Portion capsule

Abstract

The invention relates to a portion capsule (1) filled with an extraction material for preparing a brewing product, comprising a base body made of plastic and a cover (3) fastened thereto. The base body and the cover together form a capsule encapsulating the extraction material. The cover comprises a cover flange (42), the inner side of which is fixed to the base body. The cover has a substantially rectangular, in particular square, horizontal cross-section. An end-side flat cover surface (31) of the cover is offset axially outward with respect to a plane defined by the cover flange. According to one aspect of the invention, the cover comprises a reinforcing structure with at least one inwardly projecting reinforcing rib (46). Wherein the reinforcing structure is designed such that it crosses two diagonals of the cover surface.

Description

Technical Field

[0001] The present invention relates to the preparation of beverages, etc. using extraction materials (such as ground coffee) contained in capsules. In particular, it relates to a portioned capsule. Background Art

[0002] Extraction devices for preparing beverages from extraction materials in portioned packages are known, such as coffee machines, espresso machines or tea machines. In many corresponding systems, the portioned packages are designed as capsules, in which the extraction materials are isolated, for example, in an airtight manner. For extraction, the capsules are pierced on both opposite sides. Brewing liquid (usually hot water) is introduced on the first side. The brewed beverage flows out from the second side of the capsule. Here, a relatively high pressure must be maintained inside the capsule, depending on the beverage to be prepared and the system.

[0003] From WO 2010 / 118543 and WO 2015 / 096989, it is known that coffee portioned capsules are generally cubic in shape and made of plastic. Different from the known cup-shaped capsules, they do not have a ring-shaped flange at the plane of the lid surface (upper side). In the capsule systems of the prior art, such a ring-shaped flange is necessary, especially for closing the capsule by means of a foil serving as a lid. In contrast, according to WO 2010 / 118543 and WO 2015 / 096989, an arched lid is used. The capsule manufactured according to the teachings of WO 2010 / 118543 accordingly has a welded edge that forms a flange and surrounds the planes defined by the lid surface, but its extension / lateral protrusion is significantly reduced compared to the flange of the known capsules. Welding requires an energy director, which is composed of an annular rib and can be provided on the mug (according to WO 2010 / 118543) or on the lid (according to WO 2015 / 096989). By forming an arched transition region between the lid flange and the flat lid surface, the arched lid forms a flat lid surface that is offset relative to the surface extending from the lid flange.

[0004] EP 3907145 and EP 2889244 respectively show a coffee portioned capsule of the type shown in WO 2010 / 118543 and WO 2015 / 096989, in which the arched lid contains an energy director of the above type before the capsule is closed. In addition, in some embodiments, an inwardly protruding web is integrally formed at the edge of the flat lid surface (i.e., at the transition between the flat lid surface and the transition region). This web serves as a mechanical reinforcement and also serves as an auxiliary stacking function since it is located at the edge of the flat lid surface.

[0005] In particular, aluminum and plastics (such as polypropylene) have become well-known capsule materials. So-called bioplastics have also been discussed as capsule materials. On the one hand, plastics made from renewable raw materials (so-called bio-based plastics) are called bioplastics. On the other hand, bioplastics refer to plastics that are biodegradable (so-called biodegradable plastics). The plastics proposed for manufacturing portion capsules are biodegradable, some of which contain bio-based plastics.

[0006] In this article, "biodegradable" means biologically degradable according to the standard EN13432 (date: end of 2020), and "bio-based" means "made from renewable raw materials and not manufactured on a fossil basis".

[0007] EP 3922578 relates to a capsule made of a composite material, the capsule cup of which has reinforcing ribs.

[0008] The plastic capsules described in WO 2020 / 118543, WO 2015 / 096989, EP 3907145 and EP 2889 244 have proven their value. However, their manufacturing process requires certain inputs. During the manufacturing process, among other things, it is crucial to fix the lid to the substrate filled with the extraction material, especially by ultrasonic welding. Since the lid is a dimensionally stable three-dimensional entity and not just a layer of foil, it first needs to be manufactured by a forming method and then precisely positioned on the substrate for fixing. In addition, this requires the lid to be placed separately in the welding equipment, which is not only time-consuming but also increases the manufacturing cost of the entire capsule. Summary of the Invention

[0009] The object of the present invention is to provide a solution for this.

[0010] This object is achieved by the invention defined in the patent claims.

