How the compostable pods are made
Patent Information
- Application Number
- JP2024549712
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-03-03
- Filing Date
- 2023-03-01
- Publication Date
- 2025-03-13
Smart Images
Figure 2025506793000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to a method for manufacturing a pod for preparing a beverage in a beverage production machine, the pod having a wall portion that opens upon interaction with an opening element of the beverage production machine under the effect of an increased pressure of a fluid injected into the pod. [Background technology]
[0002] Disposable beverage containers for beverage preparation machines, such as capsules or pods, are known in the art. These beverage containers are generally used for the dispensing of individual servings of beverages, such as coffee, tea or hot chocolate, and have gained popularity due to their fresh taste, flavor variability, and convenience of beverage preparation.
[0003] Typically, a beverage container containing beverage ingredients is inserted into a container holder of a beverage preparation machine, the container holder is closed and the preparation of the beverage is started. A fluid, such as hot water or milk, is delivered to the beverage container and interacts with the beverage ingredients contained inside the beverage container to produce the desired beverage. When a sufficient amount of fluid fills the beverage container, the beverage container is opened under the pressure of the fluid, releasing the prepared beverage. The opening of the beverage container can be achieved by pressing the extraction surface of the beverage container against an opening structure provided in the container holder with a force brought about by increasing the pressure of the fluid inside the beverage container, such that the extraction surface tears when a breaking stress is reached. The opening structure can be several concave-convex elements, for example pyramidal elements, over which the extraction surface extends and which tears under the effect of the internal pressure of the fluid. Such pressure-controlled beverage preparation has the advantage that a high quality beverage can be produced.
[0004] Typically, known beverage containers are made of materials that require difficult processes to reuse, recycle or compost, especially after use of the beverage container, where the beverage container can often comprise a non-biodegradable plastic, such as polypropylene, and / or a metal, such as aluminum.
[0005] Therefore, in the prior art, various attempts have been made to replace these materials with biodegradable or compostable materials, such as biodegradable polymers or paper, which poses many challenges since food packaging applications generally impose high requirements on the barrier performance of the packaging in order to keep the aroma, freshness and integrity of the packaged product intact throughout its intended shelf life. Furthermore, new materials need to match or even exceed the material properties of established materials in terms of resistance to heat and pressure, as well as the length of shelf life achievable with the new packaging.
[0006] In experiments not publicly disclosed, promising results were obtained for a compostable beverage container made from a formable material and having an extraction surface made from a different material adapted to be opened during the beverage preparation process. The formable material is used to form the container body and comprises a cutout that is covered and connected with a material to form the extraction surface. For example, such a beverage container is described in International Application No. PCT / EP21 / 077158.
[0007] Unfortunately, it has been found that there are also many challenges in developing a suitable manufacturing process for this type of beverage container that facilitates the provision of a reliable oxygen barrier at the connection of the different materials. Typically, the two materials are connected to each other before being formed together into the final shape of the beverage container, so that a strong material bond can be guaranteed. However, it has been identified that the connection between the different materials is susceptible to breaking or tearing during the forming process. Thus, in addition to the finished beverage container having an ineffective oxygen barrier, there is an increased risk of delamination or leakage before or during the beverage preparation process. A possible reason for this may be the shear forces that are generated during the forming process and that stress the connection. Here, the shear forces may be particularly detrimental to the bond between the different materials, thus causing tearing of the connection between the different parts of the beverage container. However, these situations are detrimental to ensuring the integrity of the product inside the beverage container, and therefore the shelf life is reduced. Although improvements have been made by additional auxiliary measures such as pre-wetting the formable material, or by assisting the forming process by further applying heat and / or pressure during the forming process, the fundamental problem and the corresponding problems remain.
[0008] It is therefore an object of the present invention to provide a method for the manufacture of beverage containers, such as pods, which makes it possible to overcome the above-mentioned drawbacks of the prior art. It is also an object of the present invention to manufacture compostable beverage containers with a reliable and effective oxygen barrier and with a reduced risk of leakage before or during the beverage preparation process. It is further an object of the present invention to manufacture beverage containers without the need for auxiliary measures, such as pre-wetting the wall material of the formable container, in order to facilitate the manufacture of the beverage containers using existing production lines and equipment.
[0009] These and other objects which will become apparent on reading the present specification are solved by the subject matter of independent claim 1. The dependent claims refer to preferred embodiments of the invention. Summary of the Invention
[0010] A first aspect of the invention relates to a method for manufacturing (compostable) pods for preparing beverages in a beverage production machine.
[0011] Here, a pod may be understood as, for example, a receptacle or container enclosing a volume for containing substances necessary for beverage preparation. The pod may be flat and (generally) rounded in shape and / or may have the shape of a (circular and / or biconvex) lens. Unlike capsules for beverage preparation (e.g. as generally known in the art), the pod may not, for example, comprise a substantially flat top surface (which in such capsules is typically formed by a lid), but instead may comprise one outwardly bulging surface on either side of the contents of the pod.
[0012] In this method, two sheet elements are provided, each made from a formable material, preferably a biodegradable material.
[0013] Here, a sheet element may be understood as an element which may be thin, for example compared to its length and width, and / or which may be provided from a sheet.
[0014] Furthermore, the term "formable" may be understood as a characteristic of a material that is malleable, flexible, and / or moldable, for example, with or without the support of additional tools and / or with or without the application of heat and / or water. For example, in a dry pulp molding process, a blank of dry cellulose fibers is provided and may be formed into the (permanent) shape of a pod with a tool. For example, the formable material of the pod may facilitate providing the pod with shape stability, rigidity, and / or stiffness, each of which properties are sufficient to build up pressure inside the pod during beverage preparation.
[0015] Furthermore, a "biodegradable" material may be understood as any material that can be decomposed by (the action of) living organisms (microorganisms, such as bacteria, fungi or algae) into environmentally harmless products.
