Note: Descriptions are shown in the official language in which they were submitted.
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Method and apparatus for fabricating a beverage capsule
Field of the Invention
This invention relates generally to a method for the fabrication of a
beverage capsule for use in a beverage machine. It also relates to an
apparatus
for performing said method, as well as the beverage capsules so produced. In
particular, this invention relates to such capsules as adapted for coffee
beverages.
Background
It is known in the art to package perishable food products in sealed
packages or containers. This excludes air and moisture from the unopened
container, improving the shelf life and flavor of the products within. This
method is
especially advantageous for packaging roasted coffee.
The roasting process is what produces the characteristic flavor of coffee
by causing the green coffee beans to expand and to change in color, aroma, and
density. The oils and aromatic volatiles contained and/or developed during
roasting confer the aroma and flavor of the coffee beverage produced
therefrom,
but are also prone to degradation when exposed to the oxygen in the
surrounding
air. Packaging coffee in sealed containers will protect it from the
surrounding air,
resulting in greater shelf life and optimal flavor and aroma during
consumption.
Recently, it has been common to package coffee and other such
beverage ingredients in single-serving capsules, adapted for use in a beverage
system which prepares a beverage on demand from such capsules. These
capsules contain a pre-portioned amount of a beverage ingredient or
ingredients in
the form of finely-textured edible granules. Such beverage capsules may be
hermetically-sealed, preventing degradation of the beverage ingredient(s)
within
prior to consumption.
While this document is primarily concerned with beverage capsules
containing roasted coffee, it is understood that other alimentary substances
may be
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used in such capsules. By way of non-limiting example, such edible granules
may
comprise ground roasted coffee, soluble coffee, powdered milk, powdered cocoa,
loose tea leaves and/or other herbs, broth, or any combination thereof.
To prepare the beverage, the beverage capsule is placed into the
beverage production machine, which introduces hot water into the beverage
capsule and dispenses the resulting beverage into a container for consumption.
While this document refers to a "capsule," it is understood that other terms,
such as
"pod," "cartridge," or "packet," may be employed instead.
To offer further protection of the edible granules from degradation prior
to consumption, it is also known to seal beverage capsules under modified
atmosphere (e.g. an atmosphere saturated with nitrogen or carbon dioxide) or
under vacuum. In particular, a vacuum may be applied to the capsule when the
capsule is filled with a beverage ingredient to remove the air from within.
The
beverage capsule is formed of gas-tight packaging materials and hermetically
sealed to preserve the vacuum therein. In this way, any oxygen present in the
capsule is removed prior to sealing and the edible granules are thus protected
from
degradation prior to consumption.
However, sealing a beverage capsule by vacuum-sealing introduces
additional complications. Since the edible granules are generally of small
size and
light weight, the application of a vacuum may suck them from the capsule. Such
edible granules may be aspirated into the vacuum-application means, causing
damage to and increasing maintenance costs of the vacuum-sealing apparatus.
The edible granules may also become entrained between the sealing
walls of the capsule, e.g. between the body and the capsule sealing means,
preventing the latter from being properly bonded to the former. This
compromises
the strength and aesthetic quality of the beverage capsule seal, and by
extension
the protection of the edible granules within the seal of the beverage capsule.
The entrainment of edible granules may also result in tearing of the seal
of the beverage capsule due to the pressure increase within the capsule during
the
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beverage preparation process. This can result in the rupture of the capsule
and
the liberation of wet coffee powder through the broken seal, soiling the
beverage
machine and producing a foul-tasting beverage.
The sealing of a beverage capsule under vacuum containing ground
coffee is known in the art, for example in the US patent 5,472,719 and also in
European patent EP 1 866 942. The latter document discloses a beverage
capsule containing a quantity of coffee, which has been compressed into a
tablet,
reducing the size of the capsule and obviating the need for a filter therein.
A
vacuum is created within the capsule and the capsule is sealed by a flexible
lid,
thereby preventing degradation of the coffee tablet within.
W02008129350 refers to a machine for packaging capsules also in a
vacuum and/or in a controlled atmosphere. After filling with coffee, the
capsules
are partially closed by hermetic film. Then, a vacuum is formed inside the
capsules
and sealed by a thermo-sealing vacuum device.
U53775932 refers to a packaging apparatus for making vacuum
packages of a product by sealing of two superimposed films together with the
product contained therebetween. A
vacuum is drawn by a vacuum tube
connection in the partially sealed package whereby the edge of the packaging
film
is captured between the sealing head and a resilient strip with the edge of
the
superimposed film being free.
W02010007633 refers to a machine for packaging products, in
particular capsules for machines for delivering infusion beverages. A vacuum
bell
provides vacuum around each capsule to be welded. At the same time, vacuum
compensating means take care of inserting gas, in particular nitrogen, inside
each
capsule in such a way to compensate the presence of vacuum. Afterwards, the
welding means take care of welding the aluminium sheet onto the edge of the
respective capsule.
