherein, in the closed position, the further sealing projection conjointly with the outer shoulder in the radial cross section configures a punctiform contact. The tightness is particularly advantageously further improved as a result.
A further subject matter of the present invention is a method for producing a single serve capsule according to the invention, wherein in a first step a base element having a capsule base, an encircling flange, and a capsule wall which extends between the capsule base and the encircling flange is generated, wherein in a second step a sealing crimp is molded in the flange, wherein in a third step the cavity of the base element is filled at least with a beverage raw material, wherein in a fourth step the base element is closed with a capsule lid, wherein the capsule lid along a first fastening face and along a second fastening face is fastened, in particular sealed, to the flange. A single serve capsule which offers all of the advantages mentioned in the context of the single serve capsule according to the invention is advantageously provided by the method according to the invention.
The advantages and refinements discussed in the context of the method according to the invention also apply in an analogous manner to the other subjects of the present invention and vice versa.
According to a preferred embodiment of the method according to the invention it is provided that the fourth step comprises at least one first sub-step and one second sub-step, wherein in the first sub-step fastening, in particular sealing, by means of a fastening means, in particular a heat sealing tool, takes place along the second fastening face, and wherein in the second sub-step fastening, in particular sealing, by means of a fastening means, in particular a heat sealing tool, takes place along the first fastening face and preferably the second fastening face. The person skilled in the art understands that the fastening at all times takes place across the entire encircling fastening face so as to achieve the required tightness. The first sub-step corresponds in particular to pre-sealing. Pre-sealing in this context means that first fastening takes place, which in comparison to the fastening of the second sub-step is not as strong for example, thus takes place using a lower force and/or in a shorter time for example. The fastening means of the first and of the second sub-step are preferably at least partially identical. Partially identical here is understood to mean that individual elements of the fastening means are replaced, for example, the sonotrode and/or the receptacle element is replaced in the case of a heat sealing tool, for example. Alternatively, a first fastening means, in particular a first heat sealing tool, is used in the first sub-step, and a second fastening means, in particular a second heat sealing tool, is used in the second sub-step.
The fastening in the first sub-step preferably takes place at a sealing temperature of between 160° C. and 260° C., particularly preferably between 190° C. and 230° C., and in particular 210° C. The fastening in the first sub-step preferably takes place with a sealing time of between 200 ms and 300 ms, particularly preferably between 230 ms and 270 ms, and in particular 250 ms. The fastening in the first sub-step preferably takes place with a sealing force of between 250 N and 350 N, particularly preferably between 280 N and 320 N, and in particular 300 N.
The fastening in the second sub-step preferably takes place at a sealing temperature of between 160° C. and 260° C., particularly preferably between 190° C. and 230° C., and in particular 210° C. The fastening in the second sub-step preferably takes place with a sealing time of between 300 ms and 600 ms, particularly preferably between 400 ms and 500 ms, and in particular 450 ms. The fastening in the second sub-step preferably takes place with a sealing force of between 700 N and 1100 N, particularly preferably between 850 N and 950 N, and in particular 900 N.
According to a preferred embodiment of the method according to the invention it is provided that in a further sub-step of the fourth step, prior to the first sub-step, the capsule lid is generated, preferably cut and/or punched, from a strip stock. The person skilled in the art understands that an, in particular circular, capsule lid is preferably punched from an aluminum foil when aluminum foil is the material for the capsule lid. The further sub-step here is particularly preferably likewise carried out by the fastening means, in particular in one pass. For example, the capsule lid is punched from an aluminum foil and subsequently sealed to the base element in one movement. Alternatively, the capsule lid, in particular as round blank, is supplied to the fastening means. The production of the single serve capsule is simplified and the production time shortened as a result. Potential positioning errors are also advantageously avoided.
According to a preferred embodiment of the method according to the invention it is provided that the first step comprises a first sub-step, a second sub-step, and preferably a third sub-step, wherein in the first sub-step a basic shape is generated, in particular punched, from a strip stock, wherein in the second sub-step a preform is generated in such a manner that the base element is formed from the basic shape, wherein in the third sub-step a bead is formed, in particular rolled and/or flared, from the outer free end of the flange. The second sub-step preferably takes place by means of a die.
In a further sub-step, encircling concentric grooves are preferably molded in the capsule wall, at least on the external side.
According to a preferred embodiment of the method according to the invention it is provided that the third step takes place in a modified atmosphere, and/or that a nitrogen layer is applied to the bed from the beverage raw material, in particular in such a manner that no oxygen is present in the single serve capsule after the fourth step.
According to a preferred embodiment of the method according to the invention it is provided that in a fifth step, which takes place after the first step and prior to the third step, a filter is incorporated in the cavity and preferably fastened to the base element, in particular in the region of the capsule base. The filter particularly preferably comprises a non-woven material and/or a felt material. The filter is most particularly preferably configured with one or a plurality of plies. The filter is preferably configured so as to be disk-shaped, in particular round. Alternatively, the filter is configured so as to be angular, for example rectangular, hexagonal, octagonal, or decagonal. It is preferably provided that the filter is disposed in the region of the base. The filter is most particularly preferably fastened, in particular, sealed in portions or an encircling manner in the region of the capsule base to the latter and/or to the capsule wall and/or in a transition region between the capsule base and the capsule wall. Particularly preferably, the filter is cut by a tool, moved into the cavity and fastened, in particular sealed, there in one pass.