[0016] An aperture is cut into (at least) one of the sheet elements.
[0017] Here, the expression "opening" may be understood as an opening that may be formed, for example, by cutting away matter from a material. For example, the opening may be defined by a sharp edge that defines its periphery. For example, the opening may be a notch or a (through) hole or a perforation in the material and / or may preferably form a passage between two opposing sides of the material in which the opening is cut.
[0018] The opening is covered with a sheet material. The sheet material and the individual sheet elements are connected (preferably by heat or ultrasonic sealing) at a connection area. The connection area circumferentially surrounds the opening. The sheet material so connected forms (in the finished pod) a delivery wall. The two sheet elements are each formed in the shape of a half shell. An injection wall (of the pod) is formed for injecting fluid into the pod. The substances necessary for the preparation of the beverage are provided.
[0019] Here, the term "half shell" may be understood as a structure that may form, for example, a part (half) of the outer casing of a pod. A substance may be understood as, for example, any kind of (solid, liquid, at least partially soluble and / or permeable) substance having a specific or defined chemical structure. Examples of substances may be instant coffee or roast and ground coffee, tea leaves, syrup concentrates, fruit extract concentrates, chocolate products, dehydrated edible substances, and / or combinations thereof.
[0020] The two half shells are connected to form a pod body around the material to form the pod.
[0021] Thus, a pod may be composed of two pod halves, such as two half shells, which are connected (e.g. sealed) to each other to form a pod body. Here, the connection between the two pod halves may extend in a plane sandwiched by the two pod halves. The plane may be a symmetry plane of the pod. In comparison, a capsule for beverage preparation may comprise a capsule body constituted by a continuous wall and may comprise an opening at the top (and / or bottom) of the capsule, which is closed by a (substantially flat) membrane, e.g. a lid (respectively). Thus, as an illustrative example, the shape of the capsule is (mainly) defined by its capsule body, whereas the shape of the pod may be defined once the two half shells are connected.
[0022] The pod body together with the delivery wall and the inlet wall bounds a chamber containing a substance for preparing a beverage upon interaction of the substance with a fluid injected through the inlet wall.
[0023] Here, a "chamber" may be understood as, for example, a (sealed) enclosed space.
[0024] The delivery wall is adapted (configured) to open upon interaction with an (external) opening element of the beverage production machine under the effect of an increase in pressure of a fluid being injected (through the injection wall) into the pod, thereby dispensing the prepared beverage from the pod.
[0025] Here, the expression "configured to be opened" may be understood as the ability, configuration and / or design of the delivery wall to be provided with holes, punctures and / or ruptures, for example, preferably during the beverage preparation process. For example, the provision of such openings may preferably be subject to certain conditions and / or circumstances, such as the provision of an opening element and / or the exceedance of a certain pressure inside the pod. This indicates that the pod, unlike commonly known pads for beverage preparation, facilitates the build-up of pressure inside the chamber sufficient to open the delivery wall in the above specified manner with an external opening element. Typically, the pad is made of a soft and flexible filter material that is designed to be perfused but not designed to build up pressure inside the pad.
[0026] The connection regions are sandwiched from both sides of the sheet elements when forming the individual half shells.
[0027] Here, the expression "the connection regions are sandwiched" may be understood as, for example, applying pressure from two sides to at least the radially outer section of the individual regions and / or compressing the individual regions preferably between two opposing surfaces (either hard with respect to the sheet elements or incompressible with respect to the forces present during the forming process).
[0028] Thereby, it is possible to make or produce pods in a process that facilitates the pods to be made from compostable materials, while maintaining the general layout and all the functionality of a conventional pod, including the provision of an intact oxygen barrier. Providing the individual sections of the pod from different materials all supplied as sheets allows for the formation of strong connections between these materials, simplifying the manufacturing. Furthermore, the formability of the sheet elements makes it easy to convert the connected sheet materials into a pod with very few restrictions on the design of its three-dimensional shape. As mentioned above, the section of connected sheet material, including the bond between the different materials, is supported, especially during the forming process, through the application of (compressive) forces from two opposite sides. Thus, this section of connected sheet material can be made to be unaffected by shear forces during the forming process. Thus, the connection between the materials remains unaffected by the stresses occurring in the forming process. As a result, the oxygen barrier formed by said connection remains intact. Also, the risk of leakage occurring at the connection before or during beverage preparation can be reduced. Furthermore, the method of the present invention does not require altering the material properties of the sheet material with auxiliary measures for the forming process, as the forming process can be completed without compromising the integrity of the oxygen barrier, and therefore existing equipment and manufacturing lines for manufacturing pods can be used.
[0029] Thus, the method of the present invention overcomes the shortcomings of the prior art.
[0030] Preferably, the pods are (home) compostable.
[0031] Here, the term "compostable" may be understood to mean that a material can be substantially decomposed into organic matter within a few weeks or months when composting. This may be achieved in industrial composting sites and / or home composters. In such sites, there may be specific conditions related to wind, sunlight, drainage and other factors. At the end of the composting process, the ground may be provided with nutrients when the material is completely decomposed. International standards such as EU13432 or US ASTM D6400 provide a legal framework for specifying the technical requirements and procedures for determining the compostability of a material. For example, one test for compostability requires that at least 90% of the material in question is biologically decomposed within 6 months under controlled conditions in order to be considered "industrially compostable". Similar tests exist for the certification of home compostability. According to the above mentioned standard, all compostable plastic materials must simultaneously possess the following properties in order to be considered compostable: The material must be biodegradable and disintegratable, i.e., it must break down and be invisible in the final compost, and must not adversely affect the composting process and quality. Thus, compostable pods have advantages regarding disposal of the pods after use.
