Single serve capsule for preparing a beverage in a beverage preparation machine, system for preparing a beverage and method and insallation for producing a single serve capsule

Abstract

A portion capsule for preparing a beverage in a brewing chamber of a beverage production machine is proposed, wherein the portion capsule comprises a base element with a cavity for receiving a beverage raw material and a capsule lid closing the cavity, wherein the base element comprises a capsule bottom, a circumferential flange and a capsule wall extending between the capsule bottom and the circumferential flange, wherein the flange has a sealing element formed integrally with the flange in the form of a sealing bead pointing away from the capsule lid, wherein the sealing bead comprises an inner flank and an outer flank, wherein the flange has a first flange region between the capsule wall and the inner flank and a second flange region between the outer free end of the flange and the outer flank.wherein the capsule lid is fastened along a first circumferential mounting surface in the first flange area and along a second circumferential mounting surface in the second flange area.

Description

State of the art

[0001] The present invention is based on a portion capsule for preparing a beverage in a brewing chamber of a beverage production machine, wherein the portion capsule has a base element with a cavity for receiving a beverage raw material and a capsule lid closing the cavity, wherein the base element comprises a capsule base, a circumferential flange and a capsule wall extending between the capsule base and the circumferential flange, wherein the flange has a sealing element formed integrally with the flange in the form of a sealing bead pointing away from the capsule lid, wherein the sealing bead comprises an inner flank and an outer flank, wherein the flange has a first flange region between the capsule wall and the inner flank and a second flange region between the outer free end of the flange and the outer flank.

[0002] Such portion capsules are known from the prior art. For example, the document WO 2016 / 186 488 A1 discloses such a generic portion capsule. This portion capsule is intended to be inserted into a brewing chamber in which the capsule base is perforated in order to introduce brewing liquid in the form of hot water under pressure into the cavity. This increases the pressure inside the portion capsule, whereby the capsule lid is pressed against a relief or pyramid plate in the brewing chamber and is perforated or breaks open at the contact points when a predetermined pressure is reached. The beverage produced by the interaction between the introduced water and the beverage raw material, in particular roasted and ground coffee, leaves the portion capsule through these perforations in the capsule lid. In other words, these portion capsules are surrounded by water orThe beverage flows through the capsule. This generic portion capsule is therefore fundamentally different from another type of portion capsule, in which the flow occurs in the opposite direction, i.e., the water enters the portion capsule through the capsule lid, and the beverage leaves the portion capsule through the capsule base.

[0003] What all portion capsules have in common is that a sufficient seal between the brewing chamber and the portion capsule in the area of ​​the flange is necessary so that the water inside the brewing chamber flows through the beverage raw material to form the beverage and does not flow past the beverage raw material outside the portion capsule, i.e. between a wall of the brewing chamber and the outside of the capsule wall.

[0004] For this purpose, these types of portion capsules have a sealing element in the flange area, which seals against a brewing chamber element in the brewing chamber. It is desirable for the sealing element to be made of the same material as the capsule body (also known as the base element) to keep the production costs of the portion capsule low and to facilitate the disposal or recycling of used portion capsules.

[0005] Portion capsules with such sealing elements are disclosed, for example, in the publications WO 2016 / 186 488 A1 and WO 2016 / 041 596 A1. The portion capsules disclosed therein have an embossed sealing bead in their flange. The sealing effect between the sealing bead and the brewing chamber element is intended to be achieved by a simple deformation of the sealing bead. Another portion capsule with a circumferential sealing element is known to those skilled in the art from the publication EP 2 872 421 A1.

[0006] The aforementioned portion capsules all have in common that the sealing effect of their sealing elements is based on a strong deformation of the sealing elements themselves. For this purpose, inner flanks with the flattest possible angle are used so that the brewing chamber element can act on the flank when the brewing chamber closes, thus leading to a slight deformation of the sealing element.

[0007] The disadvantage of a sealing solution based on deformation of the sealing element is that this requires significantly increased forces to close the brewing chamber. The ease of use and longevity of the beverage preparation machine are thus considerably increased. In addition, the sealing elements known from the prior art are designed asymmetrically. If deformed, these sealing elements therefore tilt sideways. Although this achieves an increased sealing effect, the lateral tilting of the sealing elements regularly creates the problem that the brewing chamber element is clamped by the sealing element in such a way that the portion capsule can no longer be separated from the brewing chamber element after the brewing process without increased force. Ejecting the used portion capsule from the brewing chamber is therefore made considerably more difficult and significantly impairs ease of use.

[0008] An alternative would be separate sealing elements made of a sealing material, as known from EP 1 654 966 A1 and EP 1 839 543 A1. However, such sealing elements have the aforementioned disadvantage that, due to the use of separate materials, the manufacturing costs for the portion capsules are significantly higher, and, on the other hand, the disposal or recycling of used portion capsules is more difficult because the different materials must be separated from one another.

[0009] Another problem with conventional single-portion capsules is the attachment of the capsule lid to the flange. Such capsule lids are usually made at least partially of aluminum and are usually sealed to the flange along a circumferential sealing surface. This is particularly unproblematic for single-portion capsules with a continuous flange, where the capsule lid can be attached over the entire surface or at least easily with a sufficiently large sealing surface.

[0010] The situation is different with single-dose capsules, which, as described above, have a sealing bead formed integrally with the flange. In this case, the flat surface of the flange available for sealing is limited, making it difficult to achieve a reliable seal. If the capsule lid seal has even a few flaws, liquid can escape through the capsule lid.

[0011] Furthermore, if the lid is sealed to a region of the flange located radially outside the sealing bead, as in the aforementioned WO 2016 / 041 596 A1, liquid can flow into the cavity of the sealing bead and remain there as dead volume. This amount of liquid is not only missing from the desired total volume of the beverage, but it can also leak from the sealing bead after the brewing process, thus causing unwanted dripping from the portion capsule. Disclosure of the invention

[0012] It is an object of the present invention to provide a portion capsule of the type mentioned above that does not have the problems outlined in connection with the prior art. In particular, a portion capsule is to be provided that ensures secure attachment of the capsule lid even when the portion capsule has a sealing bead. Furthermore, a method for producing such a portion capsule and a system for producing such a portion capsule are to be provided.

[0013] The object of the present invention is achieved with a portion capsule for preparing a beverage in a brewing chamber of a beverage production machine, wherein the portion capsule has a base element with a cavity for receiving a beverage raw material and a capsule lid closing the cavity, wherein the base element comprises a capsule base, a circumferential flange and a capsule wall extending between the capsule base and the circumferential flange, wherein the flange has a sealing element formed integrally with the flange in the form of a sealing bead pointing away from the capsule lid, wherein the sealing bead comprises an inner flank and an outer flank, wherein the flange has a first flange region between the capsule wall and the inner flank and a second flange region between the outer free end of the flange and the outer flank,The capsule lid is secured along a first circumferential fastening surface in the first flange region and along a second circumferential fastening surface in the second flange region. Preferably, the first and / or second fastening surface is a flat plane. Particularly preferably, the first and / or second fastening surface is circular, with the first fastening surface and the second fastening surface having, in particular, substantially the same radial extent.

[0014] The portion capsule according to the invention has the advantage over the prior art that, by fastening the capsule lid in at least two disparate areas, a pressure-resistant and secure attachment of the capsule lid is achieved. In particular, advantageously, no liquid can penetrate into the cavity formed by the sealing bead. It was surprising and unexpected for the skilled person that secure attachment is also possible on two different, individually small surfaces.

[0015] Advantageous embodiments and further developments of the invention can be found in the dependent claims and the following description with reference to the drawings. These advantageous embodiments and further developments also relate to the other objects of the invention, and vice versa.

[0016] According to a preferred embodiment of the present invention, the base element is made in one piece from aluminum. Those skilled in the art will understand that the sealing element, which according to the invention is provided in one piece with the flange, is also made of aluminum in this case. In the context of this invention, aluminum is also intended to include aluminum laminates and other materials that contain at least aluminum. In particular, materials that additionally have paints and / or coatings are also intended to be included, whereby these can also include plastic materials, for example. Aluminum is the preferred material for the portion capsule according to the invention, but alternatively the base element can also be made from a plastic material and / or a biodegradable material.It is crucial that the sealing element is formed as a sealing bead integrally with the flange, and that a secure attachment of the capsule lid to the first flange area and the second flange area is possible. The base element is preferably manufactured by cold or hot forming, in particular deep drawing, in which the sealing bead is integrally embossed into the flange. The portion capsule is preferably frustoconical or cylindrical.

[0017] According to a preferred embodiment of the present invention, the capsule lid comprises an aluminum foil. Here, too, the term "aluminum foil" is understood to mean an aluminum laminate foil and / or an aluminum foil with a one- or two-sided coating and / or lacquer. The capsule lid can be provided in one or more layers and, in particular, also comprise a layered structure.

