Flexible package with rigid section for food or beverage preparation

Abstract

The present invention relates to a flexible or semi-flexible closed package (1) for containing ingredients for preparing an edible product in a food or beverage preparation machine, the package (1) comprising: (i) flexible or semi-flexible side walls (2) forming a flat package body; and (ii) a cup-shaped bottom (3) adapted for insertion of a fluid injection element of the machine. The package (1) is formed from a single elongated primary flat blank sheet (5) made of a flexible material, folded into a U-shape about its transverse axis of symmetry (Lx) and sealed along its side edges (4) and top edge (34). The cup-shaped bottom (3) is a hollow volume having a concave lower surface (7) and convex side surfaces (8), the contour of which is identical to the contour of each of the side surfaces (8).

Description

[Technical Field]

[0001] The present invention relates to a closed flexible sachet containing beverage ingredients and adapted for use in a beverage preparation machine by piercing the sachet wall and injecting liquid therein to mix with the ingredients. [Background technology]

[0002] It is known in the art to prepare a beverage by introducing a capsule containing a food or beverage ingredient, such as soluble coffee, milk, or chocolate, into a beverage dispenser and then injecting water into the capsule to mix with the ingredient. The soluble beverage or food ingredient is typically dissolved in water to form a beverage or desired end product, which flows from the capsule through a suitable outlet. In some cases, the ingredient may be tea leaves, and the beverage is prepared by infusing the leaves in water introduced into the capsule. As with the soluble ingredients described above, the tea thus infused is then dispensed from the capsule through a dispensing outlet. Such known capsules are typically rigid or semi-rigid capsules made of plastic material(s) or metal (e.g., aluminum).

[0003] Recently, beverage preparation systems have been developed that include flexible packaging instead of capsules, which offer several interesting features compared to capsules, such as compactness, speed of production (the forming, pouring, and sealing operations can be performed sequentially), and improved recyclability.

[0004] Such a flexible package is described, for example, in EP 3414187 A1 and comprises a flexible wall and a functional insert (sometimes called a "spout") located at the bottom of the package, the functional insert being attached to or otherwise enclosed within the flexible wall. The insert is a flat element made of rigid or semi-rigid plastic and comprising holes and channels for fluid-tightly connecting the bottom side of the flexible package to a beverage machine. In use, when the flexible package is functionally connected to the beverage machine, the beverage machine introduces water into the inside of the package through the fluid-conducting channels of the insert, which are then mixed with ingredients to form a beverage product that is dispensed onto the outside of the flexible package through the product-dispensing channels of the insert.

[0005] Importantly, fluid communication between the package and the beverage machine is achieved by connecting the machine's fluid-conducting elements to the flat wall of the package. A flat surface between the ingredient package and the beverage machine ensures a substantially leak-proof connection between the two. Furthermore, the rigidity of the flat surface of the package is essential to ensure that the package does not deform during connection to the beverage machine. Connection is typically achieved by piercing or otherwise inserting a machine connection element, such as a needle or similar element, into the flat surface of the package. Connection can also be achieved by opening the package wall and pressing the machine's nozzle against the package wall to create a leak-tight fluid connection. If the flat wall of the package is mechanically too weak, bending or other deformation of the wall will occur when the beverage machine connection element is pressed against or inserted through the wall, resulting in leakage or loss of fluid connection. On the other hand, the package must be easily and reliably openable by the machine. To this end, the force required to open the package wall must be sufficiently small.

[0006] In some examples, as described for example in EP 3500503 A1 or EP 3500504 A1, the functional insert comprises several parts that are movable relative to one another so that the insert itself can be actuated to open and close, thereby enabling complex sequences of water injection, mixing and product dispensing, adapted to the specific preparation requirements imposed by the type of beverage ingredient being dissolved. The reclosability of the insert also provides excellent cleanliness for the beverage preparation system.

[0007] However, such existing flexible packaging has drawbacks. First, the functional insert is made of a material that is not easily recyclable. Furthermore, it is a single-material element and therefore heavy. It is also expensive to manufacture.

[0008] Other flexible packages exist, such as gusseted bags or pouches. These packages are manufactured by folding and sealing a thermoplastic material to form a gusset in its bottom sidewall. While such gusseted sachets can form a flat bottom sidewall that can be used to connect to a beverage machine, the manufacture of such sachets requires a complex multiple-fold process to form the gusseted bottom. The multiple folds create overlapping layers of material, which are then sealed. This well-known manufacturing method requires the material to have good sealing properties, which can only be achieved with thermoplastic films. When non-thermoplastic films are used, weak seals can lead to delamination between the folded film layers or even the creation of unsealed spaces, which are highly detrimental to the mechanical and barrier properties of the package. Furthermore, such gusseted flexible packages are undesirable because they require thermoplastic materials to form and are not environmentally friendly.