[0011] A portion capsule filled with an extraction material for preparing a brewed product, which in a manner known per se includes a substrate usually made of plastic and a plastic lid fixed thereto. The substrate and the lid together form a capsule for accommodating the extraction material. The substrate forms a base region, a circumferential side wall and a circumferential substrate flange, and the circumferential substrate flange is connected to the circumferential side wall on the side facing the lid. The lid includes a lid flange, the inner side of which is fixed to the substrate flange, for example, welded thereto. The capsule has a generally rectangular, especially square, horizontal cross-section, and at least in the flange region, the capsule has a generally rectangular, especially square, horizontal cross-section through the substrate and the lid.

[0012] In particular, the capsule as a whole can be at least approximately cube-shaped.

[0013] The lid is not flat but arched outwards (relative to the inside of the capsule), so it arches out axially, i.e., the flat lid surface at the (axial) end side is axially displaced outwards relative to the plane defined by the flange. Thus, this lid is different from flat lid elements, such as foil or sheet lid elements. It is an object with a three-dimensional shape. In other words, the lid forms an arch, so it increases the volume of the capsule by the offset of the lid surface relative to the lid flange.

[0014] According to one aspect of the invention, the lid forms a reinforced structure with at least one inwardly protruding reinforcing rib. Here, the reinforced structure is designed to cross at least two diagonals of the lid surface.

[0015] Specifically, the reinforced lid is located on the lid surface, i.e., it protrudes inwards from the lid surface.

[0016] "Protruding inwards" here means "protruding in the direction of the inside of the capsule".

[0017] The reinforcing rib is designed such that it increases the stiffness of the lid surface, which is not present in structures known from the prior art mentioned, for example.

[0018] The meaning of "crossing" the diagonal is that at least one reinforcing rib crosses the diagonal, i.e., extends from one side of the diagonal to the other. Specifically, it not only runs along the edge of the lid surface but also keeps a considerable distance from the corner points (e.g., at least 5% of the diagonal length, or at least 10%). Assuming the diagonal length of the lid surface is 30 to 40 mm, the diagonal can cross at least two points, each at least 3 mm or at least 5 mm from the corner point, and / or in the middle of the diagonal. If the corner points are rounded or chamfered, the distance is measured from the effective actual edge of the lid surface, not from the corner point in the mathematical sense.

[0019] Therefore, the fact that it crosses the diagonals of the lid surface also means that the reinforcing rib not only extends along the edge of the lid surface but also extends inside the lid surface.

[0020] It has been found that this reinforced structure is beneficial for the industrial production of the capsule. Due to this reinforced structure, the lid can be prevented from bending during transportation to the production equipment, where the capsule consists of a lid, a matrix, and extraction material. First, it should be recognized that for the capsule lid shape with a rectangular horizontal cross-section and a lid surface offset with respect to the flange described here, the deformation of the capsule lid mainly occurs along the diagonal. This reinforced structure that crosses two diagonals can prevent these deformations. On the contrary, due to the design itself, it has sufficient flexural stiffness on the side lengths. Second, we recognize that it is precisely these deformations that impede reasonable industrial production: they will prevent bundling multiple capsule lids together and placing them in the welding equipment.

[0021] The shape of the lid from the radially outer side to the radially inner side generally includes a lid flange, a transition region such as a curved one, and a lid surface as a central flat region. The transition region defines an offset between the axial positions of the flange and the lid surface, that is, for example, it extends approximately "vertically" (if the horizontal is defined by the lid surface), but in any case not perpendicular to the axis.

[0022] "Flat" here refers to the outer surface, and the reinforcement structure and possibly more inwardly protruding structures represent deviations from the flat shape. Relief-like lettering or similar patterns can also be adopted on the flat lid surface on the outer side.

[0023] The transition region can be curved, for example, in an S-shaped manner, or continuously extend from the outside at an angle to the flange plane to the intermediate flat lid surface. Here, the dimensions are selected such that, for example, the intermediate flat region (lid surface) is visually dominant, for example, it is the same size as or slightly smaller (for example, at most 10%) than the capsule base surface. In particular, the flat region can occupy more than 60% of the capsule diameter, thus occupying at least 40% of the surface area.