[0018] Preferably, the beverage raw material provided in the cavity formed by the base element and sealed, in particular hermetically, by the capsule lid comprises coffee roast granules, instant coffee, chocolate powder, tea blend, milk powder and / or the like.

[0019] 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 flanged, in such a way that it forms a circumferential bead, wherein the bead preferably has a vertical extension relative to the flange greater than zero, particularly preferably on both sides of the flange, wherein very particularly preferably the vertical extension of the bead on the side of the flange facing away from the capsule lid is less than the vertical extension of the sealing bead and / or wherein the vertical extension of the bead on the side of the flange facing away from the capsule lid is less than on the side of the flange facing away from the capsule lid. In other words, it is preferably provided that the bead is smaller than the sealing bead, particularly preferably on both sides of the flange.Most preferably, the bead is formed substantially symmetrically to the flange, particularly with regard to its vertical extent. Alternatively, it is also possible for the vertical extent of the bead on the side of the flange facing away from the capsule lid to be greater than the vertical extent of the sealing bead and / or for the vertical extent of the bead on the side of the flange facing away from the capsule lid to be greater than on the side of the flange facing away from the capsule lid. Most preferably, the bead is provided in such a way that no sealing effect develops during beverage preparation. Such a bead advantageously protects a user from unintentional injuries, particularly when the base element is made of aluminum.However, even with single-dose capsules made of plastic materials, the outer free end of the flange can be sharp and / or contain production-related defects that pose a risk of injury to the user. This is particularly advantageously avoided by providing a bead, effectively a rounded outer free end of the flange. The bead is formed in particular by rolling the flange edge, with the flange edge preferably being rolled toward the capsule base.

[0020] According to a preferred embodiment of the present invention, the inner flank and the outer flank are designed symmetrically to one another. In particular, they have the same angles and / or the same material thicknesses. This advantageously enhances the inventive effect of a stable and reliable seal.

[0021] According to a preferred embodiment of the present invention, both the outer flank and the inner flank are aligned at an angle of greater than 80 to less than 90 degrees, preferably of 81 to 89 degrees, particularly preferably of 83 to 87 degrees, very particularly preferably of 84 to 86 degrees and in particular of substantially 85 degrees, to a horizontal plane running through the first flange region and the second flange region, respectively. Those skilled in the art will understand that, in the context of the present invention, horizontal refers in particular to a conventional arrangement of the capsule, in which the central longitudinal axis of the preferably rotationally symmetrical capsule is arranged vertically and the first and / or the second flange region are arranged perpendicular to this capsule axis.Particularly preferably, the horizontal extension of the first and / or second flange region coincides with a horizontal extension of the first and / or second fastening surface. It has been shown that, in this angular range, on the one hand, the deformation of the sealing bead can be reduced and the rigidity of the sealing bead can be increased because the angle is as steep as possible and the sealing bead thus ensures a high level of stability against forces acting on the sealing bead perpendicular to the first and / or second fastening surface (also referred to as the vertical direction and thus in particular parallel to the central longitudinal axis of the portion capsule). On the other hand, simple and cost-effective production of the portion capsule is enabled because the angle is always smaller than a right angle. If there was a right angle on both flanks of the sealing bead, the inner flank and the outer flank, demolding of the portion capsule from the mold orEmbossing tool in the production of the portion capsule is much more difficult.

[0022] According to a preferred embodiment of the present invention, the sealing bead is designed such that when the brewing chamber is closed, it is deformed by a maximum of only 30%, preferably a maximum of 20%, particularly preferably a maximum of 10%, and very particularly preferably a maximum of 5% of its total height perpendicular to the first and / or second flange region or to the first and / or second fastening surface. In particular, the sealing bead is designed such that when a force of up to 100 N is applied to the sealing bead perpendicular to the first and / or second fastening surface, it is deformed by a maximum of only 30%, preferably a maximum of 20%, particularly preferably a maximum of 10%, and very particularly preferably a maximum of 5% of its height perpendicular to the first and / or second fastening surface.

[0023] According to a preferred embodiment of the present invention, the sealing bead is designed such that, when the brewing chamber is closed, it is only deformed parallel to the first and / or second fastening surface to such an extent that its radius relative to a central longitudinal axis (around which the flange is arranged rotationally symmetrically) of the portion capsule shifts only by a maximum of 10%, preferably by a maximum of 8%, particularly preferably by a maximum of 5%, and most particularly preferably by a maximum of 4% parallel to the first and / or second fastening surface. This advantageously prevents the brewing chamber element from becoming trapped by the laterally tilting sealing bead, so that the brewed portion capsule can always be removed from the brewing chamber easily and without increased effort.

[0024] The sealing bead is therefore particularly designed to be so stiff and stable that when a force of in particular up to 100 N is applied centrally to the sealing bead perpendicular to the first and / or second fastening surface, i.e. along the vertical direction, parallel to the central longitudinal axis of the portion capsule, which force acts in particular flat on the tip of the sealing bead or on the inner and / or outer flank of the sealing bead or on a flat transition plane of the sealing bead, a reduced deformation of the sealing bead takes place. The height of the sealing bead should in particular be variable by a maximum of 30%, preferably by a maximum of 20%, particularly preferably by a maximum of 10% and most preferably by a maximum of 5%. Furthermore, it is conceivable that only a reduced lateral displacement orDeformation occurs along a direction parallel to the first and / or second fastening surface, i.e., in particular, in the radial direction R as viewed from the central longitudinal axis of the concentrically formed portion capsule. Here, too, it is provided that the tip of the sealing bead, i.e., the transition region of the sealing bead, shifts or deforms by a maximum of 10%, preferably by a maximum of 8%, particularly preferably by a maximum of 5%, and most preferably by a maximum of 4% of its total radius from the central longitudinal axis of the portion capsule. The total radius can be considered, for example, to be the radius from the center of the sealing bead.

[0025] It is preferably provided that the angle between the inner and outer flank is preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees and most particularly preferably substantially 10 degrees.

[0026] According to a preferred embodiment of the present invention, it is provided that the first fastening surface and the second fastening surface each have a substantially horizontal extension. Particularly preferably, the extension of the first and / or second fastening surface coincides with the extension of the first or second flange region in the region of the respective fastening surface. This means in particular that it is preferred if the first fastening surface corresponds to a, in particular horizontal, surface section of the first flange region on the side of the flange facing the capsule lid and / or if the second fastening surface corresponds to a, in particular horizontal, surface section of the second flange region on the side of the flange facing the capsule lid.The horizontal extension of the fastening surfaces enables a conventional fastening by sealing using a flat sonotrode in a particularly advantageous manner.

[0027] According to a preferred embodiment of the present invention, the base element has a preferably constant, but at least average, material thickness of 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 preferably substantially 0.11 mm. The base element preferably has the above-mentioned material thickness at least in the region of the sealing bead, the capsule wall, the capsule base, and / or the flange, in particular the first and / or second flange region.

[0028] According to a preferred embodiment of the present invention, the first fastening surface and the second fastening surface are vertically spaced from one another, wherein preferably the first fastening surface has a smaller vertical distance from the capsule base than the second fastening surface. Particularly preferably, this also applies accordingly to the first and second flange regions. In this way, a portion capsule is provided whose flange has two, in particular horizontal, sections at different heights. This is particularly advantageous since, due to manufacturing reasons, a minimal offset between the first flange region and the second flange region cannot often be avoided. It was extremely surprising to the person skilled in the art and was not to be expected that secure fastening of the capsule lid is also possible in two regions that are at different heights relative to the central longitudinal axis.In particular, the available first fastening surface of the first flange area is very small, so secure fastening was not to be expected. Alternatively, the first flange area and the second flange area are at the same height. This has the advantage that when the brewing chamber is closed, there is no indirect displacement or deformation of the sealing bead due to the first flange area and the second flange area deforming or displacing relative to each other in the vertical direction. Instead, both flange areas can be supported on the closure element of the brewing chamber and thus build up a suitable counterforce to prevent any significant deformation of the sealing bead.

[0029] According to a preferred embodiment of the present invention, the vertical distance between the fastening surfaces and / or the first and second flange region is less than three times the thickness of the flange in the region of the first and / or second fastening surface or the first and / or second flange region, preferably less than 0.035 mm, particularly preferably less than 0.030 mm, in particular a maximum of 0.025 mm. Most preferably, the vertical offset is less than twice the material thickness and even more preferably less than one material thickness. In this case, the material thickness is in particular the material thickness of the base element in the region of the first and / or second flange region, in particular measured vertically to the extension in the aforementioned region.This advantageously allows for a certain tolerance in the heights of the flange areas due to production reasons, while still ensuring a secure and tight fastening of the capsule lid.