U54069349 refers to a process for vacuum packaging of roasted ground
coffee in pouches. The pouches are partially sealed, with a tortuous unsealed
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passage, and then stored for a predetermined period of time to permit the
gases to
evolve from the pouches and then sealing the pouches to prevent further
gaseous
passage to and from the product.
The prior art references do not, however, resolve the problem of
aspiration and entrainment of the edible granules.
It is accordingly an object of the invention to provide a method for the
fabrication of beverage capsules in which edible granules may be sealed under
vacuum within a beverage capsule, while reducing or eliminating the aspiration
of
such edible granules and thereby producing a seal of high integrity.
According, therefore, to a first aspect of the invention, the invention is
directed to a method for fabricating a beverage capsule, comprising the steps
of
providing a first wall member, said first wall member at least partially
delimiting a
cavity and having a flange disposed circumferentially about an open end
communicating with said cavity; providing a quantity of edible granules within
said
cavity of said first wall member; positioning a second wall member upon said
flange and said open end of said first wall member; attaching said second wall
member to said flange at at least two regions of said flange, thereby dividing
the
flange circumferentially into at least two attached regions and at least two
unattached regions; applying a vacuum between said first and second wall
members, thereby evacuating the gas from within said cavity and said edible
granules through said at least two unattached regions of the flange and
creating a
vacuum within said cavity; and sealing said first and second wall members
along
said flange, thereby maintaining said vacuum within said cavity.
The attachment of the second wall member to the flange of the first wall
member along at least two regions prevents the second wall member from moving
in any direction along the flange when a vacuum is applied. This is
advantageous
because the attachment of the second wall member to at least two regions of
the
flange of the first wall member will reduce or eliminate the aspiration of
edible
granules during the application of the vacuum. This also prevents the second
wall
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member from being displaced (e.g. moved off-center), deformed, or folded prior
to
the sealing step, preventing the formation of wrinkles, creases, plies, or
other
undesirable forms in the second wall member. As a result, it is possible to
produce
capsules at a faster pace on the production line while guaranteeing the
quality with
5 a high vacuum level.
According to a feature, the second wall member is attached to said
flange at a plurality of regions of said flange, thereby dividing the flange
circumferentially into a plurality of attached regions and a plurality of
unattached
regions; and the vacuum is applied between said first and second wall members,
thereby evacuating the gas from within said cavity and said edible granules
through said plurality of unattached regions of the flange, thereby creating a
vacuum in said cavity.
The term "plurality" in the present context means more than two.
This is advantageous because the attachment of the second wall
member to a plurality of regions of the flange of the first wall member will
reduce or
eliminate the aspiration of edible granules during the application of the
vacuum.
Particularly, the attached regions prevent the edible granules from leaving
the
capsule. However, the gas within the cavity and edible granules may still be
removed, as it may still flow through the spaces between the flange and the
second wall member at the unattached regions.
Thus, since the edible granules may be confined to the first wall member
during the application of the vacuum, the quantity of such edible granules
which
are aspirated into the vacuum-sealing apparatus is greatly reduced. The amount
of damage the edible granules cause to the sealing and vacuum means of the
apparatus, and the consequent maintenance and repair costs, are reduced or
eliminated. The performance of this method is thereby rendered more cost-
effective and reliable, while the quality of the beverage capsules so produced
is
simultaneously improved.
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The entrainment of edible granules between the second wall member
and the flange of the first wall member is similarly reduced or eliminated.
Since the
edible granules no longer interfere with the interface between the wall
members,
the strength and aesthetic quality of the seal between the two are improved.
The
physical properties of the beverage capsule are thus optimized, providing more
effective protection to the edible granules and better preserving the flavor
and
aroma of the beverage produced from them.
Finally, the method permits the above-mentioned advantages to be
realized while providing vacuum and sealing the beverage capsules
individually.
The attachment of the second wall member to the flange of the first wall
member
prior to the application of a vacuum and the sealing of the beverage capsule
permits a vacuum to be rapidly applied while still maintaining a high level of
strength and aesthetic quality in the sealed beverage capsules. Since the
vacuum
is applied only to one beverage capsule at a time, the sealing of each
beverage
capsule may be individually monitored and controlled. The sealing process may
thus be made adaptable so that each capsule is given a seal of the highest
possible quality. In this way, the efficiency of the method is maximized while
simultaneously ensuring that the beverage capsules so fabricated are of the
highest possible quality.
According to another feature, the method is characterized in that said
first wall member is a self-supporting capsule body and said second wall
member
is a flexible membrane.
This is advantageous in that first and second wall members in the form
of a self-supporting capsule body and a flexible membrane facilitate the
provision
of coffee within the capsule body and the sealing of the membrane upon the
flange. Also, a self-supporting capsule body will give structural strength to
the
unsealed beverage capsule, facilitating handling during the manufacturing
process.
The advantages of the invention may be realized with a minimum of effort and
expense.
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According to another feature, the steps for attaching and sealing said
second wall member onto said flange are performed by heat sealing.