[0024] The shape of the reinforcement structure can in particular be adapted to the geometry of the puncturing device, which is used to perforate the capsule in a targeted manner on the lid side during the extraction process. Reinforcing ribs can in particular be provided where there is no puncturing spike penetrating the lid.

[0025] Specifically, the reinforcing ribs can be fixed on the transition region, and / or can form a complete circumferential structure, such as an annular structure around the center, or a polygonal structure around the center. In the first case (fixed on the transition region), the reinforcing ribs are supported on the edge of the capsule lid, which is designed to be relatively hard. In the second case, they form a structure that is rigid in itself.

[0026] Examples of the reinforcement structure include: a pair of reinforcing ribs diagonally extending between the corners (the two diagonals are spanned by corresponding reinforcing ribs extending along the other diagonal); a pair of reinforcing ribs extending parallel to the sides from the center (each diagonal is spanned by two reinforcing ribs); or a pair of reinforcing ribs extending along the corners, with both ends of each reinforcing rib connected to the transition region. Another example is an annular reinforcing rib. Combinations of these concepts are easily achievable.

[0027] Specifically, the lid can be manufactured by injection molding, and so can the base body. Accordingly, the manufacturing method of the capsule can include the following steps: manufacturing the base body by a molding method (here, molding methods such as injection molding and re - molding methods such as deep - drawing molding are also regarded as molding methods); manufacturing the lid by injection molding, wherein the mold is designed to form a reinforcement structure and, for example, an energy director in addition to the lid flange, the transition region, and the lid surface; filling the extraction material (such as ground coffee) into the base body; fixing the lid to the base body such that the lid flange is connected to the base - body flange, for example, by ultrasonic welding; optionally, after the connection, separating the outer part of the flange formed by the base - body flange and the lid flange.

[0028] In this text, "radial" and "axial" always refer to being related to the axis of the capsule, which passes centrally through the capsule and is perpendicular to the plane defined by the flange (usually also perpendicular to the plane of the capsule base and the lid surface). This axis is also related to the function of the capsule: during brewing, the liquid flows axially, that is, from the capsule base towards the capsule lid (or vice versa). The "radial" direction is perpendicular to the axis of the capsule. Therefore, "radial" does not mean that the horizontal cross - section of the capsule is circular.

[0029] In an embodiment, the base body and / or the lid can exist, for example, in the form of a multi - layer system of bioplastic (such as Ecovio) / polyvinyl alcohol (PVOH) / bioplastic, where PVOH forms a diffusion - barrier layer. A so - called connecting layer, that is, an adhesive layer, can be arranged between the PVOH layer and the bioplastic, especially for a deep - drawable layer system, so that the structure can be bioplastic / connecting layer / PVOH / connecting layer / bioplastic. Biodegradable connecting layers are already known and can be bought on the market, such as natural wax.

[0030] As an alternative to the bioplastic design, the base body and the lid can also have different plastic designs, such as with a diffusion - barrier layer, such as polypropylene.

[0031] The plastic material of the lid can be the same as that of the base body. However, the lid can also be made of plastic with other compositions, provided that the composition can be welded to the base - body plastic.

[0032] The wall thickness of the base - body region is particularly, for example, between 0.2 mm and 0.5 mm, for example, between 0.25 mm and 0.45 mm. The wall thickness of the lid can be between 0.25 mm and 0.55 mm, for example, between 0.35 mm and 0.45 mm. In an embodiment, the wall thickness of the lid roughly corresponds to that of the base body.

[0033] The capsule (this applies to all embodiments and also to the first aspect) can in particular be designed such that the matrix and the lid together completely enclose the extraction material without an opening covered by, for example, a foil or the like. Specifically, it can be sealed and oxygen-impermeable, for example by providing a suitable diffusion barrier. Description of the Drawings

[0034] Embodiments of the present invention will be described below in conjunction with the drawings. In the drawings, the same reference numerals denote the same or similar elements. The drawings are not drawn to scale, and the elements partially correspond to each other and have different sizes. In the figures:

[0035] Figure 1 : Capsule;

[0036] Figure 2 : For manufacturing Figure 1 The matrix of the shown capsule;

[0037] Figure 3 : Lid;

[0038] Figure 4 : The lid according to the prior art (seen from the inside); and

[0039] Figure 5 : Lid with a reinforcement structure;

[0040] Figure 6 : Another lid with a reinforcement structure;

[0041] Figure 7 : The lid according to another embodiment;