A further subject matter of the present invention is a heat sealing station for closing a single serve capsule with a capsule lid for producing a single serve capsule according to the invention, having at least one first heat sealing tool, wherein the first heat sealing tool is configured to seal the capsule lid to the flange along the second fastening face, and wherein the first heat sealing tool or a second heat sealing tool is configured to seal the capsule lid to the flange along the first fastening face and preferably the second fastening face. The person skilled in the art understands that the first as well as the second sealing can take place using the same heat sealing tool, i.e. the first heat sealing tool, or that both sealing procedures can take place by way of at least two different heat sealing tools, i.e. at least the first and the second heat sealing tool. The first sealing procedure here corresponds in particular to pre-sealing, and the second sealing procedure corresponds to post-sealing or primary sealing in which the desired final tightness is achieved. As a result of the heat sealing station according to the invention, the production of a single serve capsule according to the invention with sealing of the capsule lid in the first flange region as well as in the second flange region is now also advantageously made possible. By being sub-divided into two steps, sealing of the capsule lid along the first and the second fastening face is particularly advantageously also made possible for the event that the first flange region and the second flange region are at different heights. In this way, the capsule lid is pre-fixed in particular in the first step.
The advantages and refinements discussed in the context of the heat sealing station according to the invention also apply in an analogous manner to the other subjects of the present invention and vice versa.
According to a preferred embodiment of the heat sealing station according to the invention it is provided that the first heat sealing tool and/or the second heat sealing tool each comprise at least one sonotrode and at least one receptacle element, wherein the receptacle element has an open cavity for receiving the single serve capsule, wherein the receptacle element furthermore has at least one counter-holding means, wherein the counter-holding means, on that side of the flange that faces away from the capsule lid, in particular in the region of the first fastening face and/or of the second fastening face, is configured to provide a counterforce to the force exerted by the sonotrode. A sonotrode is usually a flat element. In order to achieve reliable sealing also in flange regions of different height, it is essential that a counter-holding means on the flange lower side, i.e. on the side that faces away from the capsule lid, provides a counterforce to the force exerted by the sonotrode. The heat sealing station particularly preferably comprises a first heat sealing tool and a second heat sealing tool, wherein the receptacle element of the first and of the second heat sealing tool has a counter-holding means in the region of the second fastening face as well as in the region of the first fastening face. Alternatively, the receptacle element of the first heat sealing tool has only one counter-holding means in the region of the second fastening face. The person skilled in the art understands that the receptacle element here is different from the receptacle element of the beverage preparation machine of the system according to the invention, but both receptacle elements are preferably similar in terms of construction and function. Both preferably have a cavity for at least partially receiving the single serve capsule, or the base element. The receptacle elements differ in particular in that the receptacle element of the beverage preparation machine has a sealing contour as described above, while the receptacle element of the heat sealing tool preferably has counter-holding means only in the region of the first and/or the second fastening face, but there is in particular no contact with the sealing crimp. Safe and reliable sealing in both fastening faces is particularly advantageously guaranteed by the counter-holding means.
According to a preferred embodiment of the heat sealing station according to the invention it is provided that the receptacle element has at least one counter-holding means in the region of the first fastening face, wherein an upper face of the counter-holding means is disposed so as to be at least 0.05 mm, preferably at least 0.10 mm, in particular at least 0.15 mm, higher in comparison to an upper face of the counter-holding means of the first heat sealing tool and/or of the second heat sealing tool in the region of the second fastening face. In this context, higher means in particular a greater extent in the vertical direction. The counter-holding means is particularly preferably a plunger. The applicant has surprisingly established by experiments that a particularly positive hot sealing quality is achieved in that the counter-holding means has different heights in the regions of the two fastening faces, and in particular has a greater height in the region of the first fastening face. The person skilled in the art understands that the aforementioned numerical values are to apply in particular in the event that the first flange region and the second flange region are disposed at the same height relative to the central longitudinal axis. The numerical values have to be correspondingly adapted in the case of a predetermined offset.
According to a preferred embodiment of the heat sealing station according to the invention it is provided that the sonotrode of the first and/or the second heat sealing tool has a diameter of between 34 mm and 36 mm, particularly preferably between 34.4 mm and 35.2 mm, and in particular of 34.8 mm. Reliable sealing of high quality can take place as a result, without the bead being contacted by the sonotrode, for example.
According to a preferred embodiment of the heat sealing station according to the invention it is provided that the sonotrode of the first and/or the second heat sealing tool has a heat-discharging means which is in particular centrically disposed. The heat-discharging means is particularly preferably at least partially made from a ceramic material. A significant amount of heat is transferred to the single serve capsule in particular in the two-stage sealing provided according to the invention. This can damage the capsule lid, on the one hand, and compromise the beverage raw material, on the other hand. An excessive influence of heat is particularly advantageously avoided by disposing such a heat-discharging means, for example in the form of a ceramic insert. The heat-discharging means most particularly preferably has a diameter of at least 25 mm, yet more preferably of at least 28 mm, or at least 30 mm.
A further subject matter of the present invention is an installation for producing a single serve capsule according to the invention, in particular by a method according to the invention, having a forming station for forming a base element, a filling station for filling a cavity of the base element with at least one beverage raw material, and a closing station for closing the base element with a capsule lid, wherein the closing station is a heat sealing station according to the invention.
The explanations that apply to this subject matter of the present invention also apply to the other subjects according to the invention and vice versa.
Further details, features and advantages of the invention are derived from the drawings, and from the description hereunder of preferred embodiments by means of the drawings. The drawings here merely illustrate exemplary embodiments of the invention, which do not limit the substantial concept of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 show schematic sectional views of a single serve capsule and of a system for preparing a beverage according to an exemplary first embodiment of the present invention.