This is advantageous in that heat sealing processes can rapidly produce
seals which are generally airtight, durable, flexible, and sanitary. Heat-
sealing
means may also be integrated into an apparatus embodying this method, such as
by the incorporation of hot air jets, electric resistance heaters, or the
like. Heat
sealing processes may also be adapted to work with a variety of materials,
improving the compatibility of this method.
Furthermore, the bonds created between the second wall member and
the flange of the first wall member during the attachment step will be
substantially
identical to the seal created during the sealing step. This results in a seal
which is
uniform across its entire surface, without any areas of diminished strength or
other
undesirable variations. Moreover, this feature is advantageous in that the
first and
second wall members need only be suitable for a single type of bonding process
rather than two types, increasing the selection of possible materials for the
components of the beverage capsule. This feature, therefore, makes the
invention
simpler and easier to practice while producing improved results.
In a possible alternative, the steps for attaching and sealing of said
second wall member onto said flange are performed by ultrasonic welding.
This is advantageous in that, as with heat sealing, ultrasonic welding
can rapidly produce seals which are generally airtight, durable, flexible, and
sanitary. Ultrasonic welding is also advantageous in that it does not require
the
first and second wall members to be heated in order to create the seal,
permitting
these components to be fabricated from materials which may not be suitable for
heat sealing. The versatility of the invention is thereby improved.
According to still another feature, the second wall member is attached to
said flange over an area comprising between 25% and 90%, preferentially
between
30% and 75% of the total sealed surface of said flange of said first wall
member.
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This is advantageous in that attaching the second wall member to the
flange over the ranges given above will permit the vacuum to be applied with
maximum speed and minimal aspiration of the edible granules within the
beverage
capsule. As a result, the efficiency and cost-effectiveness of the method are
improved.
According to still another feature, the edible granules are provided within
the cavity in loose form.
This is advantageous in that providing the edible granules in this way
eliminates the need for compacting the edible granules within the beverage
capsule. Instead, the edible granules are simply inserted into the cavity and
sealed
therein, without requiring any time for compacting them or additional
apparatus for
doing so. In this way, the process is rendered faster, more efficient, and
more
economical
According to still another feature, the application of vacuum and sealing
while maintaining the vacuum within the cavity are carried out immediately
after the
attaching of the second wall member to the flange and dividing the flange into
the
at least two or a plurality of attached and unattached regions. By
"immediately", it is
meant that there is no pause higher than a few seconds allowing the edible
granule
to significantly loose gas and consequently aroma.
According to a second aspect, the invention is directed to a beverage
capsule fabricated as described above.
This is advantageous in that a beverage capsule so fabricated will
embody the advantages of the invention as detailed above.
According to a third aspect, the invention is directed to an apparatus for
the fabrication of a beverage capsule, comprising an attachment means, said
attachment means being configured to attach a first wall member to a second
wall
member at a flange disposed circumferentially about an open end of said first
wall
member, said attachment being situated over at least two regions of said
flange
and thereby dividing the flange into at least two attached regions and at
least two
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unattached regions, said first wall member at least partially delimiting a
cavity in
communication with said open end and being provided with a quantity of edible
granules within said cavity; a vacuum application means, said vacuum
application
means being provided with a receptacle adapted for airtight communication with
said first and second wall members, and being further configured to evacuate
the
gas from said first wall member and edible granules through the at least two
unattached regions of the flange, thereby creating a vacuum within said
cavity; and
a sealing means, said sealing means being configured so as to create a seal
between said first and second wall members along said flange, thereby
maintaining
said vacuum within said cavity.
This is advantageous in that such an apparatus embodies the method
for fabricating a beverage capsule described above. The advantages of the
invention are thereby embodied in beverage capsules whose production is
rendered more efficient, adaptive, consistent, and economical.
In a preferred mode, the first wall member is a self-supporting capsule
body defining said cavity and said flange and the second wall member is a
flexible
membrane. The membrane may have a thickness comprised between 10 and 250
microns, preferably between 30 and 100 microns. The membrane contains at least
one layer fabricated from a material having gas barrier properties, such as
aluminum. The membrane also preferably comprises a sealant layer comprised of
a material such as polypropylene.
According to a feature, the apparatus is characterized in that the
attachment means attaches said second wall member to said flange over a
plurality of regions of the flange, thereby dividing the flange into a
plurality of
attached regions and a plurality of unattached regions and the vacuum
application
means is configured to evacuate the gas from said first wall member and edible
granules through the at least one unattached region of the flange.
The term "plurality" in the present context means more than two.
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This is advantageous in that it permits one to optimize the attachment
and vacuum-application means, as described above.
According to another feature, the attachment means comprises a
plurality of faces disposed perpendicular to and in radial symmetry about an
axis of
5 said attachment means, and which are configured to attach said second
wall
member to said flange of said first wall member over a plurality of regions
corresponding to said plurality of faces.
This is advantageous in that such an attachment means will attach the
second wall member to the flange of the first wall member over a uniform,
10 symmetric pattern, thereby providing a plurality of equally symmetric
and uniform
unattached regions. The resulting attachment will be thus rendered more
uniform
and reliable. This further reduces the aspiration and entrainment of the
edible
granules during the application of the vacuum, and produces beverage capsules
having further improved seal quality. The efficiency and cost-effectiveness of
the
apparatus are thereby improved.