[0009] Other types of flexible packages are known that are manufactured by various processes, such as folding or punching a flexible flat blank material to form a three-dimensional volume. However, in these known processes, wrinkles often form on the surface of the package during the transformation of the flexible flat sheet into a three-dimensional volume. Wrinkles are highly undesirable because they cause the package to seal inconsistently and therefore leak. They also increase the risk of incorrect interaction between the package and a processing unit, such as a beverage preparation machine, due to the irregular surface of the package.

[0010] It is therefore a primary object of the present invention to provide an improved flexible package for use with beverage preparation machines that overcomes the above-mentioned drawbacks of existing packages and that is made from particularly environmentally friendly materials and that can be easily connected to the beverage machine in a substantially leak-proof manner. Summary of the Invention

[0011] The present invention relates to a flexible or semi-flexible closed package for containing ingredients for use in a food or beverage preparation machine to prepare an edible product by mixing the ingredients with a mixing fluid injected into the package by the machine, the package comprising: (i) flexible or semi-flexible side walls forming a flat package body; and (ii) a cup-shaped bottom adapted for insertion of a fluid injection element of the machine. The package is formed from a single elongated piece of a primary flat blank sheet made of a flexible material, preferably a fiber-based material, that is folded into a U-shape about its transverse axis of symmetry and sealed along its side and top edges, the cup-shaped bottom being a hollow volume with a concave lower surface and convex side surfaces, the profile curvature of the lower surface being identical to the profile curvature of each of the side surfaces.

[0012] In one particular embodiment of the invention, the cup-shaped bottom has a hexagonal prism shape, the prism having two opposite vertical edges aligned with the transverse axis of the package, the vertical edges extending downward to form downwardly extending tips, the extended edges having a height such that the sum of the two heights of the cup-shaped bottom and the width of the underside of the cup-shaped bottom is constant for each transverse cross-section of the cup-shaped bottom measured along the entire transverse axis of the package.

[0013] Advantageously, said elongated primary flat blank sheet is made of a fiber-based material coated on its inner surface with a sealant layer, said fiber-based layer being selected from the list of paper, cardboard, cabasse-based, bamboo-based or starch-based materials, cellophane or combinations thereof, such materials being considered ecologically sustainable packaging materials.

[0014] The primary flat blank sheet preferably further comprises a barrier coating sandwiched between the fiber-based material and the sealant layer, said barrier coating being an oxygen and / or moisture transmission preventing coating selected from the list of a metallized coating, a silicon oxide (SiOx) coating, an aluminum oxide (AlOx) coating, an atomic layer deposition (ALD) coating, or a combination thereof.

[0015] In a particularly preferred embodiment of the present invention, the package according to the present invention further comprises a secondary thickness reinforcing sheet arranged on at least the inner surface of the cup-shaped bottom of the package, the secondary thickness reinforcing sheet being made of a fiber-based material coated with a sealant layer, the fiber-based layer being selected from the list of paper, cardboard, birch-based, bamboo-based or starch-based material, cellophane or combinations thereof.

[0016] Advantageously, the package of the present invention comprises an identification means selected from the list of: a mechanical code, an optical code (including color codes and codes printed with invisible ink), an RFID tag, a one-dimensional bar code, a two-dimensional bar code, a magnetic code, a conductive code, a detection hole, or any combination thereof.

[0017] Furthermore, the package of the present invention preferably further comprises a centering cross hole located at the sealed side (lateral) edge of the package, the centering hole being adapted to receive a centering pin of a beverage preparation machine, thereby preventing the package from moving relative to the machine during beverage preparation.

[0018] Preferably, the concave lower surface of the package comprises a flat portion that is aligned with the transverse and longitudinal axes of the cup-shaped bottom. It has been found that connecting a fluid injection element, such as a water injection needle, of a food or beverage preparation machine via a flat surface improves the quality of the interface between the package and the machine and reduces the need for complex or bulky fluid injection elements to achieve leak-free fluid communication between the two.

[0019] For the same reason, the flat surface is preferably oriented so that when a fluid injection element of the machine is inserted into the sachet, the insertion occurs along an axis perpendicular to the plane of the flat surface.

[0020] Advantageously, the package of the present invention is a sachet or a pouch.