FIGS. 3 to 5 show schematic detailed views of the single serve capsule according to the different exemplary embodiments of the present invention.

FIGS. 6 to 15 show different schematic views of heat sealing tools according to different exemplary embodiments of the present invention.

FIG. 16 shows a schematic detailed view of the single serve capsule according to a further exemplary embodiment of the present invention in cross section.

EMBODIMENTS OF THE INVENTION

References to dimensions are contained in some images. These images correspond to technical drawings from which dimensions and/or size ratios can thus be derived. This applies in particular at least to FIGS. 3 to 5, and 12 to 15 .
Illustrated in FIGS. 1 and 2 are a schematic lateral view of a single serve capsule 1 and a sectional view of a system composed of the single serve capsule 1 and part of a beverage preparation machine 13 for preparing a beverage according to an exemplary first embodiment of the present invention.
The single serve capsule 1 has a base element 2 which by way of example is configured to be frustoconical and in the shape of a cup and which on the closed side thereof has a capsule base 5 and on the open side thereof has an encircling flange 6. A capsule wall 7 extends about a cavity 3 between the capsule base 5 and the flange 6. The single serve capsule 1 is constructed so as to be rotationally symmetrical about its central center longitudinal axis M, the latter defining a vertical direction Y. The flange 6, which is configured so as to be circular and thus to encircle in the circumferential direction, protrudes outward beyond the capsule wall 7 in the radial direction R.
The flange 6 is fixedly connected to a capsule lid 4 in the form of a lid foil, in particular an aluminum foil, which closes the cavity 3 on the open side of the base element 2. The flange 6 to this end has according to the invention a first fastening face 100 that faces the capsule lid 4, and a second fastening face 200, said fastening faces 100, 200 preferably extending approximately perpendicularly to the vertical direction Y. The capsule lid 4 in the peripheral region thereof is sealed, welded or adhesively bonded to the flange 6 in the first and the second fastening face 100, 200.
The capsule lid 4 is preferably embodied from an aluminum material or plastics material, which may also comprise laminates in each case. The cavity 3 which is filled with beverage raw material, for example roasted coffee granules, instant coffee, chocolate powder, blended tea, milk powder and/or the like is configured within the base element 2 (the beverage raw material is not illustrated for reasons of clarity), said cavity 3 being closed by the capsule lid 4.
The cup-shaped design embodiment of the base element 2 is preferably generated by thermoforming, for example deep drawing by means of a vacuum, positive pressure and/or a movable die. The base element 2 is preferably configured as a deep-drawn aluminum part. Alternatively, it would also be conceivable, however, that the base element 2 is configured as a plastic part from polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), or polyethylene terephthalate (PET). Alternatively, the single serve capsule 1 is produced by means of injection molding, in particular in the single-component, multi-component or in-mold method. A two-component method in which an aluminum layer, in particular with a layer thickness of 90 μm, is provided with a layer of PP, in particular with a layer thickness of 30 μm, is particularly preferable as the multi-component method. The PP layer is most particularly preferably disposed on one side or on both sides of the aluminum layer, in particular on the internal side of the base element 2 and/or of the cavity 3. Due to the absence of PVC, a better connection between the flange 6 and the capsule lid 4 is advantageously made possible as a result.
The single serve capsule 1 when in use in a beverage preparation machine 13 is introduced into a brewing unit. The brewing unit comprises a first brewing chamber part and a second brewing chamber part, wherein the first or the second brewing chamber part is movable relative to the other brewing chamber part between a converged position, in which the first and the second brewing chamber part form a closed brewing chamber 12, and an open position, in which the first and the second brewing chamber part are mutually spaced apart for inserting or ejecting the single serve capsule 1.
The first brewing chamber part is configured as a cup-shaped receptacle element 21 which largely receives the single serve capsule 1, in particular when the brewing chamber 12 is in the dosed position. The second brewing chamber part is configured as a closure element 22 for the receptacle element 21. In the closed position depicted in FIG. 2 , the flange 6 of the single serve capsule 1 is jammed in a sealing manner between a peripheral region 23 of the receptacle element 21 and the closure element 22.
In this closed position, the capsule lid 4 and the capsule base 5 are successively or simultaneously perforated. The one or the plurality of perforation openings in the capsule base 5 here are in particular formed by one or a plurality of perforation tips on the receptacle element 21 while closing the brewing chamber 13, whereas the perforation openings in the capsule lid 4 are preferably generated by perforation structures in the base of the closure element 22 already while closing the brewing chamber 12, or only as a result of the pressure build up in the interior of the single serve capsule 1 during the beverage preparation process.
A pressurized extraction liquid is directed into the cavity 3 through the one or the plurality of perforation openings in the capsule base 5. The desired beverage is created as a result of the interaction between the extraction liquid and the beverage raw material, said beverage exiting the single serve capsule 1 through the perforation openings in the capsule lid 4 and being supplied to a beverage container. Potential particles of the beverage raw material can be filtered from the beverage and retained in the single serve capsule 1 by an optional filter medium. However, the capsule lid 4, which has multiple perforations, preferably functions as the filter element.
Illustrated in FIGS. 3 to 5 are detailed views of the single serve capsule 1 illustrated in FIGS. 1 and 2 according to an exemplary embodiment of the present invention. The figures here show the sectional illustration of the flange 6 on the right side of FIG. 1 or 2 in an enlarged illustration, respectively. FIGS. 3 to 5 here are true to scale and illustrated with more exact reproduction of the angular and longitudinal ratios.
The depicted flange 6 extends substantially horizontally, thus parallel to the radial direction R, from the upper end of the capsule wall 7 to the free outer end of said flange 6, at which the flange 6 terminates by way of a bead 8. The bead 8 comprises in particular a flange end that is rolled up in the direction of the capsule base 5.
Moreover, the bead 8, in particular on both sides of the flange 6, protrudes in the vertical direction Y, wherein the flange 6 on the lower side projects from the flange 6 by less than one sealing crimp 9, and furthermore on the upper side projects beyond the flange 6 by less than or the same as on the lower side.
The flange 6, between the bead 8 and the end of the capsule wall 7, has the sealing crimp 9 which is configured in the form of an embossing which is directed away from the capsule lid 4 in the vertical direction Y and in the circumferential direction concentrically encircles the central longitudinal axis M. The sealing crimp 9 here has an inner shoulder 10 which faces the capsule wall 7, and an outer shoulder 11 which faces the bead 8. The sealing crimp 9 is integrally formed here from the flange 6 and, as can be seen in the figures, has substantially the same thickness as the capsule wall 7 and/or a first flange region 18 between the capsule wall 7 and the inner shoulder 10 and/or a second flange region 19 between the bead 8 and the outer shoulder 11.