According to another feature, said vacuum-application means and said
sealing means are disposed coaxially about a longitudinal axis, said vacuum-
generating means being adapted to translate along said longitudinal axis
relative to
said sealing means.
This is advantageous in that the sealing means may be disposed within
the vacuum application means. This conserves space in the apparatus,
effectively
placing the two means in the space of one. This is also advantageous in that
the
steps for vacuum application and sealing may be performed simultaneously as
described above. This feature will thereby improve the output and efficiency
of the
apparatus, while simultaneously making it more compact and space-efficient.
According to still another feature, the apparatus further comprises a
means for cutting said second wall member to substantially match the outline
of
said flange and open end of said first wall member.
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This is advantageous in that it permits the material from which the
second wall member is fabricated to be provided in bulk form, such as a sheet
or
ribbon, thereby facilitating the handling of said second wall member and
reducing
the overall complexity of the apparatus. Furthermore, cutting said second wall
member to substantially match the outline of said flange and open end of said
first
wall member will result in a second wall member which does not have to be
trimmed after the fabrication of the beverage capsule. This eliminates the
need for
additional means for trimming. In this way, the efficiency and speed of the
invention may be improved.
According to still another feature, said means for cutting said second
wall member is disposed about said attachment means, said attachment means
and means for cutting said second wall member being coaxial about a
longitudinal
axis, and said cutting means being adapted to translate along said
longitudinal axis
relative to said sealing means.
This is advantageous in that the two means may be disposed so that the
attachment means is within the means for cutting the second wall member. This
conserves space in the apparatus, effectively placing the two components in
the
space of one. The vacuum application and sealing means may be adapted to act
upon the first and second wall members simultaneously, thereby reducing the
time
required to carry out the attachment and cutting steps. This feature will
thereby
improve the output and efficiency of the apparatus, while simultaneously
making it
more compact and space-efficient.
Brief Description of the Drawings
Other particularities and advantages of the invention will also emerge
from the following description.
In the accompanying drawings, given by way of non-limiting examples:
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- Figure 1 is a series of orthogonal section views depicting an
attachment means, a cutting means, a vacuum-application means, and a sealing
means;
- Figure 2 is a series of views of attachment apparatuses in four
different configurations; and
- Figure 3 is a flowchart depicting the method of the invention as
integrated into a process for the fabrication of beverage capsules, said
process
comprising a series of steps.
Description of the Invention
The following description will be given with reference to the above-
mentioned figures.
Figure 1 is a sequence of section views depicting the sealing of a
beverage capsule according to the invention. Figure 1 depicts the attachment
and
cutting steps in views A through D, and the vacuum application and sealing
steps
in views E through H. Portions of the apparatus are omitted from each of these
views for purposes of clarity.
View A depicts an attachment means 100 and a cutting means 101
disposed in a first position, prior to the start of an attachment step. The
attachment
means 100 and the cutting means 101 are generally tubular and coaxial about
the
first longitudinal axis 102. Preferably, the cutting means 101 will be
disposed
around and capable of translation relative to the attachment means 100, as
depicted here.
A capsule body 103 is positioned within the base plate 104, which is
provided with a capsule seat 105 in which the capsule body 103 is positioned.
The
base plate 104 is preferably configured to be mobile, facilitating a high rate
of
production of beverage capsules. This mobile configuration may comprise such
means as a conveyor belt system or rotating turret, for example. In the
preferred
embodiment, the capsule body 103 is positioned beneath the attachment means
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100 and cutting means 101 so as to be coaxial with them about the first
longitudinal axis 102.
The capsule body 103 defines a cavity 106, in which a predetermined
quantity of ground coffee powder 107 is provided. The capsule body 103 is
substantially cup-shaped, and is provided with an open end 108 communicating
with said cavity 106. The capsule body 103 is further provided with a flange
109,
disposed about the circumference of the capsule body 103 at the open end 108.
The capsule body 103 is preferably fabricated from a formable material
such as aluminum, plastic, starch, cardboard, or combination thereof. Where
the
capsule body itself is not gas-impermeable, a gas barrier layer may be
incorporated therein to prevent the entry of oxygen. The gas barrier may
comprise
a coating, film, or layer of aluminum, ethylene vinyl alcohol, polyamide,
oxides of
aluminum or silicon, or combinations thereof.
For example, in one embodiment, the capsule body 103 is formed of
deep-drawn aluminum. In another embodiment, the capsule body 103 is formed of
deep-drawn polypropylene and aluminum. In a third embodiment, the capsule
body 103 is thermoformed from a combination of polypropylene, ethylene vinyl
alcohol, and polyethylene terephthalate.
In a preferred embodiment, the flange 109 and the capsule seat 105 are
configured so that the capsule body 103 protrudes through the base plate 104,
with
the flange 109 resting directly on the base plate 104 and substantially the
entire
beverage capsule 103 being disposed beneath the base plate 104. In an
alternate
configuration, the capsule seat may be configured as a cup, in which the
capsule
body is seated.