[0032] According to a preferred embodiment, the sheet elements can each be formed into the shape of a half shell by drawing at least a portion of the individual sheet elements into a forming die. Preferably, the individual sheet elements can be stretched into the shape of the half shell by the mechanical action of a punch or by application of a vacuum. For example, they can be stretched into the shape of the half shell by deep drawing the individual sheet elements.
[0033] This allows each part of the pod to be manufactured with a uniform wall thickness. In addition, the mechanical stresses peak in the sections of the sheet material that are used to hold it in the forming die, so that the connection areas can be avoided from being subjected to tensile stresses. Furthermore, the process of deep drawing is a consistent and cost-effective process, which is particularly suitable for continuous production.
[0034] According to a further preferred embodiment, the clamping of the connection area may be performed by a punch, which may be arranged on one side of the sheet element, and a counter punch, which may be arranged on the other side of the sheet element with respect to the punch. Preferably, the punch and the counter punch may be movable relative to each other and / or to the sheet element. Furthermore, preferably, the counter punch may be configured to damp and / or resist a displacement force exerted by the punch on the connection area. Alternatively or additionally, the counter punch may be elastically supported in the forming die, for example by an elastic element such as a spring. Furthermore, the counter punch may preferably be spring-elastically biased towards the punch so as to exert a defined clamping force on the connection area during the forming step. This may preferably be the case at least during the forming step.
[0035] Thereby, it can be achieved that the connection area is subjected to a compressive force that can reduce or (completely) compensate for the tensile stresses occurring during the forming process, thereby making it possible to avoid shear stresses in the connection. In addition, the above-mentioned configuration is particularly suitable for implementing a fast and efficient manufacturing process.
[0036] According to a preferred embodiment, each of the two half shells may comprise a peripheral flange. For example, the peripheral flange may extend radially outward relative to the respective half shell. The peripheral flange may be formed on each of the two half shells by clamping an area of the respective sheet element between a blank holder surrounding the punch and a forming die when forming the respective sheet element into the shape of the half shell. Preferably, the two half shells may be connected to each other via the peripheral flange.
[0037] Thereby, it is possible to maximize the volume of the pod available for receiving material, since the connection between the two half shells is provided along their respective peripheries. Furthermore, if a forming die is used, the peripheral flange can be formed as part of the deep drawing process, thereby reducing the number of different steps in the manufacturing process of the pod.
[0038] According to a further preferred embodiment, the two sheet elements may be provided by cutting or punching a sheet, which may be made from a formable and / or biodegradable material. Preferably, cutting the openings in the sheet elements may be performed before, during or after the two sheet elements are cut or punched from the sheet.
[0039] This allows the material to be provided on rolls of material which can be processed quickly, thereby increasing production speed and efficiency.
[0040] According to a preferred embodiment, the half shells may be configured such that the two half shells may be separated by a gap when enclosing the substance prior to the step of connecting the two half shells, where the size of the gap may depend on the volume of the substance. Preferably, at least one of the half shells may be configured such that the volume of the pod corresponds to the volume of the substance after the step of connecting the two half shells. Furthermore, the gap may be reduced or eliminated upon connection of the two half shells.
[0041] Alternatively or additionally, when the two half shells are arranged around the material before connecting the two half shells, a gap is at least partially formed between one material and at least one or both of the half shells surrounding the other material before connecting the two half shells. Preferably, the gap can be reduced or eliminated when connecting the two half shells.
[0042] Preferably, the two half shells may be connected under application of a vacuum and / or heat and / or ultrasonic sealing. The half shells may be hermetically connected via a sealing section extending along the periphery of each of the half shells (or preferably along the peripheral flange, if present).
[0043] Preferably the substance is prepared as a tablet made of compressed beverage powder, preferably made of coffee powder.
[0044] Preferably, at least one of the half shells (preferably the half shell including the injection wall) may conform in shape and size to part of the contour of the adjacent tablet in the pod prior to the step of connecting the two half shells. Alternatively, a substance may be compressed inside one of the half shells (preferably the half shell including the injection wall) so as to conform in shape and size to the contour of the individual half shell.
[0045] Each of the aforementioned configurations facilitates that the substance can be tightly packed inside the pod. For example, the two (formable) half shells together have a lower height than the (compressed) substance. Thus, when the two half shells are connected (under vacuum), the substance and / or at least one of the half shells is sized to enclose the substance, for example, by (further) compressing the substance to the combined volume of the half shells or by bending / stretching / stretching the material of the half shells using the compressed substance as a support surface. Thus, the risk of packaging foreign objects or gases in the pod manufacturing process is reduced. In addition, the beverage preparation process of the so manufactured pod can be improved, since in such a process, empty spaces, gaps or cavities are eliminated, so that the injected fluid is forced to move into and through the substance in the intended manner, thereby building up the necessary pressure inside the capsule.
[0046] According to a further preferred embodiment, the injection wall may be formed when forming one of the half shells, preferably the half shell other than the half shell provided with the opening or delivery wall.
[0047] Thereby, it is possible to define on the half shells the pouring wall that is best suited for the purpose of the application or specification of the beverage production machine used.
[0048] According to a preferred embodiment, forming the injection wall may include cutting a further opening in one of the sheet elements (preferably a sheet element other than the one in which the opening is cut, such that the separate sheet element includes the further opening). Forming the injection wall may further include covering the further opening with a further sheet material and connecting the further sheet material to the separate sheet element in a further connection area circumferentially surrounding the further opening, the further sheet material so connected forming the injection wall. Preferably, the connection between the further sheet material and the separate sheet element may be achieved by heat sealing or ultrasonic sealing.
[0049] According to a further preferred embodiment, the half shells may be identical.
[0050] According to a preferred embodiment, at least one or both of the sheet elements may have a disk shape.
[0051] With any of these configurations, the pods can have a symmetrical layout, which is advantageous since the user does not need to pay attention to how to place the pods in the beverage production machine. In addition, the pod half shells are composed of identical or at least similarly formed half shells, which can simplify the pod production process.