A transition region 14 in the form of the transition plane 15, which runs so as to be in particular flat (thus rectilinear) and parallel to the first and/or the second flange region 18, 19, extends between the inner shoulder 11 and the outer shoulder 12. The outer shoulder 11 in relation to the second flange region 19 runs at an angle β of approx. 85 degrees.
The outer shoulder 11 has in particular a rectilinear shoulder portion 20 which preferably comprises a length between 0.5 mm and 0.9 mm. The second flange region 19 preferably has a length of 0.2 mm to 0.8 mm.
The flange 6 between the inner shoulder 10 and the upper end of the capsule wall 7 has a first flange region 18. The first flange region 18 in the present example in the radial cross section is at least in portions configured so as to be rectilinear and horizontal. The rectilinear region has in particular a length of 0.07 mm to 0.09 mm.
The inner shoulder 10 in the radial cross section has a rectilinear contact region 16, i.e. the rectilinear contact region 16 is the length of the straight line between the two transitions in the profile of the inner shoulder 10. The length of the contact region 16 in the present example is preferably 0.5 mm to 0.9 mm.
According to the invention, the angle α between the inner shoulder 10, or the rectilinear contact region 16, and the first flange region 18 is substantially 85 degrees, respectively.
The angle between the inner and the outer shoulder 10, 11 is thus preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees, and most particularly preferably substantially 10 degrees.
The first flange region 18 and the second flange region 19 in the vertical direction Y here are at the same height. The height 17 of the sealing crimp 9 corresponds to the overall extent of the sealing crimp 9 from the lower side of the first and the second flange region 18, 19 to the lower side of the flange 6 in the region of the transition plane 15. This height 17, perpendicular to the first or the second flange region 18, 19, is between 0.9 mm and 1.0 mm, respectively.
The material thickness of the aluminum in the region of the flange 6 is preferably between 0.1 mm and 0.13 mm, in particular substantially 0.11 mm or 0.12 mm.
For reasons of clarity, the peripheral region 23 of the receptacle element 21, which engages in a sealing manner with the flange 6 of the single serve capsule 1, is not illustrated in FIGS. 3 to 5 . The peripheral region 23 comprises a sealing contour for engaging in a sealing manner with the sealing crimp 9. To this end, the sealing contour has a depression which encircles in the circumferential direction, and, configured adjacent to the depression, a sealing projection which likewise encircles in the circumferential direction. When viewed in the radial direction R, the depression is disposed outside the sealing projection so that an outer sealing projection shoulder of the sealing projection forms an inner wall of the depression.
In the closed position depicted in FIG. 2 , the sealing projection engages in the first flange region 18, while the sealing crimp 9 engages in the depression. Configured as a result in the radial cross section between the sealing projection shoulder and the inner shoulder 10 is a contact 16. This contact 16 is preferably present in an encircling manner in the circumferential direction and in this way forms the actual seal between the flange 6 and the receptacle element 21 so that hardly any extraction liquid, or no extraction liquid, can flow to the outlet of the brewing chamber 12 past the beverage raw material. The apex of the sealing projection optionally touches the lower side of the first flange region 18, whereas the lower side of the transition plane 15 optionally touches the base of the depression.
The afore-described configuration and sizing of the sealing crimp 9 leads to the sealing crimp 9 not being significantly deformed when closing the brewing chamber 12 and/or when brewing the beverage. The sealing takes place mainly by the in particular encircling contact 16 which by virtue of the stiffness of the sealing crimp 9 is relatively intensely impinged with force.
In other words: the sealing crimp 9 is configured in such a manner that said sealing crimp 9 when closing the brewing chamber 12 and/or brewing the single serve capsule 1 is deformed only by at most 30%, preferably by at most 20%, particularly preferably by at most 10%, and most particularly preferably by at most 5% of its height 17 perpendicular to the first and/or the second flange region 18, 19. In particular, the sealing crimp 9 in this way is configured in such a manner that said sealing crimp 9, when impinged with a force of up to 100 N acting on the sealing crimp 9 perpendicularly to the first and/or the second flange region 18, 19, is deformed only by at most 30%, preferably by at most 20%, particularly preferably by at most 10%, and most particularly preferably by at most 5% of its height 17 perpendicular to the first and/or the second flange region 18, 19. Sufficient force for the contact 16 is available only in this way.
It is conceivable that the sealing crimp 9 when closing the brewing chamber 12 and/or brewing the single serve capsule 1 in terms of its height 17 is varied in particular by at most 0.2 mm, preferably by at most 0.15 mm, particularly preferably by at most 0.1 mm, and most particularly preferably by at most 0.05 mm in the vertical direction Y. Alternatively, the sealing crimp 9 is displaced only in the radial direction R and not in the vertical direction Y, however.
The sealing crimp 9 as a result is preferably likewise configured so as to be stiff in such a manner that there is also no excessive lateral displacement or deformation in the radial direction R, respectively. It is provided that the sealing crimp 9 is configured in such a manner that said sealing crimp 9 when closing the brewing chamber 12 is preferably deformed or displaced parallel to the first and/or the second flange region 18, 19 only to the extent that the radius of said sealing crimp 9 in relation to a central center longitudinal axis M of the single serve capsule 1 is displaced parallel to the first and/or the second flange region 18, 19 only by at most 5% so that the single serve capsule 1 can be easily again retrieved from the brewing chamber 12 after brewing, and the sealing projection is not jammed by the laterally tilting sealing crimp 9.
It is conceivable that when closing the brewing chamber 12 and/or brewing the single serve capsule 1 it is preferably provided for the sealing crimp 9 that the tip of the sealing crimp 9, thus the transition region 14 of the sealing crimp 9, is displaced or deformed by at most 0.2 mm, preferably by at most 0.15 mm, particularly preferably by at most 0.1 mm, and most particularly preferably by at most 0.05 mm, in the radial direction R.
The other dimensions numerically indicated in FIG. 3 can preferably likewise be considered as essential to the invention.
Illustrated in FIG. 4 is a detailed view of the single serve capsule 1 illustrated in FIGS. 1 and 2 according to an exemplary further embodiment of the present invention. FIG. 4 here shows the sectional illustration of the sealing crimp 9 in an enlarged illustration (in the same alignment as in FIG. 3 , thus the capsule wall 7 on the left and the bead 8 on the right).
This embodiment is substantially similar to the embodiment illustrated and explained in the context of FIG. 3 , so that all preceding explanations apply in an analogous manner.
In contrast, the transition region 14 is however configured as a curved transition region and not as a rectilinear, flattened transition plane 15. The rectilinear contact region 20 on the outer shoulder 11 has a length of 0.5 mm to 0.6 mm, in particular 0.53 mm. The rectilinear contact region 16 on the inner outer shoulder 10 has a length of 0.4 mm to 0.55 mm, in particular 0.473 mm.
The angle between the inner and the outer shoulder 10, 11 is preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees and most particularly preferably substantially 10 degrees.
Illustrated in FIG. 5 is a detailed view of the single serve capsule 1 illustrated in FIGS. 1 and 2 according to an exemplary further embodiment of the present invention. FIG. 5 here shows the sectional illustration of the sealing crimp 9 in an enlarged illustration (in the same alignment as in FIGS. 3 and 4 , thus the capsule wall 7 on the left and the bead 8 on the right).