A portion of membrane material 110 is disposed between the cutting
means 101 and the base plate 104. Said membrane material 110 is preferably
provided in the form of a continuous sheet or web, which may be fed into the
apparatus by techniques adapted from those known in the art of materials
handling. The membrane material 110 is preferably flexible, permitting
moderate
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elastic deformation. The membrane material 110 may have a thickness between
and 250 microns, preferably between 30 and 100 microns.
In a preferred embodiment, the membrane material 110 comprises at
least a base layer fabricated of aluminum, polyester (e.g. PET or PLA),
5 polyolefin(s), polyamide, starch, paper, or any combination thereof. The
base layer
is preferentially formed of a laminate comprising two or more sub-layers of
these
materials. The base layer may comprise a sub-layer which acts as a gas
barrier, if
none of the other sub-layers are of a material which is impermeable to gas.
The
gas barrier sub-layer is fabricated from a gas-impermeable material such as
10 aluminum, ethylene vinyl alcohol, polyamide, oxides of aluminum or
silicon, or
combinations thereof. The membrane material 110 preferably also comprises a
sealant layer, e.g. polypropylene, disposed to create a seal with the capsule
body
103.
For example, in one embodiment the membrane material 110 is an
aluminum layer between 25 and 40 microns. In another embodiment, the
membrane material 110 comprises a base layer with two sub-layers: an external
sub-layer made of PET and an internal sub-layer made of aluminum. The
aluminum sub-layer serves the function of preventing undesirable transmission
of
light, moisture, and oxygen. In another embodiment, the membrane material 110
comprises three sub-layers: an external sub-layer of PET 5 to 50 microns
thick, a
middle sub-layer of aluminum 5 to 20 microns thick, and an internal sub-layer
of
cast polypropylene 5 to 50 microns thick.
View B depicts the apparatus in a second position, during a cutting step.
The cutting means 101 is advanced downward along the first longitudinal axis
102
into the membrane material 110. In a preferred embodiment, the cutting means
101 is sharpened along its peripheral edge 111 so as to cut the membrane
material
110 when pressed into it. However, alternate configurations, such as a hot-
knife
apparatus, may be preferable for certain compositions of heat-sensitive
membrane
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material. The cutting means 101 is advanced through the membrane material 110,
cutting a membrane 112 from the membrane material 110.
View C depicts the apparatus in a third position, during an attachment
step. At the lower end 113 of the attachment means 100 are disposed a
plurality of
5 faces
disposed substantially perpendicular to the longitudinal axis 102, which are
pressed into the membrane 112. The attachment means 100 is advanced so that
the lower end 113 presses the membrane 112 into the flange 109 over a
plurality of
regions corresponding to the aforementioned faces.
The attachment means 100 is configured to attach the membrane 112 to
10 the
flange 109 over the regions where the faces of the lower end 113 press said
membrane 112 into the flange 109 of the capsule body 103. In the present
embodiment, the attachment of the membrane 112 to the flange 109 of the
capsule
body 103 is achieved by heat-sealing; though in other embodiments alternate
techniques such as ultrasonic welding may be preferred.
15 The
attachment means 100 is therefore preferably furnished with
appropriate means for attaching the membrane 112 to the flange 109 during the
attachment step. For example, such means may comprise an electrical resistance
heater, hot air jet, or ultrasonic welding horn. This will make the apparatus
more
compact and space-efficient.
Said regions of the flange 109 corresponding to the faces of the lower
end 113 of the attachment means 100 will comprise a portion of the total
surface of
the flange 109. The cavity 106 of the capsule body 103 thereby remains in
communication with the surrounding atmosphere, via the spaces between the
flange 109 and the membrane 112 where the membrane 112 remains unattached
to the flange 109.
View D depicts the apparatus in a fourth position, after the completion of
the attachment step. The attachment means 100 and cutting means 101 are
withdrawn from the capsule body 103 and membrane 112. The scrap membrane
material 110 may be removed, while the base plate 104 is advanced in direction
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114 to both place the current beverage capsule in position for vacuum sealing
and
bring the next beverage capsule into position for the attachment and cutting
steps.
Preferably, the step for cutting the membrane 112 as depicted in View B
and the step for attaching said membrane 112 to the flange 109 as depicted in
View C are performed sequentially but in a continuous movement of descent of
the
cutting and attachment means 101, 100. A slight vacuum is further applied
through
the attachment means to maintain the membrane 112 in coaxial position in axis
102 during the cutting and attachment steps. This is advantageous, in that it
minimizes the time to fabricate a capsule and thus increases the rate at which
capsules are produced.
View E depicts the apparatus in a fifth position, prior to the start of a
sealing step. The cutting and attachment means depicted in the previous steps
are
omitted here for clarity; however, the cutting and attachment means are
ideally
disposed adjacent or in close proximity to the vacuum-application means 115
and
sealing means 116, making the apparatus more compact and space-efficient.