[0030] According to a preferred embodiment of the present invention, the first fastening surface and the second fastening surface are arranged such that there is no fluid connection between the cavity of the portion capsule and the cavity existing between the capsule lid and the sealing bead. This means that, in particular, the fastening of the capsule lid in the first flange region via the first fastening surface is designed to be fluid-tight. This advantageously provides a water- and airtight portion capsule.

[0031] According to a preferred embodiment of the present invention, a transition region extends between the inner flank and the outer flank, wherein the transition region is preferably curved or has a transition plane extending parallel to the first flange region and / or the second flange region. In particular, the transition plane is horizontal. The curved design of the transition region has the advantage that the sealing bead gains stability and deformation can thus be prevented even more effectively. In contrast, the flat design of the transition region has the advantage that the sealing bead is flatter and therefore engages less deeply into the recess of the sealing contour of the receiving element of the brewing chamber, so that less force is exerted on the sealing bead when the brewing chamber is closed. In addition, the risk of the brewing chamber part becoming trapped is lower with the flat sealing bead.

[0032] According to a preferred embodiment of the present invention, the transition region has a radial extension 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 in the radial cross section of the circumferential sealing bead, the transition region has a rectilinear connection region which has a width of between 0.05 mm to 0.20 mm, preferably of 0.07 mm to 0.17 mm, particularly preferably of 0.10 mm to 0.14 mm, and in particular of 0.12 mm.

[0033] According to a preferred embodiment of the present invention, the portion capsule has a radius of 0.03 mm to 0.20 mm, preferably 0.06 mm to 0.15 mm, and particularly preferably 0.09 mm to 0.13 mm, in particular 0.11 mm, in the transition from the outer flank to the second flange region and / or from the inner flank to the first flange region. The preferred dimensioning of the sealing bead described above results in the sealing bead being sufficiently stable to prevent deformation thereof during the closing of the brewing chamber and / or the brewing of the capsule in the brewing chamber.

[0034] Preferably, in the radial cross-section of the circumferential sealing bead, both the inner flank and the outer flank each have a linear contact area extending between the flange and the transition area. The term "in the radial cross-section" means that one is looking at a sectional view of the flange contour along the circumferential direction of the circumferential flange contour. The plane of the sectional view is therefore spanned by the vertical direction and the radial direction, as in the Figures 3 to 5 illustrated.

[0035] According to a preferred embodiment of the present invention, the linear contact area has a length of 0.1 mm to 1.5 mm, preferably 0.3 mm to 1.3 mm, particularly preferably 0.5 mm to 1.0 mm, and most particularly preferably 0.7 mm to 0.9 mm. Simulations and experiments have shown that an optimal seal between the sealing contour of the brewing chamber element and the flange can be achieved with a linear contact area of ​​the stated lengths.In other words: A positive and non-positive flat contact of the inner flank with a sealing nose flank of the sealing contour of the brewing chamber element over a length of 0.1 mm to 1.5 mm, preferably from 0.3 mm to 1.3 mm, particularly preferably from 0.5 mm to 1.0 mm and most preferably from 0.7 mm to 0.9 mm is sufficient to achieve a sufficient sealing effect (in the area of ​​the inner flank), without a strong deformation of the sealing bead due to the sealing contour being necessary.

[0036] According to a preferred embodiment of the present invention, it is provided that the portion capsule 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 in the transition from the linear contact region to the transition region on the side facing the capsule lid. According to a preferred embodiment of the present invention, it is provided that the portion capsule 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 in the transition from the outer flank to the transition region on the side facing the capsule lid. According to a preferred embodiment of the present invention, it is provided that the height of the sealing bead perpendicular to the sealing plane is 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 preferred dimensioning of the sealing bead described above results in the sealing bead having sufficient stability so that no significant deformation of the same occurs during the closing of the brewing chamber and / or the brewing of the capsule in the brewing chamber.

[0037] According to a preferred embodiment of the present invention, the portion capsule has one or more, preferably two, three, four, five, six, seven, or eight, concentrically circumferential grooves on its capsule wall, in particular on the outer side of the capsule wall. The grooves can be designed as inwardly or outwardly directed depressions and / or elevations. Such grooves advantageously serve to stiffen or reinforce the capsule wall, so that the portion capsule can withstand the pressures occurring during beverage production.

[0038] According to a preferred embodiment of the present invention, the portion capsule has a filter in the region of the capsule base. The filter particularly preferably comprises a nonwoven material and / or a felt material. Most preferably, the filter is designed in one or more layers. Preferably, the filter is disc-shaped, in particular round. Alternatively, the filter is angular, for example square, hexagonal, octagonal or decagonal. It is preferably provided that the filter is arranged in the region of the base. Most preferably, the filter is attached, in particular sealed, in sections or circumferentially to the capsule base and / or to the capsule wall and / or in a transition region between the capsule base and the capsule wall.

[0039] A further subject of the present invention is a system for preparing a beverage comprising a beverage production machine and a portion capsule according to the invention, wherein the beverage production machine has a brewing unit with a first brewing chamber part and a second brewing chamber part, wherein the first and / or the second brewing chamber part is movable relative to the other brewing chamber part between an approximate 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 spaced apart from each other for inserting or ejecting a portion capsule, wherein the first brewing chamber part comprises a receiving element for at least partially receiving the portion capsule and the second brewing chamber part comprises a closure element for the receiving element,wherein in the closed position the flange of the portion capsule is positively and sealingly received between an edge region of the receiving element and the closure element.

[0040] The portion capsule according to the invention is part of the system according to the invention, which is why all advantages and further developments explained in connection with the portion capsule also apply equally to the system according to the invention - and to the further objects of the present invention - and vice versa.

[0041] According to a preferred embodiment of the present invention, a sealing contour is formed in the edge region of the receiving element for sealing engagement with the sealing bead, wherein the sealing contour comprises a circumferential recess and a circumferential sealing nose formed adjacent to the recess, wherein the recess is preferably arranged radially outside the sealing nose and wherein an outer sealing nose flank forms an inner wall of the recess and / or wherein, in the closed position, the sealing nose engages in the first flange region and the sealing bead engages in the recess such that the sealing nose flank forms a line contact with the inner flank in radial cross-section. Such a design of the brewing chamber part is particularly advantageous since it improves the tightness of the system. In particular, a path extension for any water that may penetrate is achieved.

[0042] According to a preferred embodiment of the present invention, in the closed position, the sealing bead is deformed by the sealing contour by only a maximum of 30%, preferably a maximum of 20%, particularly preferably a maximum of 10%, and most particularly preferably a maximum of 5% of its height perpendicular to the first and / or second fastening surface. This advantageously limits the acting forces and thus reduces the risk of damage to the beverage production machine and / or the portion capsule.

[0043] According to a preferred embodiment of the present invention, the sealing contour has a further circumferential sealing nose, wherein the recess is arranged radially between the sealing nose and the further sealing nose, wherein the sealing nose is longer than the further sealing nose, and wherein, in the closed position, the further sealing nose forms a point contact with the outer flank in the radial cross-section. This further improves the seal in a particularly advantageous manner.

[0044] A further subject of the present invention is a method for producing a portion capsule according to the invention, wherein in a first step a base element having a capsule base, a circumferential flange and a capsule wall extending between the capsule base and the circumferential flange is produced, wherein in a second step a sealing bead is formed into the flange, wherein in a third step the cavity of the base element is filled with at least one beverage raw material, wherein in a fourth step the base element is closed with a capsule lid, wherein the capsule lid is fastened, in particular sealed, to the flange along a first fastening surface and along a second fastening surface. The method according to the invention advantageously provides a portion capsule which offers all the advantages mentioned in connection with the portion capsule according to the invention.

[0045] The advantages and further developments explained for the method according to the invention also apply equally to the other objects of the present invention and vice versa.

[0046] According to a preferred embodiment of the method according to the invention, the fourth step comprises at least a first sub-step and a second sub-step, wherein in the first sub-step, fastening, in particular sealing, takes place by means of a fastening means, in particular a sealing tool, along the second fastening surface, and wherein in the second sub-step, fastening, in particular sealing, takes place by means of a fastening means, in particular a sealing tool, along the first fastening surface and preferably the second fastening surface. The person skilled in the art will understand that the fastening always takes place over the entire circumferential fastening surface in order to achieve the required tightness. In particular, the first sub-step corresponds to a pre-sealing.In this context, pre-sealing means that a first fastening takes place which, for example, is less firm than the fastening in the second sub-step, i.e., for example, takes place with less force and / or in a shorter time. Preferably, the fastening means of the first and second sub-steps are at least partially identical. Partially identical should mean that, for example, individual elements of the fastening means are replaced, e.g., in the case of a sealing tool, the sonotrode and / or the receiving element are replaced. Alternatively, a first fastening means, in particular a first sealing tool, is used in the first sub-step, and a second fastening means, in particular a second sealing tool, is used in the second sub-step.