[0021] The ingredients contained in the package of the present invention are preferably water-soluble powders or soluble concentrates in liquid or semi-liquid form selected from the list of soups, fruit juices, vegetable juices, bouillons, coffee, chocolate, tea, dairy ingredients such as milk or creamers, smoothies, purees, coulis, creams or combinations thereof, or said ingredients consist of plant leaves adapted for infusion in water.

[0022] The package formed by the manufacturing process described herein has generally flexible or semi-flexible sidewalls that enhance dissolution of the contained ingredients with the mixing fluid (typically water) injected therein, thereby enabling superior quality of the beverage product. At the same time, the package's interface with the food or beverage preparation machine to which it is designed (i.e., its bottom) is sufficiently rigid to prevent deformation of the package when the machine is fluidly connected to the package. The outer wall is particularly environmentally friendly because it is manufactured from a single blank sheet folded in two (and its construction material is preferably selected from environmentally friendly materials such as recyclable, biodegradable, industrially compostable, or home compostable materials). The three-dimensional fold at the bottom interface provides sufficient rigidity to allow proper opening during use with an external tool (e.g., a water injection needle of a food or beverage preparation machine), and the three-dimensional fold at the bottom eliminates creases that may be detrimental to the proper functioning of the package. [Brief explanation of the drawings]

[0023] Additional features and advantages of the present invention are described in, or will be apparent from, the following description of the presently preferred embodiments, which are set forth with reference to the drawings. [Figure 1] FIG. 1 is a side perspective view of a package of the present invention. [Figure 2] FIG. 1 is a top view of a primary flat blank sheet according to the present invention. [Figure 3A] FIG. 2 is a bottom view of the package of FIG. 1. [Figure 3B] FIG. 3B is a side view of the package of FIG. 3A. [Figure 4] FIG. 3 is an enlarged, partial perspective top view of one embodiment of the blank of FIG. 2. [Figure 5] 5 is a partial bottom perspective view of a package formed from the blank of FIG. 4. [Figure 6] 1 is a schematic perspective view of a manufacturing machine for producing packages according to the invention; [Figure 7] 1 is a perspective view of a roll of material for producing blank sheets according to the present invention; FIG. [Figure 8] 1 is a schematic side view of a first embodiment of a forming and sealing section of a machine for making packages according to the present invention; [Figure 9] 1 is an enlarged partial perspective view of a mold plunger for producing a package according to the present invention; [Figure 10] 1 is a schematic side view of a first embodiment of a forming and sealing section of a machine for making packages according to the present invention; [Figure 11] 1 is a schematic side view of a first embodiment of a forming and sealing section of a machine for making packages according to the present invention; [Figure 12] 1 is a schematic side view of a first embodiment of a forming and sealing section of a machine for making packages according to the present invention; [Figure 13] 1 is a schematic side view of a first embodiment of a forming and sealing section of a machine for making packages according to the present invention; [Figure 14] 1 is a schematic side view of a first embodiment of a forming and sealing section of a machine for making packages according to the present invention; [Figure 15] FIG. 15 is a schematic side view of an alternative embodiment of the forming and sealing portion shown in FIGS. 8 and 10-14. [Figure 16] FIG. 15 is a schematic side view of an alternative embodiment of the forming and sealing portion shown in FIGS. 8 and 10-14. [Figure 17] FIG. 15 is a schematic side view of an alternative embodiment of the forming and sealing portion shown in FIGS. 8 and 10-14. [Figure 18] FIG. 15 is a schematic side view of an alternative embodiment of the forming and sealing portion shown in FIGS. 8 and 10-14. [Figure 19] FIG. 15 is a schematic side view of an alternative embodiment of the forming and sealing portion shown in FIGS. 8 and 10-14. [Figure 20]1 is a partial perspective view of the sealing jaws of a form-seal machine for producing a package according to the present invention; [Figure 21] FIG. 15 is a schematic side view of an alternative embodiment of the forming and sealing portion shown in FIGS. 8 and 10-14. [Figure 22] 1 is a schematic side view of sealing jaws for sealing the sides of a package according to the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0024] The package according to the invention is adapted for use in a food or beverage preparation machine (not shown). The beverage preparation machine may be of any suitable type, such as the machine described in European Patent Application Publication No. AN19213419.5. Such machines are well known in the art and comprise a brewing chamber adapted to receive an ingredient package, an injection element adapted to inject a fluid (typically water) into the ingredient package, a fluid (e.g., water) supply means which generally comprises a fluid reservoir (or a water connection to tap water), a fluid pump, a fluid heater, and fluid pipes for circulating the fluid from the fluid source towards the brewing chamber, optionally via the heater.