[0042] Figure 8 : Figure 7 The variant of the shown lid;

[0043] Figure 9 : The lid according to another embodiment; and

[0044] Figure 10 And Figure 11 Are respectively schematic diagrams of two other variants. Detailed Description of the Invention

[0045] According to Figure 1 The capsule has generally the shape of a cube with rounded edges. However, in a strict mathematical sense, the upwardly extending part of the capsule is slightly enlarged, which makes the capsule in the shape of a truncated cone. In the figure, the inclination angle of the lateral surface with respect to the plane perpendicular to the base surface 5 (of course, it means the plane perpendicular to the base surface and passing through the edge between the base surface and the corresponding lateral surface) is very small, preferably at most 2°, for example only about 1°. In addition, the height of the capsule above the base surface is approximately equal to the length of the edge of the base surface.

[0046] The capsule comprises a base body (or cup) 2 and a lid 3 fixed thereto along a circumferential flange 4. The base body is formed by a capsule base 5 and a circumferential side wall 6, the end of the circumferential side wall 6 being located outside the axis (axis 10), and in the figure at the top, and is closed by the flange 4. The lid arches outwards through a lid surface 9, the lid surface 9 being substantially parallel to the capsule base 5 and offset outwards (and axially "vertically") relative to the circumferential flange 4, thus being offset to the Figure 1 top in

[0047] Figure 2 The state of the base body 2 (cup) before filling and sealing is shown. The base body flange 41 has an extension which can be greater than the extension of the flange 4 of the finished capsule.

[0048] Figure 3 The lid 3 is shown, which, like the base body 2, is made, for example, by injection moulding. The central region of the lid comprises a lid surface 31, a transition region 32 forming an arch, and a lid flange 42.

[0049] Figure 1 capsules of the type drawn in Figure 2 base bodies 2 of the type drawn in Figure 3 and lids 3 of the type shown are known in the prior art, for example from WO2015 / 096990.

[0050] When manufacturing the capsule, first the extraction material is filled into the base body 2, and then the lid 3 is positioned. Ultrasonic welding is then carried out. After welding is completed, depending on the initial extensions of the base body flange and the lid flange, the protruding flange parts will separate.

[0051] Figure 4 Shown from the inside is Figure 1 and Figure 3 a lid 3 of the type shown. The lid according to Figure 4 is not designed according to the present invention and does not include any reinforcement structure. It has been found that such lids are prone to bending during transportation, where the bending usually occurs along one of two diagonals ( Figure 4 the diagonal 51 is drawn in ; the bending along this diagonal 51 is indicated by the square arrow), and the bending along a bending axis parallel to the side is prevented by the stiffness resulting from the arch formed by the transition region 32, the transition region 32 thus bending away from the plane of the lid surface 31.

[0052] Figure 5Shows a lid 3 with a reinforcement structure. The reinforcement structure consists of two reinforcing ribs 46, each of which extends diagonally and is connected to each other in the middle of the capsule lid. Therefore, the reinforcing ribs extending along the other diagonal respectively cross these two diagonals. The reinforcing ribs are also connected to the transition region 32, thus forming a particularly stable structure as a whole.

[0053] In the illustrated embodiment, the height of the rib (i.e., the axially extending part) corresponds to the height of the lid arch. However, this is not necessary. The height of the rib can also be designed to be lower or higher; in the latter case, considering the manufacturing method of the capsule, in addition to serving as a reinforcement, the rib can also serve as a centering function.

[0054] In accordance with Figure 6 In the variant, there are also two staggered reinforcing ribs 46. The reinforcing ribs 46 also extend to and are connected to the transition region 32. However, different from the Figure 5 illustrated embodiment, the reinforcing ribs are parallel to the side surface, rather than diagonal. Figure 6 The diagonal 51 crossed by the reinforcing rib 46 is schematically drawn.

[0055] Figure 7 An embodiment with four reinforcing ribs 46 is shown, each of which connects the two sides formed by the intersection of the transition regions at the (rounded) vertices. These circumferential reinforcing ribs 46 also cross the diagonal 51, thus resisting bending along the diagonal. Figure 7 The distance a that the reinforcing rib crosses the diagonal 51 is also shown (in the Figure 5 and Figure 6 embodiments, the distance a is equivalent to half of the diagonal length because these diagonals exactly span at their centers).