[0047] Preferably, the fastening in the first sub-step takes place at a sealing temperature of between 160°C and 260°C, particularly preferably between 190°C and 230°C, and especially 210°C. Preferably, the fastening in the first sub-step takes place with a sealing time of between 200 ms and 300 ms, particularly preferably between 230 ms and 270 ms, and especially 250 ms. Preferably, the fastening in the first sub-step takes place with a sealing force of between 250 N and 350 N, particularly preferably between 280 N and 320 N, and especially 300 N.

[0048] Preferably, the fastening in the second sub-step takes place at a sealing temperature of between 160°C and 260°C, particularly preferably between 190°C and 230°C, and especially 210°C. Preferably, the fastening in the second sub-step takes place with a sealing time of between 300 ms and 600 ms, particularly preferably between 400 ms and 500 ms, and especially 450 ms. Preferably, the fastening in the second sub-step takes place with a sealing force of between 700 N and 1100 N, particularly preferably between 850 N and 950 N, and especially 900 N.

[0049] According to a preferred embodiment of the method according to the invention, in a further sub-step of the fourth step, prior to the first sub-step, the capsule lid is produced from a strip material, preferably cut and / or punched. Those skilled in the art will understand that, in the case of aluminum foil as the material for the capsule lid, a capsule lid, in particular a circular one, is preferably punched from aluminum foil. Particularly preferably, the further sub-step is also carried out by the fastening means, in particular in a single operation. For example, the capsule lid is punched out of aluminum foil in one movement and then sealed to the base element. Alternatively, the capsule lid, in particular as a blank, is fed to the fastening means. This simplifies the production of the portion capsule and shortens the production time. Any positioning errors are also advantageously avoided.

[0050] According to a preferred embodiment of the method according to the invention, the first step comprises a first sub-step, a second sub-step, and preferably a third sub-step. In the first sub-step, a basic shape is produced, in particular punched, from a strip material. In the second sub-step, a preform is produced such that the base element is formed from the basic shape. In the third sub-step, a bead is formed, in particular rolled and / or crimped, from the outer free end of the flange. The second sub-step is preferably carried out using a stamp.

[0051] Preferably, in a further sub-step, circumferential, concentric grooves are formed into the capsule wall, at least on the outside.

[0052] According to a preferred embodiment of the method according to the invention, it is provided that the third step takes place under a modified atmosphere and / or that a nitrogen layer is applied to the bed of beverage raw material, in particular in such a way that no oxygen is present in the portion capsule after the fourth step.

[0053] According to a preferred embodiment of the method according to the invention, in a fifth step, which takes place after the first step and before the third step, a filter is introduced into the cavity and preferably fastened to the base element, in particular in the region of the capsule base. Particularly preferably, the filter comprises a nonwoven material and / or a felt material. Very particularly preferably, the filter is designed in one or more layers. Preferably, the filter is disc-shaped, in particular round. Alternatively, the filter is angular, for example square, hexagonal, octagonal or decagonal. It is preferably provided that the filter is arranged in the region of the base. Very particularly preferably, the filter is fastened, in particular sealed, in sections or circumferentially 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 out by a tool in one operation, placed in the cavity and fixed there, in particular sealed.

[0054] A further subject matter of the present invention is a sealing station for closing a portion capsule with a capsule lid for producing a portion capsule according to the invention, with at least a first sealing tool, wherein the first sealing tool is configured to seal the capsule lid to the flange along the second fastening surface and wherein the first sealing tool or a second sealing tool is configured to seal the capsule lid to the flange along the first fastening surface and preferably the second fastening surface. The person skilled in the art understands that both the first and the second sealing can be carried out with the same sealing tool, ie the first sealing tool, or that both sealing processes can be carried out by at least two different sealing tools, ie at least the first and the second sealing tool.The first sealing process corresponds in particular to a pre-sealing process, and the second sealing process to a post-sealing or main sealing process, in which the desired final tightness is achieved. Advantageously, the sealing station according to the invention now also enables the production of a portion capsule according to the invention with a sealing of the capsule lid both in the first flange region and in the second flange region. By dividing the process into two steps, a sealing of the capsule lid along the first and second fastening surfaces is also particularly advantageously enabled in the event that the first flange region and the second flange region are at different heights. Thus, in particular, the capsule lid is pre-fixed in the first step.

[0055] The advantages and further developments explained for the sealing station according to the invention also apply equally to the other objects of the present invention and vice versa.

[0056] According to a preferred embodiment of the sealing station according to the invention, it is provided that the first sealing tool and / or the second sealing tool each comprise at least one sonotrode and at least one receiving element, wherein the receiving element has an open cavity for receiving the portion capsule, wherein the receiving element further has at least one counter-holding means, wherein the counter-holding means is provided to provide a counterforce on the side of the flange facing away from the capsule lid, in particular in the region of the first fastening surface and / or the second fastening surface, to the force exerted by the sonotrode. A sonotrode is usually a flat element. In order to achieve a reliable seal even with flange areas of different heights, it is crucial that on the underside of the flange, ieon the side facing away from the capsule lid, a counterholding means provides a counterforce to the force exerted by the sonotrode. Particularly preferably, the sealing station comprises a first sealing tool and a second sealing tool, wherein the receiving element of the first and second sealing tools has a counterholding means both in the region of the second fastening surface and in the region of the first fastening surface. Alternatively, the receiving element of the first sealing tool only has a counterholding means in the region of the second fastening surface. The person skilled in the art will understand that the receiving element here is different from the receiving element of the beverage production machine of the system according to the invention, but is preferably similar in structure and function. Both preferably have a cavity for at least partially receiving the portion capsule or the base element.In particular, the receiving elements differ in that the receiving element of the beverage production machine has a sealing contour as described above, while the receiving element of the sealing tool preferably has counter-holding means only in the area of ​​the first and / or second fastening surface, but in particular, there is no contact with the sealing bead. The counter-holding means particularly advantageously ensure a secure and reliable seal in both fastening surfaces.

[0057] According to a preferred embodiment of the sealing station according to the invention, the receiving element has at least one counter-holding means in the region of the first fastening surface, wherein an upper surface of the counter-holding means is arranged at least 0.05 mm, preferably at least 0.10 mm, in particular at least 0.15 mm higher than an upper surface of the counter-holding means of the first sealing tool and / or second sealing tool in the region of the second fastening surface. Higher in this context means in particular a greater extension in the vertical direction. The counter-holding means is particularly preferably a plunger. The applicant has surprisingly found through tests that by having the counter-holding means of different heights in the regions of the two fastening surfaces, and in particular having a greater height in the region of the first fastening surface, a particularly good sealing quality is achieved.Those skilled in the art will understand that the aforementioned numerical values ​​apply in particular to the case where the first flange region and the second flange region are arranged at the same height relative to the central longitudinal axis. If a predetermined offset exists, the numerical values ​​must be adjusted accordingly.

[0058] According to a preferred embodiment of the sealing station according to the invention, the sonotrode of the first and / or second 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 34.8 mm. This allows for a reliable and high-quality seal without, for example, the bead being contacted by the sonotrode.

[0059] According to a preferred embodiment of the sealing station according to the invention, the sonotrode of the first and / or second sealing tool has a heat dissipation means, in particular a centrally arranged heat dissipation means. Particularly preferably, the heat dissipation means is made at least partially from a ceramic material. Particularly during the two-stage sealing process provided according to the invention, a considerable amount of heat is transferred to the portion capsule. This can, on the one hand, damage the capsule lid and, on the other hand, negatively affect the beverage raw material. The provision of such a heat dissipation means, for example in the form of a ceramic insert, particularly advantageously prevents excessive heat exposure. Most preferably, the heat dissipation means has a diameter of at least 25 mm, even more preferably of at least 28 mm or at least 30 mm.

[0060] A further subject of the present invention is a plant for producing a portion capsule according to the invention, in particular according to a method according to the invention, with 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 sealing station according to the invention.

[0061] The statements applicable to this subject matter of the present invention also apply to the other subject matters of the invention and vice versa.

[0062] Further details, features, and advantages of the invention will become apparent from the drawings and the following description of preferred embodiments with reference to the drawings. The drawings merely illustrate exemplary embodiments of the invention, which do not limit the essential inventive concept. Short description of the drawings

[0063] Figures 1 and 2 show schematic sectional views of a portion capsule and 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 portion capsule according to various exemplary embodiments of the present invention. Figures 6 to 15 shows various schematic views of sealing tools according to various exemplary embodiments of the present invention. Figure 16shows a schematic detailed view of the portion capsule according to another exemplary embodiment of the present invention in cross section. Embodiments of the invention

[0064] Some illustrations contain dimensions. These illustrations correspond to technical drawings from which dimensions and / or proportions can be derived. This applies in particular to at least the Figures 3 to 5 and 12 to 15 .

