Note: Descriptions are shown in the official language in which they were submitted.
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SPECIFICATION
Title
Single serve capsule for preparing a beverage in a beverage preparation
machine, and method
for producing a single serve capsule
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
WO 2016 / 186 488 Al 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.
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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 WO 2016 / 186 488 Al and WO 2016 /041 596 Al. 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 Al.
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 closing 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
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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 Al and EP 1 839 543 Al. 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 WO 2016 / 041 596 Al, 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
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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
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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
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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
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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
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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,
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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.
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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 closing 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 ram 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 figures 3 to 5.
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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
closing 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.
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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
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wherein an outer sealing projection shoulder forms an inner wall of the
depression, and/or
wherein in the closed 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 closed
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.
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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
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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.
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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
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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
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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
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Figures 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.
Figures 3 to 5 show schematic detailed views of the single serve
capsule according to
the different exemplary embodiments of the present invention.
Figures 6 to 15 show different schematic views of heat sealing
tools according to different
exemplary embodiments of the present invention.
Figure 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 figures 3 to 5, and 12 to 15.
Illustrated in figures 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.
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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 pm, is provided with a layer of PP, in particular with a layer
thickness of 30 pm,
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
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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
closed position. The second brewing chamber part is configured as a closure
element 22 for the
receptacle element 21. In the closed position depicted in figure 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 figures 3 to 5 are detailed views of the single serve capsule 1
illustrated in figures
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 figure 1 or 2
in an enlarged
illustration, respectively. Figures 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
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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 13 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.
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According to the invention, the angle a 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 figures 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 figure 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.
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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,
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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 figure 3 can preferably likewise
be considered as
essential to the invention.
Illustrated in figure 4 is a detailed view of the single serve capsule 1
illustrated in figures 1 and 2
according to an exemplary further embodiment of the present invention. Figure
4 here shows the
sectional illustration of the sealing crimp 9 in an enlarged illustration (in
the same alignment as in
figure 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 figure 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 figure 5 is a detailed view of the single serve capsule 1
illustrated in figures 1 and 2
according to an exemplary further embodiment of the present invention. Figure
5 here shows the
sectional illustration of the sealing crimp 9 in an enlarged illustration (in
the same alignment as in
figures 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 figures 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 a, 13 are however the same.
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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
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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 figure 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
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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
figures 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 figure 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
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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 figure 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 figure 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 figures 6 and 7. This applies to figure 8 as well as to figure 9.
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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 figure 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 figures 6
t09.
It can be very clearly seen in figure 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 figure 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 figure 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
figures 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.
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Figures 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.
Figures 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 figure 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 figure 16 corresponds here substantially to the embodiments explained in
the context of
figures 3 to 5 and in particular to the embodiment illustrated in figure 5, so
that reference is
made to the respective explanations.
Figure 16 differs from figure 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.
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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 a of
50 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.
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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
a Angle
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R Angle
R Radial direction
Y Vertical direction
M Central longitudinal axis
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