This embodiment is substantially similar to the embodiments illustrated and explained in the context of FIGS. 4 and 5 , so that all preceding explanations apply in an analogous manner.
The previously discussed dimensions deviate slightly in this embodiment and can be derived from the drawing. The angles α, β are however the same.
According to the embodiment illustrated here, the radius in the transition between the capsule wall 7 and the first flange region 18 is between 0.49 mm and 0.51 mm, in particular 0.50 mm.
The first flange region 18 comprises a first fastening face 100 in which the capsule lid 4 is connected to the flange 6, in particular is sealed to the latter. Additionally however, the second flange region 19 also comprises a second fastening face 200 in which the capsule lid 4 is connected to the flange 6, in particular is sealed to the latter. Consequently, the capsule lid 4 is according to the invention connected to the flange 6 in at least two fastening faces 100, 200. These fastening faces 100, 200 are preferably disparate, i.e. different from one another, in particular without an intersection, and are disposed in the first and the second flange region 18, 19, thus in flange regions on both sides of the sealing crimp 9.
The first and the second fastening face 100, 200 here are preferably configured so as to be substantially annular. According to the exemplary embodiment illustrated here, the annuluses here have substantially the same diameter.
The fastening faces 100, 200 here are disposed horizontally and substantially at a height corresponding to the flange regions 18, 19. Alternatively however, it is also possible that the first flange region 18 and the second flange region 19 are at different heights. This is possible inter alia for reasons of production. In this way, the first flange region 18 is disposed so as to be by between 0.020 mm and 0.030 mm, in particular by up to 0.025 mm lower, i.e. at a smaller spacing from the capsule base 5, than the second flange region 19.
Also in this case, thus in the case of, in particular horizontal, flange regions 18, 19 at different heights, the capsule lid 4 is connected to the flange 6 by way of the first fastening face 100 as well as the second fastening face 200.
The radius at the transitions between the first flange region 18 and the inner shoulder 10, and the second flange region 19 and the outer shoulder 11, is between 0.10 mm and 0.12 mm, in particular 0.11 mm, whereas the radius at the transitions between the inner shoulder 10 and the transition region 14, also flat here, and the outer shoulder 11 is preferably between 0.20 mm and 0.22 mm, in particular 0.21 mm. The radii described above here are in each case measured on the side that faces away from the capsule lid 4, corresponding to the image. As the person skilled in the art understands, the difference in terms of the associated radii on the side that faces the capsule lid 4 lies in the material thickness at this location, here thus in particular 0.11 mm or 0.12 mm.
The transition between the second flange region 19 and the bead 8 preferably is between 0.19 mm and 0.21 mm, in particular 0.20 mm.
The height 17 of the sealing crimp 9 according to this embodiment in the region of the first flange region is between 0.90 mm and 0.98 mm, in particular 0.90 mm, and in the region of the second flange region is between 1.00 mm and 0.90 mm, in particular 0.90 mm.
The bead 8 has in particular a vertical extent of between 1.20 mm and 1.40 mm, in particular 1.30 mm.
According to the example illustrated here, the transition plane 15 has a radial extent of preferably between 0.10 mm and 0.14 mm, in particular 0.12 mm.
Illustrated in FIG. 6 is a heat sealing tool, in particular a first heat sealing tool 24, according to an exemplary embodiment of the present invention. Such a heat sealing tool serves for sealing the capsule lid 4 to the flange 6 of the single serve capsule 1.
A special heat sealing tool is here an essential requirement for achieving sealing according to the invention on both sides of the sealing crimp 9.
Heat sealing tools 24, 25 of this type are already known in principle here, which is why only the points of differentiation in comparison to known heat sealing tools, in particular with a view to the single serve capsule 1 according to the invention, will be discussed below.
The heat sealing tool 24 here comprises inter alia a sonotrode 28 which generates heat in a targeted manner and thus locally heats the material of the capsule lid 4 and of the flange 6 and causes a materially integral connection between the two. As a result, a fluid-tight connection between the base element 2 and the capsule lid 4 is generated. Since pressure also plays a decisive role alongside heat, the heat sealing tool 24 comprises a receptacle element 26 which receives the base element 2 and on the lower side of the flange 6, by way of suitable counter-holding means 27 in the region of the first and/or the second fastening face 100, 200, provides a counterforce to the force exerted by the sonotrode 28 such that a deformation of the flange and thus a defective single serve capsule 1 and/or incomplete sealing of the capsule lid 4 does not arise.
The heat sealing tool 24 will be explained in more detail in the context of the following images.
In terms of the invention it is now decisive that the sealing procedure takes place in two stages, wherein in a first sub-step the capsule lid 4, initially only in the second flange region 19, along the second fastening face 200 is connected to the flange 6, and wherein in a second sub-step the capsule lid 4 in the first flange region along the first fastening face 100 as well as in the second flange region 19 along the second fastening face 200 is connected to the flange 6.
The first sub-step here corresponds in particular to pre-sealing, i.e. a sealing procedure which in comparison to the second sub-step is carried out with at least one parameter, in particular sealing temperature, sealing time and/or sealing force, reduced in value.
A combination of a sealing temperature of preferably between 200° C. and 220° C., in particular 210° C., a sealing time of preferably between 220 ms and 280 ms, in particular 250 ms, and a sealing pressure of preferably between 100 N and 500 N, in particular 300 N, this in a preferred heat sealing tool 24 corresponding to a sealing pressure of approximately 2 bar, has proven successful in particular in the context of experiments.
In principle, it is possible to carry out both sub-steps with the same heat sealing tool 24. It is possible here, for example, optionally not to perform a change between the sub-steps, i.e. to operate with the same elements, but changed parameters, and/or to replace the sonotrode 28 and/or the receptacle element 26.
Alternatively, the two sub-steps are carried out in different heat sealing tools, here a first heat sealing tool 24 and a second heat sealing tool 25.
This embodiment will be explained in a purely exemplary manner by means of FIGS. 6 to 15 . Thus, the external diameter of the sonotrode 28 of the first heat sealing tool 24 here is preferably between 34.0 mm and 35.0 mm, in particular 34.5 mm.
Shown in FIG. 7 is a schematic detailed drawing of the first heat sealing tool 24 in the region relevant here. In comparison to known heat sealing tools the first heat sealing tool 24 differs in that the counter-holding means 27 has two projecting regions which by way of upper faces lie below the first flange region 18 and the second flange region 19, respectively.
The counter-holding means 27 can be provided here in one piece or multiple pieces. The counter-holding means 27 here comprises in particular two plungers.
It has been surprisingly demonstrated here that best sealing results are achieved when two plungers with dissimilar heights are used for a single serve capsule 1, as has been described in the context of FIG. 5 . The inner plunger, thus the plunger that is assigned to the first flange region 18 and to the first fastening face 100, is in particular higher here than the outer plunger assigned to the second flange region 19 and to the second fastening face 200 by between 0.05 mm and 0.25 mm, preferably between 0.10 mm and 0.20 mm and in particular by 0.15 mm. For the sake of clarity, this is clearly illustrated here in an exaggerated manner not true to scale. Both plungers have upper faces which are in contact with the first flange region 18 and the second flange region 19 and thus define the first and the second fastening face 100, 200.