[0065] In Figures 1 and 2 a schematic side view of a portion capsule 1 and a sectional view of a system comprising the portion capsule 1 and a part of a beverage manufacturing machine 13 for preparing a beverage according to an exemplary first embodiment of the present invention are shown.

[0066] The portion capsule 1 has a base element 2, which is, for example, cup-shaped and frustoconical, which has a capsule base 5 on its closed side and a circumferential flange 6 on its open side. A capsule wall 7 extends around a cavity 3 between the capsule base 5 and the flange 6. The portion capsule 1 is rotationally symmetrical about its central longitudinal axis M, which defines a vertical direction Y. In the radial direction R, the flange 6, which is circular and thus circumferentially circumferential, protrudes outward beyond the capsule wall 7.

[0067] The flange 6 is firmly 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. According to the invention, the flange 6 has a first fastening surface 100 facing the capsule lid 4 and a second fastening surface 200, which preferably extend approximately at right angles to the vertical direction Y. The capsule lid 4 is sealed, welded, or glued to the flange 6 in its edge region in the first and second fastening surfaces 100, 200.

[0068] The capsule lid 4 is preferably made of an aluminum or plastic material, which may also include laminates. Within the base element 2, the cavity 3 is formed, which is filled with beverage raw material, for example, roasted coffee granules, instant coffee, chocolate powder, tea blend, milk powder, and / or the like (for reasons of clarity, the beverage raw material is not shown) and which is closed by the capsule lid 4.

[0069] The cup-shaped design of the base element 2 is preferably produced by thermoforming, for example deep drawing using negative pressure, positive pressure and / or a movable stamp. The base element 2 is preferably designed as a deep-drawn aluminum part. Alternatively, it would also be conceivable for the base element 2 to be designed as a plastic part made of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC) or polyethylene terephthalate (PET). Alternatively, the portion capsule 1 is produced by injection molding, in particular using a single-component, multi-component or in-mold process. As a multi-component process, a two-component process is particularly preferred, in which an aluminum layer, in particular with a layer thickness of 90 µm, is provided with a layer of PP, in particular with a layer thickness of 30 µm.Most preferably, the PP layer is arranged on one or both sides of the aluminum layer, in particular on the inside of the base element 2 and / or the cavity 3. This advantageously enables a better, PVC-free, connection between the flange 6 and the capsule lid 4.

[0070] In use, the portion capsule 1 is inserted into a brewing unit in a beverage manufacturing machine 13. The brewing unit comprises a first brewing chamber part and a second brewing chamber part, wherein the first or second brewing chamber part is movable relative to the other brewing chamber part between an approximate position in which the first and second brewing chamber parts form a closed brewing chamber 12, and an open position in which the first and second brewing chamber parts are spaced apart for insertion or ejection of the portion capsule 1.

[0071] The first brewing chamber part is designed as a cup-shaped receiving element 21, which largely accommodates the portion capsule 1, especially when the brewing chamber 12 is in the closed position. The second brewing chamber part is designed as a closure element 22 for the receiving element 21. In the Figure 2 In the closed position shown, the flange 6 of the portion capsule 1 is sealingly clamped between an edge region 23 of the receiving element 21 and the closure element 22.

[0072] In this closed position, the capsule lid 4 and the capsule base 5 are perforated sequentially or simultaneously. The one or more perforation openings in the capsule base 5 are formed in particular by one or more perforation points on the receiving element 21 during the closing of the brewing chamber 13, while the perforation openings in the capsule lid 4 are preferably created by perforation structures in the base of the closure element 22 during the closing of the brewing chamber 12 or only by the pressure buildup inside the portion capsule 1 during the beverage production process.

[0073] Extraction liquid is introduced under pressure into the cavity 3 through one or more perforations in the capsule base 5. The interaction between the extraction liquid and the beverage raw material creates the desired beverage, which leaves the portion capsule 1 through the perforations in the capsule lid 4 and is fed into a beverage container. An optional filter medium can be used to filter any particles of the beverage raw material from the beverage and retain them in the portion capsule 1. Preferably, however, the multi-perforated capsule lid 4 functions as the filter element.

[0074] In Figures 3 to 5 are detailed views of the Figures 1 and 2 illustrated portion capsule 1 according to an exemplary embodiment of the present invention. The figures show the sectional view of the flange 6 on the right side of Figure 1 or 2 in an enlarged illustration. The Figures 3 to 5 illustrated to scale and with more accurate representation of the angular and longitudinal relationships.

[0075] The illustrated flange 6 extends essentially horizontally, i.e., parallel to the radial direction R, from the upper end of the capsule wall 7 to its free outer end, at which the flange 6 terminates with a bead 8. The bead 8 comprises, in particular, a flange end rolled up toward the capsule base 5.

[0076] In addition, the bead 8 protrudes in the vertical direction Y, in particular on both sides of the flange 6, wherein the flange 6 protrudes from the flange 6 on the underside by less than a sealing bead 9 and furthermore protrudes less or identically on the upper side than on the underside over the flange 6.

[0077] Between the bead 8 and the end of the capsule wall 7, the flange 6 has the sealing bead 9, which is designed in the form of an indentation directed in the vertical direction Y away from the capsule lid 4 and concentrically circumferentially around the central longitudinal axis M. The sealing bead 9 has an inner flank 10 facing the capsule wall 7 and an outer flank 11 facing the bead 8. The sealing bead 9 is formed integrally from the flange 6 and, as can be seen in the figures, has essentially the same thickness as the capsule wall 7 and / or a first flange region 18 between the capsule wall 7 and the inner flank 10 and / or a second flange region 19 between the bead 8 and the outer flank 11.

[0078] Between the inner flank 11 and the outer flank 12 extends a transition region 14 in the form of the transition plane 15, which is particularly flat (i.e., straight) and runs parallel to the first and / or second flange region 18, 19. The outer flank 11 extends to the second flange region 19 at an angle β of approximately 85 degrees.

[0079] The outer flank 11 has, in particular, a straight flank section 20, which preferably has 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.

[0080] Between the inner flank 10 and the upper end of the capsule wall 7, the flange 6 has a first flange region 18. In the present example, the first flange region 18 is formed, at least in sections, as a straight and horizontal section in radial cross-section. The straight region has a length of 0.07 mm to 0.09 mm.

[0081] The inner flank 10 has a straight contact area 16 in the radial cross section, ie the straight contact area 16 is the length of the straight line between the two transitions in the course of the inner flank 10. The length of the contact area 16 is preferably 0.5 mm to 0.9 mm in the present example.

[0082] According to the invention, the angle α between the inner flank 10 or the straight contact region 16 and the first flange region 18 is substantially 85 degrees.

[0083] The angle between the inner and outer flanks 10, 11 is thus preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees and most particularly preferably substantially 10 degrees.

[0084] The first flange area 18 and the second flange area 19 are at the same height in the vertical direction Y. The height 17 of the sealing bead 9 corresponds to the total extension of the sealing bead 9 from the underside of the first and second flange areas 18, 19 to the underside of the flange 6 in the area of ​​the transition plane 15. This height 17 is between 0.9 mm and 1.0 mm perpendicular to the first and second flange areas 18, 19, respectively.

[0085] The material thickness of the aluminum in the area of ​​the flange 6 is preferably between 0.1 mm and 0.13 mm, in particular substantially 0.11 mm or 0.12 mm.

[0086] In the Figures 3 to 5For the sake of clarity, the edge region 23 of the receiving element 21, which is in sealing engagement with the flange 6 of the portion capsule 1, is not shown. The edge region 23 comprises a sealing contour for sealing engagement with the sealing bead 9. For this purpose, the sealing contour has a recess extending in the circumferential direction and a sealing nose formed adjacent to the recess and also extending in the circumferential direction. Viewed in the radial direction R, the recess is arranged outside the sealing nose, so that an outer sealing nose flank of the sealing nose forms an inner wall of the recess.

[0087] In the Figure 2In the closed position shown, the sealing nose engages in the first flange area 18, while the sealing bead 9 engages in the recess. As a result, a contact 16 is formed between the sealing nose flank and the inner flank 10 in radial cross-section. This contact 16 is preferably present all the way around in the circumferential direction and thus forms the actual seal between the flange 6 and the receiving element 21, so that little or no extraction liquid can flow past the beverage raw material to the outlet of the brewing chamber 12. The apex of the sealing nose optionally touches the underside of the first flange area 18, while the underside of the transition plane 15 optionally touches the bottom of the recess.

[0088] The design and dimensioning of the sealing bead 9 described above ensures that the sealing bead 9 does not deform significantly when the brewing chamber 12 is closed and / or when the beverage is brewed. Sealing is achieved primarily by the circumferential contact 16, which is subjected to relatively strong forces due to the rigidity of the sealing bead 9.