[0052] Alternatively, the half shells may have different heights. The height difference may exist at least before they are connected to form the pod body. Preferably, the half shell comprising the inlet wall may have a greater height than the half shell comprising the outlet wall.
[0053] Thus, pods can be manufactured with significant height differences to indicate the orientation of the pod to the operator. Furthermore, the different configuration of the half shells allows for improved filling of the material into the half shells, since a larger height reduces the risk of losing material during the filling process.
[0054] According to a further preferred embodiment, the half shells can be formed before or after cutting the openings in the sheet elements. Alternatively or additionally, the half shells can be formed before or after cutting or punching other openings, if present, in the individual sheet elements.
[0055] Thereby, it can be ensured that the connection area is not subjected to shear stress during the formation process so that the integrity of the oxygen barrier is guaranteed.
[0056] A further aspect of the invention relates to the use of a pod as described above for preparing a beverage in a beverage production machine having a pod holder.
[0057] Another aspect of the invention relates to a pod for preparing a beverage in a beverage production machine, the pod comprising a pod body composed of two half shells connected to each other to define a chamber for containing a substance for the preparation of the beverage. The pod further comprises an injection wall for injecting a fluid into the chamber for preparing the beverage upon interaction of the fluid with the substance. The pod also comprises a delivery wall connected to the pod body for closing the chamber, the delivery wall being adapted to open upon interaction with an (external) opening element under the effect of a pressure increase of a fluid to be dispensed in the pod to dispense the prepared beverage from the pod. Here, preferably, the pod can be formed without pre-wetting the paper-based material used to form the pod body and / or without shearing the connection area between the pod body and the delivery wall.
[0058] The above method and pod facilitate the preparation of beverages using pods that can be manufactured from compostable materials while retaining all the functionality known from pods established in the prior art. In addition, the pods can be used with existing beverage preparation machines without the need for modifications. Thus, the pods and beverage preparation method allow for the production of high quality beverages using pods that overcome the problems currently present with the disposal of prior art pods. [Brief description of the drawings]
[0059] Further features, advantages, and objects of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the embodiments of the invention in conjunction with the accompanying drawings, in which: Where numerals are omitted from a figure, for example for clarity, the corresponding features may still be present in the figure. [Figure 1] 5 illustrates the various steps of an embodiment of a method for manufacturing a pod according to the invention. [Diagram 2]1 shows a schematic diagram of the initial steps of one embodiment of a pod manufacturing method of the present invention. [Diagram 3] 1 shows a top view of one embodiment of a pod manufactured by a pod manufacturing method according to the present invention. [Figure 4] 4 shows a schematic cross-sectional view of the pod of FIG. 3. [Diagram 5] 1 shows a schematic diagram of one embodiment of a forming step in a pod manufacturing method according to the present invention. [Figure 6A] 4A-4C show different embodiments of the final steps of the pod manufacturing method according to the invention, including assembling the filling of the pod with substances for beverage preparation and assembling the pod; [Figure 6B] 4A-4C show different embodiments of the final steps of the pod manufacturing method according to the invention, including assembling the filling of the pod with substances for beverage preparation and assembling the pod; [Figure 7A] 4A-4D show different embodiments of the connecting step of the pod manufacturing method according to the present invention. [Figure 7B] 4A-4D show different embodiments of the connecting step of the pod manufacturing method according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] Figures 1, 2 and 5-7 show different views and aspects of an embodiment of a method according to the present invention for manufacturing a pod 100 suitable for preparing a beverage in a beverage production machine. Figures 3 and 4 show different views and aspects of an embodiment of a pod 100 manufactured by the manufacturing method according to the present invention.
[0061] A first aspect of the present invention relates to a method for manufacturing pods for preparing beverages in a beverage production machine, such as the above-mentioned pod 100. The method for manufacturing the pod 100 comprises several steps, some of which are exemplarily assigned reference signs S1, S2, S3, S4, S5 and S6 in Fig. 1 and used in the other figures. It is noted that the invention is not limited to a particular order of steps exemplarily indicated by the reference signs in the figures. Fig. 2 and Fig. 5 to Fig. 7 exemplarily show further details and aspects of the steps of the method of the invention.
[0062] In the method, two sheet elements 200 are provided. Figures 1 and 2 exemplarily show this step in step S1. For example, in Figure 2 it is exemplarily shown that the sheet elements 200 can be provided from a sheet 201, which can preferably be provided on a reel 250. Each of the two sheet elements 200 can be provided separately on a reel or can be provided from the same reel 250. The sheet 201 can be unwound from the reel 250 and (then) cut and / or punched to define the sheet elements 200 (e.g. to convert the sheet 201 into the sheet elements 200). The cutting and / or punching can be performed at various points in the manufacturing process. Of course, this method of providing the sheet elements 200 is only an example and other methods of providing sheet elements are also contemplated. In particular, Figure 2 exemplarily shows how a large number of sheet elements 200 can be provided and produced on an industrial scale. Further, as exemplarily shown in Figures 1, 3, 4, 6 and 7, at least one or both of the sheet elements 200 may have a disk shape. However, it is contemplated that the sheet elements 200 may have different shapes, such as rectangular or polygonal. Preferably, the shape of the sheet elements 200 may correspond to the shape of a pod holder of the beverage production machine. The sheet elements 200 may have the same shape (as shown) or each may have a different shape.