In a preferred embodiment, the vacuum-application means 115 and the
sealing means 116 are preferably tubular and disposed coaxially about the
second
longitudinal axis 117. The sealing means 116 is in the form of a hollow
cylinder, of
approximately the same width and diameter of the flange 109 of the beverage
capsule 103. The vacuum-application means 115 is also in the form of a hollow
cylinder, and is provided with a means for creating a vacuum within.
Preferably,
the vacuum-application means 115 is configured so as to be capable of
translation
relative to the sealing means 116 along their shared second longitudinal axis
117.
The base plate 104 is advanced in the direction 114 until the capsule
body 103 and membrane 112 are also coaxial with the vacuum-application means
115 and the sealing means 116 about the second longitudinal axis 117. The
capsule body 103 and membrane 112 are thus positioned in a centered position
directly below the vacuum-application means 115 and sealing means 116.
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View F depicts the apparatus in a sixth position, during a vacuum-
application step. The vacuum-application means 115 have been advanced so as
to create an airtight seal between the mouth 118 of the vacuum-application
means
115 and the flange 109 of the capsule body 103. A vacuum 119 is applied to the
capsule body 103 through the vacuum-application means 115, reducing the
pressure in the cavity 106 of the capsule body 103 below atmospheric pressure.
The vacuum 119 causes the gas within the cavity 106 of the capsule
body 103 to be drawn out through the plurality of spaces between the flange
109
and the membrane 112, which are defined by the regions where said membrane
112 remains unattached to said flange 109. The gas can be air or any inert
gas,
such as nitrogen, CO2, or any combination thereof. In this way, the cavity 106
of
the capsule body 107 is voided of gas and a vacuum created within it.
The vacuum-application step is preferentially configured so that the
vacuum may be rapidly applied to the capsule body 103 while avoiding sucking
the
coffee powder 107 from the cavity 106. It is known that the rapid application
of a
vacuum to a beverage capsule may cause some of the coffee powder within to be
sucked out, which may result in damage to the apparatus from aspirated coffee
powder. The coffee powder may also become entrained between the sealing
surfaces of the beverage capsule, weakening the seal and diminishing its
aesthetic
properties. The application of vacuum may also cause the sealing means to
move,
further compromising seal integrity.
Here, the attachment of the membrane 112 to the flange 109 of the
capsule body 103 over a plurality of regions will prevents the aspiration and
entrainment of the coffee powder 107 between the flange 109 and the membrane
112, as well as prevent the displacement of the membrane relative to the
capsule
body during the application of the vacuum 119. The integrity of the beverage
capsule seal and the reliability of the sealing apparatus are thus preserved
even
when the vacuum is applied very rapidly, permitting higher-quality beverage
capsules to be produced at a faster rate.
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The vacuum-application step is also preferentially configured to enable
the conditions within the capsule to be monitored as the vacuum 119 is
applied.
Specifically, the vacuum-application means permits the rapid application of
the
vacuum 119 to a single capsule body 103, rather than the slower application of
a
vacuum to a group of capsule bodies in a vacuum chamber. Thus, by use of data
collection and/or control-loop methods known in the art, one may continually
adapt
the parameters of the vacuum-sealing process to optimize the sealing of each
capsule while still maintaining an overall high rate of production.
View G depicts the apparatus in a seventh position, during a sealing
step. The mouth 118 of the vacuum-application means 115 is kept in contact
with
the flange 109 of the capsule body 103, such that the vacuum within the cavity
106
of the capsule body 103 is maintained.
The sealing means 116 is preferably provided with a means for creating
a seal between the membrane 119 and the flange 109 of the capsule body 103,
similar to the attachment means as discussed above. As with the attachment
means, this may comprise such means as an electrical resistance heater, hot-
air
jets, or ultrasonic welding horn.
The sealing means 116 is advanced into contact with the membrane
112, pressing into it along the sealing edge 120 disposed at an end of said
sealing
means 116. The membrane 112 is pressed into the flange 109 by the sealing
means 116, thereby bonding the remaining unattached regions of the membrane
112 to the surface of the flange 109 and sealing the cavity 106 of the capsule
body
103. While the remaining unattached regions of the membrane are bonded, the
bond of the attached regions created during the attachment step may be
renewed.
The air-tight hermetic seal created between the flange 109 and the membrane
112
will thereby preserve the vacuum in the cavity 106 of the capsule body 103,
protecting the coffee powder 107 from exposure to air and subsequent loss of
flavor and aroma.
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View H depicts the sealed beverage capsule after the completion of the
sealing step. The sealing means 116 is withdrawn to allow the bond to
solidify.
Then the vacuum is stopped in the vacuum means, exposing the capsule body 103
and membrane 112 to atmospheric pressure and causing the membrane 112 to
take a concave form as depicted. Finally, the vacuum-application means 115 is
withdrawn. The vacuum which was applied to the capsule body 103 in an earlier
step is preserved therein by the seal between the flange 109 and the membrane
112. The base plate 104 is then moved off in direction 114, removing the
capsule
to be packaged and distributed and bringing the next capsule into position for
vacuum sealing.