[0089] In other words: the sealing bead 9 is designed such that when the brewing chamber 12 is closed and / or the portion capsule 1 is brewed, it is only deformed by a maximum of 30%, preferably by a maximum of 20%, particularly preferably by a maximum of 10%, and very particularly preferably by a maximum of 5% of its height 17 perpendicular to the first and / or second flange region 18, 19. In particular, the sealing bead 9 is thus designed such that when a force of up to 100 N is applied to the sealing bead 9 perpendicular to the first and / or second flange region 18, 19, it is only deformed by a maximum of 30%, preferably by a maximum of 20%, particularly preferably by a maximum of 10%, and very particularly preferably by a maximum of 5% of its height 17 perpendicular to the first and / or second flange region 18, 19. Only in this way is sufficient force available for the contact 16.

[0090] It is conceivable that the height 17 of the sealing bead 9 is changed, in particular by a maximum of 0.2 mm, preferably by a maximum of 0.15 mm, particularly preferably by a maximum of 0.1 mm, and very particularly preferably by a maximum of 0.05 mm in the vertical direction Y when the brewing chamber 12 is closed and / or the portion capsule 1 is brewed. Alternatively, however, the sealing bead 9 is only displaced in the radial direction R and not in the vertical direction Y.

[0091] Preferably, the sealing bead 9 is also designed to be so rigid that there is no excessive lateral displacement or deformation in the radial direction R. It is provided that the sealing bead 9 is designed such that when the brewing chamber 12 is closed, it is preferably only deformed or displaced parallel to the first and / or second flange region 18, 19 to such an extent that its radius, relative to a central longitudinal axis M of the portion capsule 1, only shifts by a maximum of 5% parallel to the first and / or second flange region 18, 19, so that the portion capsule 1 can be easily removed from the brewing chamber 12 after brewing and the sealing nose does not jam with the laterally tilting sealing bead 9.

[0092] It is conceivable that in the sealing bead 9, when closing the brewing chamber 12 and / or brewing the portion capsule 1, it is preferably provided that the tip of the sealing bead 9, i.e. the transition region 14 of the sealing bead 9, is displaced or deformed in the radial direction R by a maximum of 0.2 mm, preferably by a maximum of 0.15 mm, particularly preferably by a maximum of 0.1 mm and very particularly preferably by a maximum of 0.05 mm.

[0093] The rest in the Figure 3 The numerically shown dimensions can preferably also be considered as essential to the invention.

[0094] In Figure 4 is a detailed view of the Figures 1 and 2 illustrated portion capsule 1 according to an exemplary further embodiment of the present invention. The Figure 4 shows the sectional view of the sealing bead 9 (in the same orientation as Figure 3 , i.e. on the left the capsule wall 7 and on the right the bulge 8) in an enlarged illustration.

[0095] This embodiment is essentially similar to that used in connection with Figure 3 illustrated and explained embodiment, so that all above explanations apply analogously.

[0096] In contrast, however, the transition region 14 is designed as a curved transition region and not as a straight, flattened transition plane 15. The straight contact region 20 has a length of 0.5 mm to 0.6 mm, in particular 0.53 mm, on the outer flank 11. The straight contact region 16 has a length of 0.4 mm to 0.55 mm, in particular 0.473 mm, on the inner outer flank 10.

[0097] The angle between the inner and outer flanks 10, 11 is preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees and most particularly preferably substantially 10 degrees.

[0098] In Figure 5 is a detailed view of the Figures 1 and 2illustrated portion capsule 1 according to an exemplary further embodiment of the present invention. The Figure 5 shows the sectional view of the sealing bead 9 (in the same orientation as the Figure 3 and 4 , i.e. on the left the capsule wall 7 and on the right the bulge 8) in an enlarged illustration.

[0099] This embodiment is essentially similar to that used in connection with the Figures 4 and 5 illustrated and explained embodiments, so that all above explanations apply analogously.

[0100] The dimensions discussed above differ slightly in this embodiment; these can be seen in the drawing. However, the angles α and β are the same.

[0101] According to the embodiment shown 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.

[0102] The first flange region 18 comprises a first fastening surface 100, in which the capsule lid 4 is connected to the flange 6, in particular is sealed thereto. In addition, however, the second flange region 19 also comprises a second fastening surface 200, in which the capsule lid 4 is connected to the flange 6, in particular is sealed thereto. According to the invention, the capsule lid 4 is therefore connected to the flange 6 in at least two fastening surfaces 100, 200. These fastening surfaces 100, 200 are preferably disparate, i.e. different from one another, in particular without an intersection, and are arranged in the first and second flange regions 18, 19, i.e. in flange regions on both sides of the sealing bead 9.

[0103] Preferably, the first and second fastening surfaces 100, 200 are substantially circular in shape. According to the exemplary embodiment shown here, the circular rings have substantially the same diameter.

[0104] Here, the fastening surfaces 100, 200 are arranged horizontally and essentially at the same height, corresponding to the flange regions 18, 19. However, it is also possible, alternatively, for the first flange region 18 and the second flange region 19 to be at different heights. This is possible, among other things, for manufacturing reasons. For example, the first flange region 18 is between 0.020 mm and 0.030 mm, in particular up to 0.025 mm, lower, i.e., arranged at a smaller distance from the capsule base 5 than the second flange region 19.

[0105] Also in this case, i.e. in particular with horizontal flange areas 18, 19 at different heights, the capsule lid 4 is connected to the flange 6 via both the first fastening surface 100 and the second fastening surface 200.

[0106] The radius at the transitions between the first flange region 18 and the inner flank 10 and the second flange region 19 and the outer flank 11 is between 0.10 mm and 0.12 mm, in particular 0.11 mm, whereas the radius at the transitions between the inner flank 10 and the transition region 14, which is also flat here, and the outer flank 11 is preferably between 0.20 mm and 0.22 mm, in particular 0.21 mm. The radii described above, as shown in the figure, are each measured on the side facing away from the capsule lid 4. The difference to the corresponding radii on the side facing the capsule lid 4 lies, as one skilled in the art will understand, in the material thickness at this point, in this case in particular 0.11 mm or 0.12 mm.

[0107] The transition between the second flange region 19 and the bead 8 is preferably between 0.19 mm and 0.21 mm, in particular 0.20 mm.

[0108] According to this embodiment, the height 17 of the sealing bead 9 is between 0.90 mm and 0.98 mm, in particular 0.90 mm, in the region of the first flange region and between 1.00 mm and 0.90 mm, in particular 0.90 mm, in the region of the second flange region.

[0109] The bead 8 has in particular a vertical extension of between 1.20 mm and 1.40 mm, in particular 1.30 mm.

[0110] According to the example shown here, the transition plane 15 has a radial extension of preferably between 0.10 mm and 0.14 mm, in particular 0.12 mm.

[0111] In Figure 6 A sealing tool, in particular a first sealing tool 24, according to an exemplary embodiment of the present invention is shown. Such a sealing tool serves to seal the capsule lid 4 to the flange 6 of the portion capsule 1.

[0112] In order to achieve a sealing according to the invention on both sides of the sealing bead 9, a special sealing tool is required.

[0113] Such sealing tools 24, 25 are basically already known, which is why only the differences to known sealing tools, in particular with regard to the portion capsule 1 according to the invention, will be discussed below.

[0114] The sealing tool 24 comprises, among other things, a sonotrode 28, which generates targeted heat and thus locally heats the material of the capsule lid 4 and the flange 6, creating a material-tight connection between the two. This creates a fluid-tight connection between the base element 2 and the capsule lid 4. Since pressure as well as heat plays a crucial role, the sealing tool 24 comprises a receiving element 26, which receives the base element 2 and, on the underside of the flange 6, provides a counterforce to the force exerted by the sonotrode 28 via suitable counterholding means 27 in the region of the first and / or second fastening surface 100, 200, so that deformation of the flange and thus a defective portion capsule 1 and / or an incomplete sealing of the capsule lid 4 does not occur.

[0115] The sealing tool 24 is explained in more detail in connection with the following illustrations.

[0116] What is crucial for the invention is that the sealing process takes place in two stages, wherein in a first sub-step the capsule lid 4 is initially connected to the flange 6 only in the second flange region 19 along the second fastening surface 200, and wherein in a second sub-step the capsule lid 4 is connected to the flange 6 both in the first flange region along the first fastening surface 100 and in the second flange region 19 along the second fastening surface 200.

[0117] The first sub-step corresponds in particular to a pre-sealing, ie a sealing process which, compared to the second sub-step, is carried out with at least one parameter reduced in amount, in particular sealing temperature, sealing time and / or sealing force.

[0118] In particular, 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, has proven to be effective in tests, which corresponds to a sealing pressure of approximately 2 bar for a preferred sealing tool 24.

[0119] In principle, it is possible to perform both sub-steps with the same sealing tool 24. For example, it is possible to optionally make no changes between the sub-steps, i.e., to work with the same elements but with different parameters, and / or to replace the sonotrode 28 and / or the receiving element 26.