[0056] Figure 8 The variant shown is different from the Figure 7 illustrated embodiment, and its reinforcing rib is bent radially outward. However, compared with the Figure 7 straight - extending and side - connecting reinforcing ribs shown, the reinforcement effect of this approach is slightly weakened. However, the reinforcing rib itself is sufficient, and its advantage is that the central region of the lid surface 32 without the reinforcing rib has a greater radial extension. Therefore, such embodiments even allow the puncturing tips to be closely arranged, almost covering the entire lid surface. Figure 8 The distance a that the reinforcing rib crosses the diagonal is also shown.

[0057] Finally, Figure 9 An embodiment with a single annular reinforcing rib 46 is shown. Although the reinforcing rib is not fixed to the transition region, due to its annular design, it has stability by itself. For example, it is suitable for a brewing module with at least one puncturing tip respectively inside and outside the ring formed by the reinforcing rib.

[0058] Figure 5-9 Combinations of the concepts are also conceivable. For the sake of illustration, and as one of numerous possible examples, Figure 10 a possible structure is schematically shown in a very schematic manner, which consists of continuous reinforcing ribs 46, wherein the reinforcing ribs extend diagonally but do not extend to the center and have a central annular reinforcing rib. Unlike the Figure 5 embodiment, these reinforcing ribs also allow the arrangement of a central puncture tip. Figure 11 A variant combining Figure 8 and Figure 9 concepts is shown. Other combinations are also possible, just like other concepts, for example, having reinforcing ribs arranged in a hash-like manner, replacing the annular reinforcing rib with a square structure (or adding thereto), an irregular structure, etc.

Claims

1. A portioning capsule (1) filled with an extraction material for preparing a brewed product, comprising: - A substrate (2) made of plastic, having a base region (5), a circumferential side wall (6), and a circumferential substrate flange (41) connected to the circumferential side wall towards the lid side; and - A lid (3) made of plastic, having a circumferential lid flange (42); - Wherein, the substrate (2) and the lid (3) have a generally rectangular horizontal cross-section in the region of the flange (4); - Wherein, the lid (3) is formed with a flat lid surface (31), which is arranged offset with respect to the surface defined by the lid flange (42); - Wherein, the lid surface (31) also has a rectangular horizontal cross-section, thereby defining two diagonals (51); - Wherein, the inner side of the lid flange (42) is fastened to the substrate flange to form a common flange (4); - And wherein the substrate and the lid encapsulate the extraction material inside the capsule; It is characterized in that: - The lid (3) includes a reinforcing structure having at least one reinforcing rib (46), which protrudes towards the inside of the capsule, and the reinforcing structure passes through the two diagonals (51).

2. The portioning capsule according to claim 1, wherein the lid (3) comprises, from radially outside to radially inside, a lid flange (42), an arched transition region (32) and a lid surface (31) which is central and flat.

3. The portioning capsule according to claim 2, wherein The reinforcing structure extends to and is connected to the transition region (32).

4. The portioning capsule according to claim 3, wherein the reinforcement structure comprises a plurality of reinforcing ribs (46) extending between the two ends, each reinforcing rib being connected to the transition region at both ends and each reinforcing rib passing across a diagonal line (51).

5. The portioning capsule according to any one of the preceding claims, wherein The reinforcing structure includes a plurality of reinforcing ribs (46), which extend from the edge of the lid surface (31) towards the middle and are connected to each other.

6. The portioning capsule according to claim 5, which comprises two reinforcing ribs (46) which cross each other in the middle of the lid surface and extend in a diagonal direction or parallel to the sides of the lid surface (3).

7. The portioning capsule according to any one of the preceding claims, which comprises a reinforcing rib (46) extending in a ring around the center of the lid surface (31).

8. The portioning capsule according to any one of the preceding claims, wherein the lid (3) is manufactured by injection molding.

9. The portioning capsule according to any one of the preceding claims, wherein the lid (3) is welded to the base body (2).

10. A method of manufacturing a portioning capsule according to any one of the preceding claims, comprising the following steps: • The substrate is made by a molding method; • The lid is made by injection molding, wherein the mold is designed to form, in addition to the lid flange (42), the transition region (32) and the lid surface (31), also a reinforcing structure; • The substrate is filled with the extraction material; • The lid (3) is fastened to the substrate (2) such that the lid flange (42) is connected to the substrate flange (41).

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