In addition to the benefits realized by the invention as discussed above,
an additional benefit is realized when, as in this embodiment, the edible
granules
are of a substance that tends to evolve a gas. Such substances notably include
roasted coffee, especially ground roasted coffee powder as described here.
As a result of chemical processes triggered by the roasting process, the
coffee powder 107 will evolve gas for a period of time after the roasting
process is
completed, a process known in the art as "degassing." As the coffee powder 107
within the beverage capsule degasses, the gases which are evolved are kept
within the cavity 106 of the beverage capsule by the membrane 112, the capsule
body 103, and the hermetic seal between them.
This accumulation of evolved gases will cause the pressure within the
beverage capsule to increase until equilibrium pressure is reached. At
equilibrium,
there will be a positive pressure within the beverage capsule, i.e. a pressure
above
the atmospheric pressure, causing the membrane 112 to be deflected outwardly.
The vacuum which is sealed into the beverage capsule thus partially
offsets the pressure generated by the gases evolved from the coffee powder
107.
The degree to which the vacuum offsets the evolved gases may vary from
embodiment to embodiment, depending on the volume of the beverage capsule,
the mass of coffee provided within, and the type and degree of roast of the
coffee
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powder itself. In any case, the vacuum within the beverage capsule compensates
for the degassing at least to the extent that the evolved gas is prevented
from
compromising the structural integrity of the beverage capsule and its hermetic
properties.
5 In a
preferred embodiment, the initial vacuum pressure of the capsule
immediately after the sealing step will be between 300 and 600 mbar, and
preferably between 400 and 500 mbar. After the beverage capsule is sealed, the
gases evolved by the coffee powder during degassing will continue to
accumulate
in the cavity 106 of the beverage capsule, causing the internal pressure of
the
10
beverage capsule to rise above atmospheric pressure in approximately 5 hours
and reach equilibrium at between 1050 and 1600 mbar, and most preferably
between 1050 and 1350 mbar in approximately 72 hours.
Additionally, the method is preferably configured so that all, or
substantially all, of the degassing occurs within the beverage capsule after
it has
15 been
sealed. While the pressure within the beverage capsule will be negative at
time of sealing, the evolved gases will rapidly increase the pressure within
the
capsules. In a preferred embodiment, the capsule will rise above atmospheric
pressure in less than 5 hours and stabilize in approximately 72 hours.
Figure 2 is a series of views depicting several configurations for the
20
attachment means. As discussed above, the attachment means comprises at its
bottom end a plurality of faces, which are pressed into the membrane to attach
it to
the flange of the capsule body over a plurality of regions corresponding to
said
faces.
Figure 2A and 2B depict an orthogonal view and a perspective view,
respectively, of an attachment means 200. As previously discussed, the
attachment means 200 is substantially in the form of a hollow cylinder. Two
slots
201 have been provided in the attachment means 200, with the result that the
end
of the attachment means 200 is divided into two faces 202 and two voids 203.
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When pressed into a membrane during the attachment step as
described above, the membrane will be attached to a flange of a capsule body
over
the portion of the surface of the flange corresponding to the faces 202 of a
first
kind. The membrane will remain unattached and permit fluid communication
between the cavity of the capsule body and the surrounding atmosphere through
the unattached regions between the membrane and flange defined by the voids
203 of a first kind.
Figure 2C depicts an orthogonal view of an alternate configuration for
the attachment means, comprising four faces 204 of a second kind and four
voids
205 of a second kind. Such an attachment means will attach a membrane to a
flange of a capsule body over a plurality of regions corresponding to each of
the
four faces 204 of a second kind, while leaving the regions of the membrane
corresponding to the four voids 205 of a second kind unattached.
Figure 2D depicts an orthogonal view of another alternate configuration
for the attachment means, provided with eight faces 206 of a third kind and
separated by eight voids 207 of a third kind. As above, the faces 206 of a
third
kind will define the region over which a membrane is attached to the flange of
a
capsule body, and the voids 207 of a third kind defining where it is
unattached.
Figure 2E depicts an orthogonal view of another alternate configuration
for the attachment means, provided with eight faces 208 of a fourth kind which
are
separated by eight voids 209 of a fourth kind. Compared to the attachment
means
depicted in Figure 2D, the faces 208 of a fourth kind are much smaller than
the
faces 206 of a third kind, while the voids 209 of a fourth kind are much
larger than
the voids 207 of a third kind. As a result, the proportion of the flange of a
capsule
body to which a membrane will be attached by the attachment device in Figure
2E
is much lower than would be achieved by the attachment device of Figure 2D,
with
a corresponding increase in the size of the regions of the flange to which the
membrane remains unattached.
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The attachment devices may in this way be configured to best suit the
particular application in which the attachment device is to be employed. In
the
foregoing embodiments the attachment devices are altered by adjusting their
number and size; however, in other embodiments it may be advantageous to
modify other elements of their form and geometry such as shape, thickness, or
placement about the lower end of the attachment means.