[0120] Alternatively, the two sub-steps are carried out in different sealing tools, here a first sealing tool 24 and a second sealing tool 25.

[0121] This embodiment is shown purely as an example using the Figures 6 to 15 explained. Here, the outer diameter of the sonotrode 28 of the first sealing tool 24 is preferably between 34.0 mm and 35.0 mm, in particular 34.5 mm.

[0122] In Figure 7 A schematic detailed drawing of the first sealing tool 24 is shown in the relevant area. Compared to known sealing tools, the first sealing tool 24 differs in that the counter-holding means 27 has two protruding areas, the upper surfaces of which lie below the first flange area 18 and the second flange area 19, respectively.

[0123] The counterholding means 27 can be provided in one piece or in multiple pieces. In particular, the counterholding means 27 here comprises two plungers.

[0124] Surprisingly, it has been found that the best sealing results are achieved when a portion capsule 1, as used in connection with Figure 5 described, two plungers with different heights are used. In particular, the inner plunger, i.e. the plunger assigned to the first flange region 18 and the first fastening surface 100, is between 0.05 mm and 0.25 mm, preferably between 0.10 mm and 0.20 mm and in particular 0.15 mm higher than the outer plunger assigned to the second flange region 19 and the second fastening surface 200. This is shown here not to scale but exaggerated for the sake of clarity. Both plungers have upper surfaces which are in contact with the first flange region 18 and the second flange region 19 and thus define the first and second fastening surfaces 100, 200.

[0125] The counter-holding means 27 can be arranged so that it is height-adjustable or fixed.

[0126] Furthermore, in the present case, the first sealing tool 24 has an optional heat dissipation means 29 in the center of the sonotrode 28. This is a ceramic insert whose diameter is selected such that it covers the capsule lid 4 in the area of ​​the interior of the portion capsule 1, i.e., above the cavity 3.

[0127] The heat dissipation means 29 ensures that the increased heat generated due to the two different sealing processes does not adversely affect the beverage raw material and / or the capsule lid 4 in this area.

[0128] Since in the first sub-step only sealing takes place via the second fastening surface 200, the internal plunger for the receiving element 26 of the first sealing tool 24 is optional.

[0129] In Figure 8A second sealing tool 25 is now shown, which carries out the main sealing process (also referred to as post-sealing). The second sealing tool 25 essentially corresponds to the first sealing tool 24, so that reference is made to the explanations regarding Figures 6 and 7. This applies to both Figure 8 as well as for Figure 9 .

[0130] The sonotrode 28 of the second sealing tool 25 preferably has a larger diameter than the sonotrode 28 of the first sealing tool 24, particularly preferably between 34.3 mm and 35.2 mm and in particular 34.8 mm.

[0131] The sealing process of the second sub-step is now carried out with at least one parameter which is higher in magnitude, 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, having proven particularly successful, which in the preferred embodiment of the sonotrode 28 of the second sealing tool 25 corresponds to a sealing pressure of approximately 6 bar.

[0132] As already mentioned, in this second sub-step the capsule lid is firmly and in particular fluid- and pressure-tightly attached to the flange 6, both along the first attachment surface 100 and the second attachment surface 200.

[0133] In Figure 10is a perspective sectional view of the first and / or second sealing tool 24, 25. Reference is made to the above statements regarding the Figures 6 to 9 referred to.

[0134] In Figure 10 It is clearly evident that the counter-holding means 27 only provides a counterforce in the region of the first and second flange areas 18, 19. In the region of the sealing bead 9, as well as in the region of the capsule base 5, the receiving element 26 is clearly spaced from the base element 2.

[0135] Furthermore, Figure 10 the structure of the sonotrode 28, in particular with regard to the heat dissipation means 29, according to the embodiment shown here, can be seen.

[0136] In Figure 11 is a schematic detailed view of a cross section of the sealing tool 24, 25 according to an exemplary embodiment of the present invention similar to the illustrations in the Figures 7 and 9shown. In this regard, reference is made to the previous explanations. Here, exemplary grooves, in this case four, can be seen in the capsule wall 7 of the portion capsule 1.

[0137] The Figures 12 and 13 1 and 2 show technical drawings of the receiving element 26 and the sonotrode 28 of the first sealing tool 24 according to the previously explained exemplary embodiment of the present invention. The outer diameter of the receiving element 26 is preferably substantially 35 mm and the height is preferably 36 mm.

[0138] According to the embodiment shown here, the sonotrode 28 in turn has an outer diameter of in particular 34.5 mm, wherein the heat dissipation means 29 in the sonotrode 28 has an outer diameter of 29.7 mm.

[0139] The Figures 14 and 15show technical drawings of the receiving element 26 or the sonotrode 28 of the second sealing tool 25 according to the previously explained exemplary embodiment of the present invention, as well as a detailed drawing of the counter-holding means 27. The detailed drawing shows the height difference between the plungers, wherein the inner plunger, assigned to the first flange region 18, is 0.15 mm higher than the outer plunger.

[0140] The outer diameter of the receiving element 26 is preferably substantially 35 mm, and the height is preferably 36.15 mm. According to the embodiment shown here, the sonotrode 28, in turn, has an outer diameter of, in particular, 34.8 mm, with the heat dissipation means 29 in the sonotrode 28 having an outer diameter of 29.7 mm.

[0141] In Figure 16is a schematic detailed view of the portion capsule 1 according to another exemplary embodiment of the present invention in cross-section. Figure 16 The embodiment shown essentially corresponds to the embodiments described in connection with the Figures 3 to 5 explained embodiments and in particular the Figure 5 illustrated embodiment, so that reference is made to the relevant explanations.

[0142] From Figure 5 differs Figure 16in particular by the dimensions and / or the associated tolerances. From left to right in the figure, the following dimensions can be seen according to the embodiment shown. The transition from the capsule wall 7 to the first flange region 18 has a radius of preferably 0.30 mm to 0.50 mm on the side of the capsule lid 4. The transition between the first flange region 18 and the inner flank 10 has a radius of preferably 0.11 mm to 0.36 mm, in particular on the side facing away from the capsule lid 4. The sealing bead 9 has a height of preferably 0.82 mm to 0.90 mm between the transition region 14, which here is also a transition plane 15, i.e. has a flat extension, at least in sections, in particular 0.12 mm long, and the first flange region 18.

[0143] The transition from the inner flank 10 to the transition plane 15 preferably has a radius of 0.23 mm to 0.33 mm, particularly on the side facing away from the capsule lid 4. An angle α of 5° is preferably provided between an imaginary tip of the sealing bead 9 and a perpendicular. This corresponds to an angle of 85° between a horizontal section of the first flange region 18 and the inner flank 10.

[0144] Particularly preferably, the sealing bead 9 is also constructed symmetrically here. Thus, the virtual interior angle in an imaginary extension of the tip of the sealing bead 9 is 10°. Furthermore, the transition from the transition plane 15 to the outer flank 11, particularly on the side facing away from the capsule lid 4, preferably has a radius of 0.23 mm to 0.33 mm. The angle between the straight section of the outer flank 11 and a horizontal section of the second flange region 19 is preferably 85°.

[0145] The transition between the outer flank 11 and the second flange region 19 has a radius of preferably 0.11 mm to 0.36 mm, particularly on the side facing away from the capsule lid 4. The sealing bead 9 preferably has a height of 0.90 mm to 1.00 mm between the transition plane 15 and the second flange region 19.

[0146] The person skilled in the art will understand that, within the tolerances, the first flange region 18 and the second flange region 19 preferably lie on a horizontal plane, but due to tolerances, there may also be a slight horizontal offset of a maximum of 0.18 mm, i.e., in particular, slightly more than one material thickness.

[0147] 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 illustrated embodiment has a radial extension of approximately 1 mm and a vertical extension, i.e. a total height, of preferably 1.25 mm to 1.45 mm, in particular 1.35 mm. List of reference symbols

[0148] 1 Portion capsule 2 Base element 3 Cavity 4 Capsule lid 5 Capsule base 6 Flange 7 Capsule wall 8 Bead 9 Sealing bead 10 Inner flank 11 Outer flank 12 Brewing chamber 13 Beverage production machine 14 Transition area 15 Transition plane 16 Contact area 17 Height of the sealing bead 18 First flange area 19 Second flange area 20 Flank section 21 Receiving element 22 Closure element 23 Edge area 24 First sealing tool 25 Second sealing tool 26 Receiving element of the sealing tool 27 Counterholding means 28 Sonotrode 29 Heat dissipation means 100 First fastening surface 200 Second fastening surface α Angle β Angle R Radial direction Y Vertical direction M Central longitudinal axis

Claims

1. Portion capsule (1) for preparing a beverage in a brewing chamber (12) of a beverage production machine (13), wherein the portion capsule (1) has a base element (2) with a cavity (3) for receiving a beverage raw material and a capsule lid (4) closing the cavity (3), wherein the base element (2) comprises a capsule base (5), a circumferential flange (6) and a capsule wall (7) extending between the capsule base (5) and the circumferential flange (6), wherein the flange (6) has a sealing element formed integrally with the flange (6) in the form of a sealing bead (9) pointing away from the capsule lid (4), wherein the sealing bead (9) comprises an inner flank (10) and an outer flank (11), wherein the flange (6) has a first flange region (18) between the capsule wall (7) and the inner flank (10) and a second flange region (19) between the outer free end of the flange (6) and the outer flank (11) has a second flange region (19), characterized in thatthe capsule lid (4) is fastened along a first circumferential fastening surface (100) in the first flange region (18) and along a second circumferential fastening surface (200) in the second flange region (19).