The counter-holding means 27 here can be disposed so as to be variable in terms of height or fixed.
Furthermore, the first heat sealing tool 24 in the present case has an optional heat-discharging means 29 in the center of the sonotrode 28. This here is an insert made of ceramic, the diameter thereof being chosen in such a manner that said heat-discharging means 29 covers the capsule lid 4 in the region of the interior of the single serve capsule 1, thus above the cavity 3.
The heat-discharging means 29 ensures that the heat does not compromise the beverage raw material and/or the capsule lid 4 in this region, said heat arising to a greater extent by virtue of the two different sealing procedures.
Since sealing is only effected by way of the second fastening face 200 in the first sub-step, the inner plunger for the receptacle element 26 of the first heat sealing tool 24 is optional.
Now illustrated in FIG. 8 is a second heat sealing tool 25 which effects the primary sealing procedure (also referred to as post-sealing). The second heat sealing tool 25 here corresponds substantially to the first heat sealing tool 24, so that reference is made to the explanations in the context of FIGS. 6 and 7 . This applies to FIG. 8 as well as to FIG. 9 .
The sonotrode 28 of the second heat sealing tool 25 here preferably has a larger diameter than the sonotrode 28 of the first heat sealing tool 24, particularly preferably between 34.3 mm and 35.2 mm, and in particular 34.8 mm.
The sealing procedure of the second sub-step is now carried out with at least one parameter higher in terms of value, wherein a combination of a sealing temperature of preferably between 200° C. and 220° C., in particular 210° C., a sealing time of preferably between 420 ms and 480 ms, in particular 450 ms, and a sealing pressure of preferably between 700 N and 1100 N, in particular 900 N, which in the preferred embodiment of the sonotrode 28 of the second heat sealing tool 25 corresponds to a sealing pressure of approximately 6 bar, has proven particularly successful.
As has already been mentioned, the capsule lid in this second sub-step is fixedly and in particular in a fluid-tight and pressure-tight manner fastened to the flange 6, specifically along the first fastening face 100 as well as the second fastening face 200.
Illustrated in FIG. 10 is a perspective sectional illustration of the first and/or the second heat sealing tool 24, 25. Reference is made here to the above explanations in the context of FIGS. 6 to 9 .
It can be very clearly seen in FIG. 10 that the counter-holding means 27 provides a counterforce only in the region of the first and the second flange region 18, 19. The receptacle element 26 is clearly spaced apart from the base element 2 in the region of the sealing crimp 9 as in the region of the capsule base 5.
Furthermore to be seen in FIG. 10 is the construction of the sonotrode 28, in particular with a view to the heat-discharging means 29, according to the embodiment illustrated here.
Illustrated in FIG. 11 is a schematic detailed view of a cross section of the heat sealing tool 24, 25 according to an exemplary embodiment of the present invention similar to the illustrations in FIGS. 7 and 9 . Reference in this respect is made to the preceding explanations. By way of example, grooves, presently four grooves, can be seen in the capsule wall 7 of the single serve capsule 1 here.
FIGS. 12 and 13 show technical drawings of the receptacle element 26, or of the sonotrode 28 of the first heat sealing tool 24, according to the previously explained exemplary embodiment of the present invention, respectively. The external diameter of the receptacle element 26 is preferably substantially 35 mm, and the height is preferably 36 mm.
The sonotrode 28 according to the embodiment illustrated here in turn has an external diameter of in particular 34.5 mm, wherein the heat-discharging means 29 in the sonotrode 28 has an external diameter of 29.7 mm.
FIGS. 14 and 15 show technical drawings of the receptacle element 26, or of the sonotrode 28 of the second heat sealing tool 25, according to the previously explained exemplary embodiment of the present invention, and a detailed drawing of the counter-holding means 27. Plotted in the detailed drawing is the height differential between the plungers, wherein the inner plunger, assigned to the first flange region 18, lies higher than the outer plunger by 0.15 mm.
The external diameter of the receptacle element 26 preferably is substantially 35 mm, and the height is preferably 36.15 mm. The sonotrode 28 according to the embodiment illustrated here in turn has an external diameter of in particular 34.8 mm, wherein the heat-discharging means 29 in the sonotrode 28 has an external diameter of 29.7 mm.
Illustrated in FIG. 16 is a schematic detailed view of the single serve capsule 1 according to a further exemplary embodiment of the present invention in cross section. The embodiment shown in FIG. 16 corresponds here substantially to the embodiments explained in the context of FIGS. 3 to 5 and in particular to the embodiment illustrated in FIG. 5 , so that reference is made to the respective explanations.
FIG. 16 differs from FIG. 5 in particular in terms of the dimensions and/or the associated tolerances. The following dimensions according to the illustrated embodiment can be derived here from the image from left to right. The transition from the capsule wall 7 to the first flange region 18 on the side of the capsule lid 4 has a radius of preferably 0.30 mm to 0.50 mm. The transition between the first flange region 18 and the inner shoulder 10, in particular on the side that faces away from the capsule lid 4, has a radius of preferably 0.11 mm to 0.36 mm. The sealing crimp 9 between the transition region 14, which here too is a transition plane 15, thus has an, at least in portions, flat extent of in particular 0.12 mm in length, and the first flange region 18 preferably has a height of 0.82 mm to 0.90 mm.
The transition from the inner shoulder 10 to the transition plane 15, in particular on the side that faces away from the capsule lid 4, preferably has a radius of 0.23 mm to 0.33 mm. An angle α of 5° is preferably provided between an imaginary tip of the sealing crimp 9 and a plumb line. This corresponds to an angle of 85° between a horizontal portion of the first flange region 18 and the inner shoulder 10.
Here too, the sealing crimp 9 is particularly preferably of a symmetrical construction. In this way, the virtual internal angle in an imaginary extension of the tip of the sealing crimp 9 is 10°. Furthermore, the transition from the transition plane 15 to the outer shoulder 11, in particular on the side that faces away from the capsule lid 4, preferably has a radius of 0.23 mm to 0.33 mm. The angle between the straight portion of the outer shoulder 11 and a horizontal portion of the second flange region 19 is preferably 85°. The transition between the outer shoulder 11 and the second flange region 19, in particular on the side that faces away from the capsule lid 4, has a radius of preferably 0.11 mm to 0.36 mm. The sealing crimp 9 between the transition plane 15 and the second flange region 19 preferably has a height of 0.90 mm to 1.00 mm.
The person skilled in the art understands that, within the tolerances, the first flange region 18 and the second flange region 19 thus preferably lie on a horizontal plane but, due to tolerances, there may also be a slight horizontal offset of presently at most 0.18 mm, i.e. consequently in particular somewhat more than a material thickness.
The transition between the second flange region 19 and the bead 8 preferably has a radius of 0.20 mm to 0.45 mm, wherein the bead 8 according to the embodiment illustrated has a radial extent of approximately 1 mm and a vertical extent, thus an overall height, of preferably 1.25 mm to 1.45 mm, in particular 1.35 mm.