[0063] Each of the sheet elements 200 is made of a formable, preferably biodegradable and / or preferably (home) compostable material. For example, the sheet 201 may be made of a formable and / or biodegradable and / or compostable material. For example, the material of the sheet elements 200 (or the sheet 201) may be formable by being stretchable (and / or permanently deformable) in the transverse and longitudinal directions. For example, a material suitable for this purpose may be a formable paper material. The material of the sheet elements 200 (or the sheet 201) may be preferably 80 g / m 2 ~150g / m 2 The formable paper material may include a formable paper material having a basis weight of 1000 MPa to 30000 MPa, preferably 26000 MPa, in the cross direction of the paper material and / or preferably 2600 MPa in the machine direction of the paper material. Preferably, the sheet element 200 may be configured to have an elongation at break in the range of 8% to 15% at a tensile strength of 2000 MPa to 40000 MPa. Here, the elongation at break may generally be understood as the ratio between the changed length after break of the test specimen and the initial length, and can be used as a measure to quantify the resistance of a material to a change in shape without breakage or crack formation. For example, the elongation at break may be determined by a tensile test according to EN ISO 527. The work to break of the material of the sheet element 200 may be 100 Nmm to 200 Nmm. For example, by providing a sheet element 200 (or sheet 201) having any of the above-mentioned configurations, it is possible to provide the pod 100 with sufficient rigidity, stiffness, and / or shape stability to build up pressure inside the pod 100 during preparation of a beverage.
[0064] Preferably, the material of the sheet element 200 may have a (laminated) multi-layer structure and may preferably comprise at least one additional layer 212 (in addition to the formable paper layer 211). This is exemplarily shown in the schematic cross-section of Fig. 2. Preferably, the material of the sheet element 200 may comprise an oxygen barrier and / or a moisture barrier and / or an adhesive layer which may be provided as a coating and / or in the lamination process. For example, the oxygen barrier may be greater than 5cc / m 2 / day.
[0065] Further, in the method, an opening 210 is cut (and / or punched) in at least one of the sheet elements 200. This is exemplarily shown in step S2 in Fig. 1 and Fig. 2. It is contemplated that the opening 210 may be cut in the sheet element 200 before (Figs. 2 and 5), at the same time (Fig. 1) or after the two sheet elements 200 are cut or punched from the sheet 201. The opening 210 may have any shape and / or size. Preferably, the opening 210 may be circular and / or a through hole. The diameter D1 of the opening 210 may be between 18 mm and 30 mm, preferably 24 mm. Fig. 2 exemplarily shows this. Preferably, the sheet element 200 may comprise one or more (similar and / or different) openings. In general, there is no limit to the number of openings 210 that the sheet element 200 may have. Preferably, the opening 210 may be configured and / or provided / arranged such that elements of the beverage production machine, such as opening elements and / or pouring elements, do not engage and / or contact the remainder of the sheet element 200 within the beverage production machine during beverage preparation. This may be achieved by dimensioning and / or positioning the opening 210 relative to the opening.
[0066] Further, in the method, the opening 210 is covered with a sheet material 300. Fig. 2 exemplarily shows that in step S3, the sheet material 300 may be placed over the opening 210. Preferably, the opening 210 may be completely closed (on one side of the sheet element 200) by covering the opening 210, as exemplarily shown in Figs. 1-7.
[0067] The sheet material 300 and the individual sheet element 200 (with opening 210) are connected in a connection area 230. The connection may be established by sealing the respective elements to one another, for example by heat or ultrasonic sealing. The sheet element 200 (or sheet 201) is exemplarily shown in all figures to be connected to the sheet material 300. Figures 1 and 2 show this part of the manufacturing process as step S3. The connection area 230 circumferentially surrounds the opening 210. The connection area 230 may therefore be a section of the sheet element 200 located at, surrounding and / or directly adjacent (contiguous) to the opening 210. For example, in Figure 2 the connection area 230 is exemplarily shown as a ring-shaped (contiguous) section of the sheet 201 (or sheet element 200). Preferably, the connection area 230 may be circular and have a diameter D2 (Figure 2). The diameter D2 may be between 15 mm and 40 mm, preferably 32 mm. However, the connection area 230 may have any size or shape that preferably corresponds to and extends across the shape and size of the opening 210. The sheet material 300 may be connected to either side of the sheet element 200.
[0068] Preferably, the sheet material 300 may have any size, shape, or form. For example, in FIG. 2, it is exemplarily shown that the sheet material 300 may be provided as a sheet wound on a reel 350. The sheet material 300 may be unwound from the reel 350 such that the sheet material 300 intersects with the sheet 201, thereby covering the opening(s) 210 provided in the sheet 201. Here, it is contemplated (alternatively or additionally) that the sheet material 300 may be adjusted to assume a different shape and size before, during, or after the sheet material 300 and the sheet element 200 are connected in the connection region 230 in step S3. This is independent of providing the sheet material 300 as a sheet wound on a reel 350. For example, FIG. 2 (to the right of the intersection of the sheet material 300 with the sheet 201) and FIG. 5 show the sheet material 300 being adjusted to the size of the connection region 230. 2, the size adjustment is exemplarily shown as being achieved during the connection process of sheet material 300 and sheet 201. However, this is only one example and should not be understood as the only possible implementation of step S3.
[0069] The sheet material 300 so connected (sealed) forms the delivery wall 110 of the pod 100. Beverage is dispensed from the pod 100 through the delivery wall 110 during the process of preparing the beverage. The delivery wall 110 is exemplarily shown in all drawings, but is highlighted in Figures 1 and 3 to 7. The delivery wall 110 is adapted to be opened upon interaction with an opening element (e.g. a pyramid plate) of a beverage production machine (i.e. an opening element external to the pod 100) under the effect of an increased pressure of a fluid injected into the pod 100 in order to dispense the beverage from the pod 100.
[0070] The sheet material 300 may be provided as a continuous foil, film, sheet or membrane, or as a layered structure. Preferably, the sheet material 300 is a biodegradable and / or (home) compostable material. For example, the sheet material 300 is preferably 20 g / m 2 ~100g / m2 and / or more preferably includes a ventilated structure that provides flexibility to facilitate perforation of the sheet material 300. Additionally, the sheet material 300 may include paper, parchment paper, (coated) cellophane, (home or industrial) compostable film, and / or filter paper for filtering particles and residues of substances from the prepared beverage. Alternatively or additionally, the sheet material 300 may include an oxygen barrier (e.g., 5 cc / m 2 Preferably, the sheet material 300 may be configured to have an elongation at break in the range of 2% to 25% with a tensile strength of 250 MPa to 15,000 MPa.