2. Portion capsule (1) according to claim 1, characterized in thatthe outer free end of the flange (6) is rolled up, in particular flanged, in such a way that it forms a circumferential bead (8), wherein the bead (8) preferably has a vertical extension relative to the flange (6) greater than zero, particularly preferably on both sides of the flange (6), very particularly preferably the vertical extension of the bead (8) on the side of the flange (6) facing away from the capsule lid (4) being less than the vertical extension of the sealing bead (9) and / or wherein the vertical extension of the bead (8) on the side of the flange (6) facing away from the capsule lid (4) is less than on the side of the flange (6) facing away from the capsule lid (4).

3. Portion capsule (1) according to one of the preceding claims, characterized in thatboth the inner flank (10) and the outer flank (11) are aligned at an angle (α, β) of greater than 80 to less than 90 degrees, preferably of 81 to 89 degrees, particularly preferably of 83 to 87 degrees, very particularly preferably of 84 to 86 degrees and in particular of substantially 85 degrees, to a horizontal plane passing through the first flange region (18) or the second flange region (19).

4. Portion capsule (1) according to one of the preceding claims, characterized in that the first fastening surface (100) and the second fastening surface (200) each have a substantially horizontal extension.

5. Portion capsule (1) according to one of the preceding claims, characterized in thatthe first fastening surface (100) and the second fastening surface (200) are vertically spaced from one another, wherein preferably the first fastening surface (100) has a smaller vertical distance from the capsule base (5) than the second fastening surface (200).

6. Portion capsule (1) according to claim 5, characterized in that the vertical distance between the fastening surfaces (100, 200) is less than three times the thickness of the flange (6) in the region of the first and / or second fastening surface (100, 200), preferably less than 0.35 mm, particularly preferably less than 0.30 mm, very preferably less than 0.25 mm, even more preferably less than 0.20 mm, in particular a maximum of 0.018 mm 7. Portion capsule (1) according to one of the preceding claims, characterized in thatthe first fastening surface (100) and the second fastening surface (200) are provided such that there is no fluid connection between the cavity (3) of the portion capsule and the cavity existing between the capsule lid (4) and the sealing bead (9).

8. Portion capsule (1) according to one of the preceding claims, characterized in that the inner flank (10) and the outer flank (11) are formed symmetrically to each other.

9. Portion capsule (1) according to one of the preceding claims, characterized in that a transition region (14) extends between the inner flank (10) and the outer flank (11), wherein the transition region (14) is preferably curved or has a transition plane (15) extending parallel to the first flange region (18) and / or to the second flange region (19).

10. Portion capsule (1) according to claim 14, characterized in thatthe transition region (14) has an extension in the radial direction 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.

11. Portion capsule (1) according to one of the preceding claims, characterized in that the base element (2) is made in one piece from aluminum.

12. Portion capsule (1) according to one of the preceding claims, characterized in that the portion capsule (1) has a filter in the area of ​​the capsule base (5).

13. A system for preparing a beverage comprising a beverage production machine (13) and a portion capsule (1) according to one of the preceding claims, wherein the beverage production machine (13) has a brewing unit with a first brewing chamber part and a second brewing chamber part, wherein the first and / or the second brewing chamber part is movable relative to the other brewing chamber part between an approximate position in which the first and the second brewing chamber part form a closed brewing chamber (12), and an open position in which the first and the second brewing chamber part are spaced apart from each other for inserting or ejecting a portion capsule (1), wherein the first brewing chamber part comprises a receiving element (21) for at least partially receiving the portion capsule (1) and the second brewing chamber part comprises a closure element (22) for the receiving element (21),wherein in the closed position the flange (6) of the portion capsule (1) is received in a form-fitting and sealing manner between an edge region (23) of the receiving element (21) and the closure element (22).

14. System according to claim 13, characterized in that in the edge region (23) of the receiving element (21) a sealing contour is formed for sealing engagement with the sealing bead (9), wherein the sealing contour comprises a circumferential recess and a circumferential sealing nose formed adjacent to the recess, wherein the recess is preferably arranged outside the sealing nose in the radial direction (R) and wherein an outer sealing nose flank forms an inner wall of the recess and / or wherein in the closed position the sealing nose engages in the first flange region (18) and the sealing bead (9) engages in the recess in such a way that the sealing nose flank forms a line contact (16) with the inner flank (10) in radial cross-section.

15. A method for producing a portion capsule according to any one of claims 1-12, wherein in a first step a base element (2) having a capsule base (5), a circumferential flange (6) and a capsule wall (7) extending between the capsule base (5) and the circumferential flange (6) is produced, wherein in a second step or in the first step a sealing bead (9) is formed into the flange (6), wherein in a third step the cavity (3) of the base element (2) is filled with at least one beverage raw material, wherein in a fourth step the base element (2) is closed with a capsule lid (4), wherein the capsule lid (4) is fastened, in particular sealed, to the flange (6) along a first fastening surface (100) and along a second fastening surface (200).

16. The method according to claim 15, wherein the fourth step comprises at least a first sub-step and a second sub-step, wherein in the first sub-step a fastening, in particular a sealing, takes place by means of a fastening means, in particular a sealing tool (24, 25), along the second fastening surface (200) and wherein in the second sub-step a fastening, in particular a sealing, takes place by means of a fastening means, in particular a sealing tool (24, 25), along the first fastening surface (100) and preferably the second fastening surface (200).

17. The method according to claim 16, wherein in a further sub-step of the fourth step before the first sub-step the capsule lid (4) is produced from a strip material, preferably cut and / or punched.

18. The method according to any one of claims 15-17, wherein 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 produced from a strip material, in particular punched, wherein in the second sub-step a preform is produced such that the base element (2) is formed from the basic shape, wherein in the third sub-step a bead (8) is formed, in particular rolled and / or crimped, from the outer free end of the flange (6), wherein preferably the forming of the sealing bead takes place in the second or third sub-step.

19. Method according to one of claims 15-18, wherein in a fifth step, which takes place after the first step and before the third step, a filter is introduced into the cavity (3) and preferably fastened to the base element (2), in particular in the region of the capsule bottom (5).

20. Sealing station for closing a portion capsule (1) with a capsule lid (4) for producing a portion capsule (1) according to one of claims 1-12, with at least a first sealing tool (24), wherein the first sealing tool (24) is configured to seal the capsule lid (4) along the second fastening surface (200) to the flange (6) and wherein the first sealing tool (24) or a second sealing tool (25) is configured to seal the capsule lid (4) along the first fastening surface (100) and preferably the second fastening surface (200) to the flange (6).

21. Sealing station according to claim 20, characterized in thatthe first sealing tool (24) and / or the second sealing tool (25) each comprise at least one sonotrode (28) and at least one receiving element (26), wherein the receiving element (26) has an open cavity for receiving the portion capsule (1), wherein the receiving element (26) further has at least one counter-holding means (27), wherein the counter-holding means (27) is provided to provide a counter-force on the side of the flange (6) facing away from the capsule lid (4), in particular in the region of the first fastening surface (100) and / or the second fastening surface (200), to the force exerted by the sonotrode (28).

22. Sealing station according to claim 21, characterized in thatthe receiving element (26) has at least one counter-holding means (27) in the region of the first fastening surface (100), wherein an upper surface of the counter-holding means (27) is arranged higher by at least 0.05 mm, preferably at least 0.10 mm, in particular by at least 0.15 mm, compared to an upper surface of the counter-holding means (27) of the first sealing tool (24) and / or second sealing tool (25) in the region of the second fastening surface (200).

23. Sealing station according to one of claims 21 or 22, characterized in that the sonotrode (28) of the first and / or second sealing tool (24, 25) has a heat dissipation means (29), in particular arranged centrally 24. Plant for producing a portion capsule (1) according to one of claims 1 to 12, in particular according to a method according to one of claims 15-19, with a forming station for forming a base element (2), a filling station for filling a cavity (3) of the base element (2) with at least one beverage raw material and a closing station for closing the base element (2) with a capsule lid (4), characterized in that the closing station is a sealing station according to one of claims 20 to 23.

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