LIST OF REFERENCE SIGNS

- 1 Single serve capsule
- 2 Base element
- 3 Cavity
- 4 Capsule lid
- 5 Capsule base
- 6 Flange
- 7 Capsule wall
- 8 Bead
- 9 Sealing crimp
- 10 Inner shoulder
- 11 Outer shoulder
- 12 Brewing chamber
- 13 Beverage preparation machine
- 14 Transition region
- 15 Transition plane
- 16 Contact region
- 17 Height of the sealing crimp
- 18 First flange region
- 19 Second flange region
- 20 Shoulder portion
- 21 Receptacle element
- 22 Closure element
- 23 Peripheral region
- 24 First heat sealing tool
- 25 Second heat sealing tool
- 26 Receptacle element of the heat sealing tool
- 27 Counter-holding means
- 28 Sonotrode
- 29 Heat-discharging means
- 100 First fastening face
- 200 Second fastening face
- α Angle
- β Angle
- R Radial direction
- Y Vertical direction
- M Central longitudinal axis

Claims

1. A single serve capsule for preparing a beverage in a brewing chamber of a beverage preparation machine, comprising:

a) a base element comprising:

i. a cavity for receiving a beverage raw material;

ii. a capsule base;

iii. an encircling flange; and

iv. a capsule wall extending between the capsule base and the encircling flange; and

b) a capsule lid closing the cavity;

wherein the encircling flange has a sealing element which, in a form of a sealing crimp that points away from the capsule lid, is configured integrally with the encircling flange;

wherein the sealing crimp comprises an inner shoulder and an outer shoulder;

wherein the encircling flange between the capsule wall and the inner shoulder has a second flange region, and between an outer free end of the encircling flange and the outer shoulder has a second flange region;

wherein the capsule lid along a first encircling fastening face is fastened in the first flange region, and along a second encircling fastening face is fastened in the second flange region;

wherein a transition region extends between the inner shoulder and the outer shoulder; and

wherein the transition region in a radial direction has an extent of about 0.05 mm to about 0.20 mm.

2. The single serve capsule as claimed in claim 1, wherein the outer free end of the encircling flange is rolled up, in such a manner that the outer free end forms an encircling bead, wherein the encircling bead relative to the encircling flange has a vertical extent of more than zero on one or both sides of the encircling flange, wherein the vertical extent of the bead on a side of the encircling flange that faces away from the capsule lid is less than the vertical extent of the sealing crimp, and/or wherein the vertical extent of the encircling bead on a side of the encircling flange that faces the capsule lid is less than on the side of the encircling flange that faces away from the capsule lid.

3. The single serve capsule as claimed in claim 1, wherein the inner shoulder as well as the outer shoulder in relation to a horizontal plane running through the first flange region and through the second flange region are aligned at an angle of more than 80 to less than 90 degrees.