[0071] The two sheet elements 200 are formed into the shape of the half shells 101, 102, respectively, as exemplarily shown in step S4 in figures 1 and 5. This can be done before or after (figures 1 and 5) the openings 210 are cut in the sheet elements 200. The forming of the sheet elements 200 into the shape of the half shells 101, 102 can be achieved, for example, by drawing the individual sheet elements 200 into a forming die 400 (deep drawing). Here, the forming die 400 can comprise a blank holder 402 for holding the sheet 201 (sheet element 200) in a fixed position during the forming step S4. The forming die 400 can further comprise a forming portion 401 corresponding to the (negative) shape of the finished half shells 101, 102. Preferably, the sheet 201 or sheet element 200 can be stretched into the shape of a half shell by mechanical action of a punch 410 or by creating a pressure difference between the former 401 and its opposite side with respect to the sheet 201 (sheet element 200). For example, an overpressure or a vacuum can be applied. The punch 410 can have any shape. Preferably, the punch 410 can have a shape that corresponds to the shape of the former 401. This is exemplarily shown in FIG. 5.
[0072] The half shells 101, 102 may have any shape or form. Preferably, the shape of the half shells 101, 102 may correspond to the geometry of the pod holder. Examples of the geometry and design of the half shells 101, 102 can be taken from Fig. 1 and Figs. 3-7. In these figures, it is exemplarily shown that each of the two half shells 101, 102 may comprise a peripheral flange 140, which may extend radially outwardly with respect to the respective half shell 101, 102. Furthermore, each of the half shells 101, 102 may extend axially from an inner edge of the peripheral flange 140 towards the opening 210, if present. The peripheral flange 140 may be formed on each of the two half shells 101, 102 as part of the half shell forming process. For example, the peripheral flange 140 may be formed by clamping the radially outer region 240 of the individual sheet element 200 (or sheet 201) against the opening 210 between a blank holder 402 surrounding the punch 410 and the forming die 400. In addition, the blank holder 402 may be provided with a sharp edge that cuts the sheet 201 and separates the half shells 101, 102 from the sheet 201 (e.g., thereby preferably finishing the sheet element 200). The half shells 101, 102 may be identical to each other or different. For example, the half shells 101, 102 may differ in height. Furthermore, the half shells 101, 102 may be different insofar as one of the half shells 101, 102 includes an opening 210 and a sheet material 300 connected thereto, and the respective other half shell 102, 101 does not include the opening 210 or the opening 210 is covered by a material different from the sheet material 300. 6 and 7 show examples of such differently designed half shells 101, 102.
[0073] However, as illustrated by the figure, prior to being formed into the shape of a half shell, at least one of the sheet elements 200 (or at least one section of sheet 201) may have a configuration such that opening 210 may be covered by sheet material 300 and sheet element 200 (or at least one section of sheet 201) and sheet material 300 may be connected to each other.
[0074] The connection area 230 is sandwiched from both sides of the sheet element 200 when forming the individual half shells 101, 102. Preferably, the sandwiching of the connection area 230 can be performed by the aforementioned punch 410 being arranged on one side of the sheet element 200 and the counter punch 420 being arranged on the other side of the sheet element 200 with respect to the punch 410. The punch 410 and the counter punch 420 can be movable relative to each other and / or to the sheet element 200 (sheet 201). This is exemplarily shown in FIG. 5. The counter punch 420 can be configured to damp and / or resist the displacement force exerted by the punch 410 on the connection area 230. The counter punch 420 can be elastically supported in the forming die 400 by an elastic element 421, preferably such as a spring. Of course, other implementations of the elastic element 421 are also contemplated, such as a hydraulic spring, a pneumatic spring or an electrically driven and controlled piston. In general, any element capable of being reversibly displaceable in response to mechanical forces typical of a forming process may be contemplated for the elastic element 421. The counter punch 420 may preferably be elastically (or spring-elastically) biased towards the punch 410, so that during the forming step a defined pinching force is applied to the connection region 230 via the compressive action of the punch 410 against the counter punch 420.
[0075] An injection wall 120 of the pod 100 is formed for injecting a fluid into the pod 100. The injection wall 120 may interact or engage with an injection element of a beverage production machine during the beverage preparation process, through which a fluid (at high temperature, e.g. 60-120°C) may be injected into the pod 100 (e.g. under a pressure of 1-20 bar). The injection wall 120 may be formed when forming one of the half shells 101, 102, preferably the one half shell 101, 102 other than the half shell 101, 102 with the opening 210 or the delivery wall 110. This is exemplarily shown in Figures 1 and 3-7. For example, the injection wall 120 may be identical to the delivery wall 110, as exemplarily shown in Figures 6A and 7A. For this purpose, the injection wall 120 may be formed by cutting another opening in the sheet element 200, preferably a sheet element 200 other than the sheet element 200 in which the opening 210 is cut, so that the individual sheet element 200 comprises the other opening. This other opening may then be covered with another sheet material which may then be connected to the individual sheet element 200 in another connection area circumferentially surrounding the opening, preferably by heat sealing or ultrasonic sealing. The thus connected (sealed) other sheet material may thereby form the injection wall 120. The other opening may be cut / punched in the individual sheet element 200 before or after the half shells 101, 102 are formed. The other sheet material may be the same or different from the sheet material 300. However, it is also envisaged that the other opening may be provided in the same sheet element 200 already comprising the opening 210. Alternatively, the injection wall 120 may be formed by half shells 101, 102 that are not provided with openings 210 and may consist of the material of the sheet element 200. The injection wall 120 may therefore be defined as a wall portion of the half shells 101, 102 in such a configuration. This is exemplarily shown in Figures 6B and 7B.