[0025] In the present invention, the package is adapted to be opened, preferably pierced, by the fluid supply means of the machine, in particular by introducing a sharp element through the bottom wall of the package, preferably through the underside of the bottom wall. Typically, the fluid injection element of the machine is a hollow needle-like element. Dispensing of the food or beverage product prepared in the package by mixing a fluid with the ingredients can be carried out by gravity. However, removal of the finished food or beverage product can also be carried out through the same element that injects the mixed fluid. In the latter case, the injection and dispensing element of the machine comprises at least two channels: one channel fluidly connects the internal compartment of the package to the machine, allowing the machine to inject a fluid (e.g., water) into the compartment, and a second channel connects the internal package compartment to the exterior of the package. The injection means of the machine can also comprise an auxiliary channel for injecting air into the inside of the package during food or beverage preparation. The injection of air makes it possible to enhance foaming during the preparation of particularly aerated products such as dairy-based products (e.g. foamed milk) or chocolate-based products (foamed chocolate drinks, chocolate mousse) or smoothies.

[0026] Generally, the package has any possible shape that is amenable to being formed by folding a flexible sheet in half (a "U" formation), such as a pouch or sachet, a pad, or any other container having a generally flat configuration.

[0027] Different sized packages can be used in the same machine adapted to store different amounts of ingredients. The type of machine that can be used to extract the ingredients contained in the package is not limited by the size of the package (i.e. its height and / or width). The size of the package is adapted to the amount of beverage to be produced. For example, an Americano or soup requires a large package, while a small sachet is used to produce a short cup of beverage such as an espresso. A medium sized sachet is used to produce foamed milk for a cappuccino.

[0028] The external design of the sachet base (that part of the package dedicated to the functional fluid connection with the beverage machine) remains unchanged whatever the size or shape of the product and package to be manufactured. The idea is that the interface of the package with the machine is always the same. Also, other parameters, such as the flow rate of the injected fluid and / or the temperature of the injected fluid and / or the total amount of the injected fluid, may be varied depending on the raw material to be processed and therefore on the food or beverage product in question.

[0029] Preferably, the package is equipped with identification means that allow the beverage machine to automatically identify the type of ingredients contained therein and adapt its settings for optimal beverage preparation. Such settings include, but are not limited to, water injection pressure, water injection volume, water temperature, dissolution sequence (complex sequences of water injection, air injection, beverage dispensing in a sequential or simultaneous manner), injection of air along with water (for foam enhancement), total time for extraction. Such identification means may be selected from the list of mechanical codes, optical codes (including color codes and codes printed with invisible ink), RFID tags, one-dimensional bar codes, two-dimensional bar codes, magnetic codes, conductive codes, detection holes, or any combination thereof.

[0030] As shown in the accompanying drawings, in a preferred embodiment, the package has a planar shape oriented along an essentially vertically oriented plane during beverage production, and a fluid injection element of the beverage machine is inserted into the package so as to direct a jet of aqueous and / or gaseous fluid in a direction contained in said package plane. The fluid jet introduced into the package from the bottom develops into circular and spiral motions, creating turbulence, friction, and a high contact surface between the fluid molecules and the ingredient particles. On average, the fluid molecules rotate multiple times within the container before exiting together as a beverage or food product.

[0031] In the following, a preferred embodiment of the package according to the invention will be described with reference to the drawings, in which the package is a sachet.

[0032] 1 shows a flexible or semi-flexible closed package 1 for containing ingredients according to the present invention, said package 1 comprising (i) flexible or semi-flexible side walls 2 forming a flat package body, and (ii) a cup-shaped bottom 3, which is a hollow volume adapted for the insertion of a fluid injection element of a food or beverage preparation machine (not shown) to which said package 1 is designed to be connected.

[0033] The hollow cup-shaped bottom 3 does not have to form the entire bottom of the package: in the embodiment of Figure 1, it forms only a central portion of the entire bottom of the package and is surrounded by the side edges 4 of the package, which are sealed flat areas.

[0034] The package 1 is formed from a single elongated primary flat blank sheet 5 made of flexible material, as shown in Figure 2. The manufacturing process steps and manufacturing machines are described in more detail below.

[0035] A primary flat blank sheet 5 of paper-based material is folded into a U-shape about its transverse axis of symmetry Lx and then sealed along its side edges 4 and top edge 6.