4. The single serve capsule as claimed in claim 1, wherein the first encircling fastening face and the second encircling fastening face each have a substantially horizontal extent.

5. The single serve capsule as claimed in claim 1, wherein the first encircling fastening face and the second encircling fastening face are vertically spaced apart from one another, and wherein the first encircling fastening face has a smaller vertical spacing from the capsule base than the second encircling fastening face.

6. The single serve capsule as claimed in claim 5, wherein the vertical spacing between the first encircling fastening face and the second encircling fastening faces is less than three times a thickness of the encircling flange in a region of the first encircling fastening face and/or the second encircling fastening face.

7. The single serve capsule as claimed in claim 1, wherein the first encircling fastening face and the second encircling fastening face are provided in such a manner that there is no fluid connection between the cavity of the single serve capsule and a cavity present between the capsule lid and the sealing crimp.

8. The single serve capsule as claimed in claim 1, wherein the inner shoulder and the outer shoulder are configured so as to be mutually symmetrical.

9. The single serve capsule as claimed in claim 1, wherein the transition region is configured so as to be curved, or has a transition plane which extends parallel to the first flange region and/or to the second flange region.

10. (canceled)

11. The single serve capsule as claimed in claim 1, wherein the base element is integrally made of aluminum.

12. The single serve capsule as claimed in claim 1, wherein the single serve capsule in a region of the capsule base has a filter.

13. A system for preparing a beverage comprising:

a) a beverage preparation machine; and

b) the single serve capsule as claimed in claim 1;

wherein the beverage preparation machine has a brewing unit having a first brewing chamber part and a second brewing chamber part;

wherein the first brewing chamber part and/or the second brewing chamber part are/is movable relative to the other brewing chamber part between a converged position, in which the first brewing chamber part and the second brewing chamber part form a closed brewing chamber, and an open position, in which the first brewing chamber part and the second brewing chamber part are mutually spaced apart for inserting or ejecting the single serve capsule;

wherein the first brewing chamber part comprises a receptacle element for at least partially receiving the single serve capsule and the second brewing chamber part comprises a closure element for the receptacle element;

wherein in the closed position the encircling flange of the single serve capsule is received in a form-fitting and sealing manner between a peripheral region of the receptacle element and the closure element.

14. The system as claimed in claim 13, wherein a sealing contour for engaging in a sealing manner with the sealing crimp is configured in the peripheral region of the receptacle element;

wherein the sealing contour comprises an encircling depression and, configured adjacent to the encircling depression, an encircling sealing projection, wherein the encircling depression in a radial direction is preferably outside the encircling sealing projection, and wherein an outer sealing projection shoulder forms an inner wall of the encircling depression, and/or wherein in the closed position the sealing projection engages in the first flange region and the sealing crimp engages in the encircling depression in such a manner that the sealing projection shoulder conjointly with the inner shoulder in a radial cross section configure a linear contact.

15. A method for producing the single serve capsule as claimed in claim 1, comprising:

in a first step, generating the base element having the capsule base,

the encircling flange, and the capsule wall which extends between the capsule base and the encircling flange;

in a second step or in the first step, molding the sealing crimp in the encircling flange;

in a third steps, filling the cavity of the base element at least with a beverage raw material;

in a fourth step, closing the base element with the capsule lid;

wherein the capsule lid along a first fastening face and along a second fastening face is fastened to the encircling flange.

16. The method as claimed in claim 15, wherein the fourth step comprises at least one first sub-step and one second sub-step, wherein in the first sub-step sealing, by a heat sealing tool, takes place along the second fastening face, and wherein in the second sub-step sealing, by a heat sealing tool, takes place along the first fastening face and/or the second fastening face.

17. The method as claimed in claim 16, wherein in a further sub-step of the fourth step, prior to the first sub-step, the capsule lid is generated from a strip stock.

18. The method as claimed in claim 15, wherein the first step comprises a first sub-step, a second sub-step, and a third sub-step, wherein in the first sub-step a basic shape is generated from a strip stock, wherein in the second sub-step a preform is generated in such a manner that the base element is formed from the basic shape, wherein in the third sub-step a bead is formed from the outer free end of the encircling flange, wherein the molding of the sealing crimp takes place in the second sub-step or the third sub-step.

19. The method as claimed in claim 15, wherein in a fifth step, which takes place after the first step and prior to the third step, a filter is incorporated in the cavity and fastened to the base element in a region of the capsule base.

20. An installation for producing a single serve capsule, having a forming station for forming a base element, a filling station for filling a cavity of the base element with at least one beverage raw material, and a closing station for closing the base element with a capsule lid, wherein the closing station is a heat sealing station for closing a single serve capsule with a capsule lid for producing the single serve capsule as claimed in claim 1, having at least one first heat sealing tool, wherein the first heat sealing tool is configured to seal the capsule lid to the encircling flange along the second fastening face, and wherein the first heat sealing tool or a second heat sealing tool is configured to seal the capsule lid to the encircling flange along the first fastening face and/or the second fastening face.

21. The installation as claimed in claim 20, wherein the first heat sealing tool and/or the second heat sealing tool each comprise at least one sonotrode and at least one receptacle element, wherein the receptacle element has an open cavity for receiving the single serve capsule, wherein the receptacle element furthermore has at least one counter-holding means, wherein the counter-holding means, on a side of the encircling flange that faces away from the capsule lid, in a region of the first fastening face and/or of the second fastening face, is configured to provide a counterforce to a force exerted by the sonotrode.

22. The installation as claimed in claim 21, wherein the receptacle element has at least one counter-holding means in a region of the first fastening face, wherein an upper face of the counter-holding means is disposed so as to be at least 0.05 mm higher in comparison to an upper face of the counter-holding means of the first heat sealing tool and/or of the second heat sealing tool in a region of the second fastening face.

23. The installation as claimed in claim 21, wherein the sonotrode of the first heat sealing tool and/or of the second heat sealing tool has a heat-discharging means which is centrically disposed.

24. (canceled)