[0076] The substance 105 required for the preparation of the beverage is prepared. This is exemplarily shown in Fig. 1 and Fig. 6 as step S5. For example, the substance 105 may be prepared as a tablet made of compressed or pressed beverage powder, such as coffee powder. In general, the substance may be a (extractable) food substance, such as ground coffee powder, tea or chocolate. As part of step S5, it is also contemplated to press the substance 105 in one of the half shells 101, 102. Preferably, the half shell 101, 102 forming the injection wall 120, or more preferably, the one half shell 101, 102 without the opening 210, may be used for this purpose. This is exemplarily shown in Fig. 6B.
[0077] The two half shells 101, 102 are connected. By connecting the two half shells 101, 102, they form a pod body 130 around the substance 105 to form the pod 100. The pod body 130 together with the delivery wall 110 and the infusion wall 120 bounds a chamber containing the substance 105 for preparing a beverage upon interaction of the substance 105 with a fluid injected through the infusion wall 120. This is exemplarily shown in Figs. 1 and 7 as step S6. The connection of the two half shells 101, 102 may be established under application of vacuum and / or under application of heat and / or ultrasonic sealing and / or under application of pressure. Thereby, the half shells 101, 102 may be hermetically connected via a sealing section extending along the periphery of each of the half shells 101, 102. For example, in Figs. 1-4 and 7, the two half shells 101, 102 are shown as being connected to each other via a peripheral flange 140. Thus, the peripheral flange 140 may form a sealing section. For example, for the connection process, the two half shells 101, 102 and / or the material 105 may be concentrically aligned and / or abutted, preferably such that the material 105 is sandwiched between the two half shells 101, 102.
[0078] Surprisingly, it was found that it is also possible to configure the half shells 101, 102 such that when surrounding the material 105 prior to the step of connecting the two half shells 101, 102, the two half shells 101, 102 are initially separated (radially and / or axially) by a gap. Here, the size of the gap may depend on the volume of the material 105. However, the half shells 101, 102 may be configured such that the volume of the pod 100 corresponds to the volume of the material 105 after the step of connecting the two half shells 101, 102, whereby the gap may be reduced or even eliminated upon connecting the two half shells 101, 102. This may be a consequence of the inventive pod manufacturing method including the step of pinching the connection area 230, since the material forming the pod body 130 is mainly stretched in its part that is between the flange 140 and the opening 230. In comparison, the connection area 230 and the delivery wall 110 are not mechanically stressed and therefore a larger force is required to stretch and plastically deform this section of the pod 100. Thereby, the two half shells 101, 102 are able to stretch to match the volume and dimensions of the material 105 under conditions typically present during the filling and connection process, including the application of a vacuum during the connection process. This effect can advantageously be supported by the material 105 being squeezed, since it can act as a bending edge to stretch the half shells 101, 102. In experiments, gaps extending up to 2 mm, preferably between 0.1 mm and 2 mm, have been successfully reduced or even eliminated at the end of the connection process. Here, the configuration and / or connection process of the half shells 101, 102, material 105 may be such that at least one of the half shells 101, 102, preferably the half shell 101, 102 including the injection wall 120, can follow in shape and dimension at least a part of the contour of the adjacent compressed material 105 in the pod 100. It is also contemplated that prior to the step of connecting the two half shells 101, 102, the half shells 101, 102 may be formed with different heights.Preferably, the half shell 101, 102 with the inlet wall 120 may have a greater height than the half shell 101, 102 with the outlet wall 110. Of course, it is also contemplated that there is no gap (0 mm) between the two half shells 101, 102 at the start of the connection process. In this configuration, the substance 105 may be (additionally) compressed during the connection process.
[0079] A further aspect of the invention relates to a pod, such as the pod 100 described above, manufactured by the method described above. The pod 100 is suitable and / or configured to prepare a beverage in a beverage production machine. The beverage production machine may comprise an element for opening the pod 100 under the effect of an increase in pressure of a fluid injected into the pod 100. Figures 1, 3, 4 and 7 show an example of a pod 100. The pod 100 may be made (totally) from (homely) compostable materials so that the pod 100 can be easily disposed of in an industrial or home compost pile after use. Thus, the entire contents of the pod 100 may be compostable, including any beverage ingredients contained therein. The pod 100 comprises a pod body 130 composed of two half shells 101, 102 connected to each other to delimit a chamber for containing a substance 105 for the preparation of a beverage. Furthermore, the pod 100 comprises an injection wall 120 for injecting a fluid into the chamber to prepare a beverage upon interaction of the fluid with the substance 105. Furthermore, the pod 100 comprises a delivery wall 110 connected to the pod body 130 via a connection area 230 to close the chamber, the delivery wall 110 being adapted to open upon interaction with an (external) opening element under the effect of a pressure increase of the fluid injected into the pod 100 to dispense the prepared beverage from the pod 100. Preferably, the pod 100 contains the substance 105. Preferably, the connection between the delivery wall 110 and the pod body 130 may not be stressed by shear forces during the forming process of the half shells 101, 102. More preferably, the forming process of the half shells 101, 102 may be accomplished without pre-wetting the formable material used for the pod body 130.
[0080] A further aspect of the invention relates to the use of a pod, such as the above-mentioned pod 100 manufactured in the above-mentioned manner, for preparing a beverage in a beverage production machine having a pod holder, where the pod 100 may be placed inside the pod holder of the beverage production machine, the pod holder may be closed and a beverage may be prepared in the above-mentioned manner and released from the pod 100 by interaction of the delivery wall 110 with an opening element of the beverage production machine.
[0081] The present invention is not limited to the above-described embodiments, insofar as it is encompassed by the scope of the appended claims. All features of the above-described embodiments can be combined in any possible manner and provided interchangeably.