[0036] According to the general principle of the present invention, as shown in Figures 3A and 3B, the cup-shaped bottom 3 is a hollow volume having a concave lower surface 7 and convex side surfaces 8, and the curvature Plw of the contour of the concave lower surface seen when the package is viewed from the side, as shown by the bold line in the profile view of Figure 3B, is identical to the curvature Plt of the contour of each of the side surfaces seen when the package is viewed from below, as shown by the bold line in the bottom view of Figure 3A.

[0037] More precisely, in the embodiment shown in Figures 1, 3A, 3B, and 5, the cup-shaped bottom is a hollow volume having the shape of a hexagonal prism, with two opposing vertical edges 9 aligned with the transverse axis Lx of the package, the vertical edges 9 extending to form downwardly extending tips 10. The extended edges 9 have a height such that the sum of the two heights of the cup-shaped bottom and the width of its underside is constant for each transverse cross-section of the package measured along the entire transverse axis Lx of the package. An example of this rule is shown in Figures 3A and 3B. Figure 3A shows the first width "W1" of the underside measured at a first cross-section of the bottom. Figure 3B shows the first height "H1" of the cup-shaped bottom measured at the same first cross-section. Figure 3A also shows the second width "W2" of the underside measured at a second cross-section of the bottom. 3B also shows a second height "H2" of the cup-shaped bottom, measured about the same second cross section. When calculating the sums S1=(2xH1)+W1 and then S2=(2xH2)+W2, in accordance with the principles of the present invention, S1=S2, or more generally, S1=S2=Sn, where Sn is measured at any cross-sectional point of the cup-shaped bottom 3.

[0038] The elongated primary flat blank sheet 5 used to manufacture the package 1 is made of a paper material coated on its inner side (i.e. the side that will become the inner side of the package 1 after forming of said sheet 5) with a sealant layer.

[0039] Furthermore, in this embodiment of the present invention, the primary flat blank sheet 5 further comprises a barrier coating sandwiched between the fiber-based material and the sealant layer, the barrier coating being an oxygen and moisture transmission preventing coating selected from the list of a metallized coating, a silicon oxide (SiOx) coating, an aluminum oxide (AlOx) coating, an atomic layer deposition (ALD) coating, or a combination thereof.

[0040] In a preferred embodiment of the present invention, shown in FIG. 2 , the package 1 further comprises a secondary thickness reinforcement sheet 11 arranged on the inner surface of the cup-shaped bottom 3 of the package. The thickness reinforcement sheet 11 is made of a paper material coated with a sealant layer. This thickness reinforcement sheet 11 offers the possibility of reducing the thickness of the side walls 2 of the package 1. Reducing this thickness makes these side walls much more flexible, which has been found to be advantageous in improving the quality of the product prepared in the package 1. More precisely, the Applicant has found that the swirling movement of the fluid injected into the package is unexpectedly improved if the side walls 2 of the package are allowed to flex and deform outward during beverage preparation. Such deformation temporarily increases the internal space of the package compartment between the side walls 2 of the package. However, maintaining a good rigidity of the cup-shaped bottom 3 is essential, as explained above (to maintain an adequate seal at the interface between the package and the beverage preparation machine, and to ensure that the package does not deform or collapse when pierced by the machine's fluid injection elements, impairing or even preventing the piercing action). The presence of the secondary thickness stiffening sheet 11 makes it possible to achieve a balance between the flexibility of one wall of the package and the rigidity of its base.

[0041] Advantageously, the package 1 further comprises a centering cross-hole 12, shown in Figures 1, 3B and 5, which is located in the sealed edge 4 of said package 1. Said hole is adapted in shape and diameter to receive a centering pin (not shown) of a beverage preparation machine so as to prevent movement of said package 1 relative to the machine during beverage preparation, in particular during insertion of the fluid injection elements of the machine through the package wall.

[0042] In a highly desirable embodiment, the concave lower surface 7 of the package 1 includes a flat portion 13 centered across the transverse and longitudinal axes of the cup-shaped bottom 3, as shown in FIGS.

[0043] 4, in a preferred embodiment, the package 1 further comprises a tertiary lamina between the material forming the package wall and the secondary thickness reinforcing layer 11. This tertiary lamina is produced by sealing or otherwise attaching a tertiary flexible flat blank sheet 14 between the primary flexible flat blank sheet 5 and the secondary flexible flat blank sheet 11.