In this way, one may configure the attachment means to reduce the time
required to apply the vacuum to the capsule body while still minimizing the
aspiration and entrainment of the coffee powder or other edible granules
contained
within the capsule body. The sealing of the beverage capsules may thus be
optimized to achieve a maximum output at a minimum cost.
Figure 3 is a flowchart depicting a process for the fabrication of
beverage capsules, said operation comprising a series of elements. The first
step
of the operation is Capsule Body Destacking 300. The empty capsule bodies are
generally stored stacked atop each other when stored before use, and so must
be
separated before they can be further processed. In the step for Capsule Body
Destacking 300, the capsule bodies are separated from each other and placed in
the proper orientation to continue in the process.
Simultaneously, the Coffee Preparation Process 301 furnishes a supply
of coffee powder for packaging within the beverage capsules. In the Coffee
Preparation Process 301, coffee beans are roasted to the desired degree of
roasting and then ground to the desired degree of fineness.
As discussed above, the gases generated within the coffee beans
during roasting are evolved from the coffee. Some degassing will occur between
the roasting of the coffee and the sealing of the beverage capsule. It is
preferable,
however, to configure the process for fabrication of beverage capsules to
minimize
degassing outside of the capsule, so that the degassing essentially occurs
after the
beverage capsule has been sealed. In a preferred embodiment, the duration
between the grinding of the coffee and its provision within the beverage
capsule is
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less than ten minutes; in this way the flavor and aroma of the beverage
ultimately
produced from the beverage capsule is best preserved.
Furthermore, since the coffee is not degassed before the sealing
process, the infrastructure required to degas the coffee beforehand is no
longer
necessary. This renders the beverage capsule sealing operation more compact,
economical, and flexible.
During Product Filling & Densifying 302, a portion of the coffee powder
provided by the Coffee Preparation Process 301 is placed within the capsule
body
and densified, so that the coffee is settled within the capsule body and the
amount
of gas therein is so minimized. In an alternate embodiment, the beverage
powder
may be compacted into a tablet during the Coffee Preparation Process 301 step,
which is then positioned in the capsule body during the step of Product
Filling &
Densifying 302.
Ideally, each element of the operation is linked by a step for Transport
303, where the capsule body is transferred between the devices for carrying
out
each element of the operation. In addition, it is understood that the elements
for
carrying out each of the elements of the process may be located in proximity
to
each other, or even integrated into each other, so that the time required for
transporting the beverage capsule between elements is minimized. The process
is
thereby rendered more space-efficient and economical.
After this is Membrane Attachment and Cutting 305, as depicted in
Views A-D of Figure 1. In this step, the membrane is attached to the flange of
the
capsule body at a plurality of regions of the flange, leaving a plurality of
unsealed
regions on said flange as well. The membrane is also cut to a size which will
cover
the flange and open end of the capsule body.
Following Membrane Attachment & Cutting 305 is Vacuum Application &
Sealing 306, depicted in Figure 1, Views E-H. A vacuum is applied to the
capsule
body, removing the gasfrom within through the plurality of unsealed regions of
the
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flange. The membrane is then sealed over the entirety of the surface of the
flange,
preserving the vacuum within the capsule.
In beverage capsules containing roasted, ground coffee as shown here,
it is particularly advantageous that the vacuum within the capsule is a
reduction of
pressure high enough to offset the pressure generated by the gases evolved by
the
coffee as it degasses in the capsule. A normally configured beverage capsule
will
so resist the pressure accumulated within the sealed capsule as a result of
the
evolved gases.
Finally, the capsule is transferred to Distribution 308, where it may be
packaged in a box, sleeve, bag, or the like and distributed for sale.
Of course, the invention is not limited to the embodiments described
above and in the accompanying drawings.
Modifications remain possible,
particularly as to the construction of the various elements or by substitution
of
technical equivalents, without thereby departing from the scope of protection
of the
invention.
In particular, it should be understood that the present invention may be
adapted to fabricate beverage capsules for the preparation of various kinds of
alimentary substances, for example broth, cocoa, coffee, infant formula, milk,
tea,
tisane or any combination thereof. It should also be understood that the
edible
granules comprising said alimentary substances may be provided in various
forms
and sizes, such as flakes, grains, granules, pellets, powders, shreds, or any
combination thereof. While the particular embodiment of the preceding
description
is directed to a beverage capsule containing a quantity of roasted, powdered
coffee, it should not be construed as limiting the scope of the invention to
beverage
capsules so configured.
Furthermore, while the embodiments depicted in the accompanying
figures depict an attachment means which is configured to attach a membrane to
a
flange of a capsule body over a plurality of regions, it should be understood
that an
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attachment device which does so over only one region of the flange of the
capsule
body may equally be feasible.
The exact configuration and operation of the invention as practiced may
thus vary from the foregoing description without departing from the inventive
5 principle described therein. Accordingly, the scope of this disclosure is
intended to
be exemplary rather than limiting, and the scope of this invention is defined
by any
claims that stem at least in part from it.