Claims
1. A method for manufacturing a pod (100) for preparing a beverage in a beverage production machine, comprising: Providing (S1) two sheet elements (200), each made of a formable, preferably biodegradable, material; (S2) cutting an opening (210) in one of said sheet elements (200); - a step (S3) of covering said opening (210) with a sheet material (300) and connecting said sheet material (300) to the individual sheet elements (200) in a connection area (230) circumferentially surrounding said opening (210), preferably by heat sealing or ultrasonic sealing, said sheet material (300) thus connected forming a delivery wall (110); forming (S4) the two sheet elements (200) into the shape of half shells (101, 102), respectively; forming an injection wall (120) of the pod (100) for injecting a fluid into the pod (100); - providing (S5) the substances (105) necessary for the preparation of said beverage; a step (S6) of connecting the two half shells (101, 102) to form a pod body (130) around the substance (105) to form the pod (100), the pod body (130) together with the delivery wall (110) and the injection wall (120) defining a chamber containing the substance (105) for preparing the beverage upon interaction of the substance (105) with the fluid injected through the injection wall (120), the delivery wall (110) being adapted to open upon interaction with an opening element of the beverage production machine under the effect of a pressure increase of the fluid injected into the pod (100) to dispense the prepared beverage from the pod (100); Including, The method, wherein the connection regions (230) are sandwiched from both sides of the sheet element (200) when forming the individual half shells (101, 102).
2. 2. The method according to claim 1, wherein the sheet elements (200) are formed into the shape of half shells (101, 102) respectively by drawing at least a portion of the individual sheet elements (200) into a forming die (400), preferably by mechanical action of a punch (410), more preferably by deep drawing the individual sheet elements (200).
3. 3. The method according to claim 1 or 2, wherein the clamping of the connection area (230) is performed by a punch (410) arranged on one side of the sheet element (200) and a counter punch (420) arranged on the other side of the sheet element (200) with respect to the punch (410), preferably the punch (410) and the counter punch (420) being movable relative to each other and / or to the sheet element (200).
4. the counter punch (420) is configured to dampen and / or resist the displacement force exerted by the punch (410) on the connection region (230); and / or 4. The method of claim 3, wherein the counter punch (420) is resiliently supported in the forming die (400) by a resilient element (421), preferably a spring.
5. 5. The method according to claim 3 or 4, wherein the counter punch (420) is preferably spring-loaded towards the punch (410), preferably at least during the forming step, so as to apply a defined clamping force on the connection area (230) during the forming step.
6. 6. The method according to claim 1, wherein each of the two half-shells (101, 102) comprises a peripheral flange (140), preferably extending radially outwardly with respect to the respective half-shell (101, 102), and preferably the peripheral flange (140) is formed on each of the two half-shells (101, 102) by clamping an area (240) of the respective sheet element (200) between a blank holder (402) surrounding the punch (410) and the forming die (400) when forming the respective sheet element (200) into the shape of the half-shell (101, 102).
7. 7. The method according to claim 6, wherein the two half shells (101, 102) are connected to each other via the peripheral flanges (140).
8. The two said sheet elements (200) are prepared by cutting or punching a sheet (201) made of a formable material, preferably a biodegradable material; A method according to any one of claims 1 to 7, wherein preferably cutting the openings (210) in the sheet elements (200) is performed before, during or after two of the sheet elements (200) are cut or punched from the sheet (201).
9. The method according to any one of claims 1 to 8, wherein the half shells (101, 102) are configured such that, prior to the step of connecting the two half shells (101, 102), the two half shells (101, 102) are separated by a gap when surrounding the substance (105), preferably the size of the gap being dependent on the volume of the substance (105), preferably at least one of the half shells (101, 102) being configured such that, after the step of connecting the two half shells (101, 102), the volume of the pod (100) corresponds to the volume of the substance (105) and / or the gap is reduced or eliminated when connecting the two half shells (101, 102).
10. the injection wall (120) is formed during the formation of one of the half-shells (101, 102), preferably the one half-shell (101, 102) being the half-shell (101, 102) other than the half-shell (101, 102) comprising the opening (210) or the delivery wall (110), or forming the injection wall (120) cutting another opening in one of the sheet elements (200), preferably a sheet element (200) other than the one in which the opening (210) is cut, so that the respective sheet element (200) comprises the other opening; covering said other opening with another sheet material and connecting said other sheet material to said individual sheet elements (200) in another connection area circumferentially surrounding said other opening, preferably by heat or ultrasonic sealing, said other sheet material thus connected forming said injection wall (120). The method according to any one of claims 1 to 9.
11. The method according to any one of claims 1 to 10, wherein the half shells (101, 102) are formed before or after cutting the openings (210) in the sheet element (200), preferably before or after cutting or punching the other openings, if present, in the respective sheet elements (200).
12. The method according to any one of the preceding claims, wherein at least one or both of the sheet elements (200) have a disk shape.
13. the half shells (101, 102) are identical, or The method according to any one of claims 1 to 12, wherein the half shells (101, 102) have different heights, at least before being connected to form the pod body (130), and preferably the half shell (101, 102) comprising the inlet wall (120) has a greater height than the half shell (101, 102) comprising the outlet wall (110).
14. said substance (105) is provided as a tablet made of compressed beverage powder, preferably made of coffee powder, and / or The method according to any one of claims 1 to 13, wherein prior to the step of connecting the two half shells (101, 102), at least one of the half shells (101, 102), preferably the half shell (101, 102) comprising the injection wall (120), follows in shape and dimensions a part of the outline of the adjacent tablets in the pod (100).
15. The method according to any one of claims 1 to 14, wherein the two half shells (101, 102) are connected under application of a vacuum and heat or ultrasonic sealing, preferably the half shells (101, 102) are hermetically connected via a sealing section extending along the outer periphery of each of the half shells (101, 102), preferably along the peripheral flange (140), if present.