[0044] The tertiary flexible flat blank sheet 14 is a thin layer selected from the list of polyethylene (PE), polypropylene (PP), polylactide (PLA), polyhydroxyalkanoate (PHA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyvinyl alcohol (PVOH), starch-based polymers, polymers containing food-grade oxygen and / or moisture scavengers, or combinations thereof, and is preferably made from a blown or cast polymer film with stretch properties.

[0045] In this embodiment, as shown in Figure 4, the primary sheet 5 includes primary holes 15 drilled through its entire thickness. The primary holes 15 have a diameter selected to be at least equal to, but preferably slightly larger in cross section (or diameter) than, the outer diameter (or cross section) of the beverage machine injection means (typically a needle). The larger diameter prevents material, such as paper fibres, from being separated by friction when the injection means is inserted therethrough. Typically, the diameter of the holes (which are preferably cylindrical) is between 1 mm and 20 mm, preferably between 5 mm and 12 mm.

[0046] Furthermore, the secondary sheet 11 comprises secondary holes 16 drilled through at least the paper layer of said sheet 11. The secondary holes 16 may also be drilled through the entire thickness of the secondary sheet 11. The diameter of the secondary holes 16 is selected in relation to the diameter of the fluid injection element of the machine to which the package will be connected, and they are typically cylindrical with a diameter of 1 mm to 20 mm, preferably 5 mm to 12 mm.

[0047] The diameter of the primary holes 15 is equal to or larger than the diameter of the secondary holes 16 in the secondary flexible flat blank sheet 11 .

[0048] 4 and 5, which have three superimposed layers in the area of ​​the cup-shaped bottom 3 of the package 1, ensure a seal between the package 1 and the machine's fluid injection element. When the machine's fluid injection element is inserted through the wall of the package, it passes through the primary hole 15 and then perforates the tertiary sheet 14, which is preferably made of a stretchable material as described above, so that the edges of the perforated sheet 14 fit closely to the surface of the fluid injection element. Finally, the fluid injection element moves through the secondary hole 16 so that its tip is positioned within the package's internal compartment, establishing a leak-free fluid communication between the interior of the package 1 and the machine's fluid supply circuit.

[0049] Such a configuration also has the advantage that the strength required to pierce the package wall by the fluid injection element is lower, since the thickness of the entire package in the region of the holes 15, 16 and the tertiary sheet 14 is only the latter thickness, and at the same time the entire part of the package surrounding said region has a higher thickness and therefore mechanical resistance to deformation due to the presence of three superimposed layers in the cup-shaped bottom 3 of the package.

[0050] In yet another preferred embodiment shown in Figure 4, the secondary thickness stiffening sheet 11, once the holes 16 have been drilled, is further processed by using a cutting tool to make a plurality of radial cuts 22 extending radially outward from the edges of the holes 16. Such radial cuts 22 form a series of flaps therebetween that have been found to enhance the application of the package walls, particularly the third flexible layer 14, to the outer surfaces of the machine's fluid injection elements when the machine and package are connected together. Thus, the plurality of radial cuts 22 enhances the leak-proof effect.

[0051] The packages described above are produced on a forming machine as shown in Figure 6. Generally, such machines are based in part on form and seal technology machines known in the art.

[0052] It initially comprises a primary flexible flat blank sheet feeder portion 17 adapted to receive primary flat blank sheets, and optionally secondary and tertiary flat blank sheets 5, 11, 14, preferably in the form of a roll of film as shown in FIG. 6. At this stage, as previously indicated, the secondary and tertiary flat blank sheets, if present, may already be assembled together with the primary sheets 5, or alternatively, as shown in FIG. 6, they may be supplied as separate rolls of material: one roll 18 for the primary sheets, one roll 19 for the secondary sheets, and a third roll 20 for the tertiary sheets. In this case, the rolls of primary, secondary, and tertiary sheets are unfolded and cut into small flat blanks, primary holes 15 and secondary holes 16 are punched through the primary and secondary blanks, respectively, as described above, and then all blanks are finally sealed together in the configuration already described in connection with FIG. 4. The arrangement of the individual primary flat blank sheets 5 cut from the corresponding rolls of material 18 is shown in FIG. 7.

[0053] The manufacturing machine further comprises a package forming set 21. Downstream of the package forming set 21 is a pouring and sealing set 22, in which the packages are poured with raw materials and then closed by sealing the top edge of said packages.

[0054] The molded portion 21 is shown in more detail in Figures 8-22.

[0055] As shown in FIG. 8, the forming section of the machine comprises a forming plunger 23 and a forming cavity 24, which are movable relative to each other and have complementary shapes. The term "cavity 24" refers to a hollow cylinder whose tip has a shape complementary to the outer shape of the plunger's lower end 25. The principle of a forming station having a movable plunger and a cavity, and deforming a material placed therebetween, is generally known, and its details will not be described in further detail. As shown in FIG. 9, the end 25 (i.e., its lower end) of the plunger 23 has a volumetric shape with a concave lower end 26 and convex side surfaces 27, the profile of which is identical to the respective profiles of its side surfaces 27. The principle of geometric equivalence between the profiles 26 and 27 can be understood from the profile P of the cup-shaped bottom 3 in relation to FIGS. 3A and 3B. lt and P lw is the same as already mentioned above.

[0056] In one particular embodiment, the end 25 of the plunger 23 has the shape of a hexagonal prism, said prism having two opposite vertical edges 28 aligned with the plunger transverse axis Lx and extending downward to form downwardly extending tips 29, said extended edges 28 having a height such that the sum of the two heights of the end 25 and the width of its lower surface is constant for each transverse cross section of the plunger measured along the entire transverse axis Lx of the plunger. This principle is the same as that already described above for the heights H1, H2 and widths W1, W2 of the cup-shaped bottom 3 in connection with Figures 3A and 3B.

[0057] Preferably, the plunger tip 29 has rounded or other smooth edges.

[0058] As shown in FIG. 9, the plunger lower end 26 preferably includes a retractable protrusion 30 aligned with the center of the plunger 23. The protrusion 30 is spring-loaded to retract into the plunger 23 when pressed against a surface, in this case, the primary flat blank sheet 5 and the underlying forming station cavity 24. The protrusion has a diameter larger than the diameters of the primary and secondary holes 15 and 16 described above. The function of the protrusion is to gently compress the blanks 5, 11, and 14 before the plunger begins to deform them. As the forming process begins and the blank sheets begin to deform, the protrusion maintains the three blank sheets together in their sealing areas (around holes 15 and 16, as described above) to prevent unsealing and slippage due to mechanical forces applied to the material during the forming step.

[0059] The machine further comprises an actuator (not shown) for moving the plunger 23 and cavity 24 towards each other and relative to the blank sheet 5 positioned between the two as shown in FIG.

[0060] As shown in Figures 15-19 and 21, the machine further comprises a pair of plates adapted to support the flexible blank sheet 5. Both plates are coplanar at the start of the forming process as shown in Figure 15. Each plate supports a flap of the primary flexible blank sheet. The plates 31 may be fixed as shown in Figures 8 and 10-14. Alternatively, in another possible embodiment, the plates 31 are pivotable symmetrically about respective axes located on either side of the plunger 23 as shown in Figures 16-19 and 21, which represent various positions of the pivotable plates 31 during the forming process.

[0061] In the following, the primary flat blank sheet 5 being processed will be considered to also include the secondary blank sheet 11 and the tertiary blank sheet 14 attached thereto, as described above. Once the blank 5 has been conveyed along the machine to the forming section 21 of said machine and placed in position between the plunger 23 and the cavity 24 as shown in Figure 8, the forming process steps, in order, are as follows:

[0062] The plunger 23 moves downward until it contacts the top surfaces of the blanks 5, 11, and 14, as shown in Figures 10 and 11. The plunger movement initiates a folding deformation of the blanks about the transverse axis Lx of the primary blank 5. After contacting the top surfaces of the blanks 5, 11, and 14, the retractable projection 30 of the plunger 23 is retracted into the plunger 23 by the counter pressure of the cavity 24 below, as shown in Figure 11.

[0063] 12, plunger 23 continues to move downward, causing cavity 24 to move downward as well. Because plunger 23 and cavity 24 hold blanks 5, 11, and 14 between them, they both pull blanks 5, 11, and 14 downward.

[0064] During the preceding steps, a pair (or "set") of sealing jaws 32 are positioned on either side of the cavity 24, the sealing jaws 32 being adapted to seal the side edges of the blank sheet 5 as it is folded into a U-shape. During the above forming steps, the jaws are in an open position, i.e., away from the plunger, cavity and blank.

[0065] After the cavity and plunger have moved downward as described above, the jaws 32 move toward each other to surround the blank at its lower portion, as shown in Figures 13 and 20. They seal the side edges of the U-folded blank (by an ultrasonic or heat sealing process) to complete the formation of a fully formed and sealed cup-shaped bottom 3 of the package 1.

[0066] Then, as shown in FIG. 14, the jaws 32 reopen and the plunger 23 moves upward with the partially folded and sealed package 1.

[0067] A variation of the same forming sequence as described above is shown in Figures 15-19 and 21, except that the support plate 31 is pivoted during the movement of the plunger and cavity to guide the folding of the free end of the blank into a U-shape.

[0068] Finally, as shown in Figure 15, the package is completely folded into a U-shape, but the side walls 2 that form the flat package body are not yet sealed, and the sealed cup-shaped bottom 3 is a hollow volume having the shape of the plunger described above.

[0069] The package is then moved to a sealing station having elongated sealing jaws 33 which seal the side edges 4 of the package 1, as shown in Figure 22. The package 1 is now ready to be closed by sealing its top edge 34 after the ingredients have been injected.

[0070] In embodiments where the cup-shaped bottom 3 of the package has an improved wall thickness, the primary, secondary and tertiary flat blank sheets 5, 11, 14 can be attached to each other when the primary sheet 5 is produced as a roll of film (at the film manufacturer's facility) by attaching the secondary layer 11 and tertiary layer 14 as described above, or alternatively, the secondary and tertiary flat blank sheets 11, 14 can be attached to the primary flat blank sheet at a later stage just prior to forming the primary flat blank sheet (i.e., on the package production line).

[0071] According to the present invention, the food or beverage ingredient packed in the package is a water-soluble powder or a soluble concentrate in liquid or semi-liquid form selected from the list of soup, fruit juice, vegetable juice, bouillon, coffee, chocolate, tea, milk or creamer, smoothie, puree, coulis, cream or a combination thereof. Preferably, the food or beverage ingredient is a soluble food or beverage ingredient selected from the list of instant coffee powder, milk powder, cream powder, instant tea powder, cocoa powder, soup powder, fruit powder or a mixture of these powders, coffee concentrate, milk concentrate, syrup, fruit or vegetable concentrate, tea concentrate, fruit or vegetable puree.

[0072] The package may also contain plant leaves for infusion, such as tea leaves.

[0073] The powder may be agglomerated or sintered. The powder or liquid concentrate may be mixed with solid pieces to prepare, for example, soups, with the solid pieces or encapsulated pieces. The food or beverage ingredient may also be an infusible food or beverage ingredient, such as roast and ground coffee or tea leaves. In that embodiment, water extracts the infusible ingredient.

[0074] In the present invention, fluid includes either any aqueous diluent such as water, carbonated water, milk, etc. (preferably, water is the preferred aqueous diluent) or any gaseous fluid, for example, air, that can be mixed with soluble beverage ingredients to prepare a beverage. When referring to an aqueous fluid, water is the preferred fluid. When referring to a gaseous fluid, air is the preferred fluid.

[0075] According to the present invention, the package is positioned essentially vertically during the production and dispensing of the food or beverage product.

[0076] According to the present invention, the aqueous fluid (typically water) may be provided in the package at any temperature, cold, ambient or hot, depending on the type of food or beverage product being prepared.

[0077] In contrast to systems known in the prior art, in which fluids are introduced from top to bottom, in this case the beverage preparation machine injects water and optionally air from the bottom to the top of the package at high speed, thereby generating optimal turbulence inside the package compartment and thus enabling optimal dissolution of the ingredients contained therein. If air is also injected together with the water via the injection means of the machine, the air is not introduced at high pressure. The pressure is preferably 0.1 to 1.5 bar, more preferably 0.3 to 0.5 bar. According to the invention, optimal turbulence and dissolution of the ingredients is achieved by high speed, not by high pressure.

[0078] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

1. A flexible or semi-flexible closed package (1) for containing ingredients for preparing an edible product in a food or beverage preparation machine by mixing the ingredients with a mixing fluid injected into the package by the machine, the package (1) comprising: (i) flexible or semi-flexible sidewalls (2) forming a flat package body; (ii) a cup-shaped bottom (3) adapted to insert a fluid injection element of the machine, The package (1) is characterized in that both the flat package body and the cup-shaped bottom are formed from a single elongated primary flat blank sheet (5) made of a flexible material, folded into a U-shape about its transverse axis of symmetry (Lx) and sealed along its side edges (4) and top edge (34), and the cup-shaped bottom (3) is a hollow volume having a concave lower surface (7) and convex side surfaces (8), the contour of the lower surface (7) being identical to the contour of each of the side surfaces (8).

2. 2. The package (1) according to claim 1, wherein the cup-shaped bottom (3) has a hexagonal prism shape, the hexagonal prism shape having two opposite vertical edges (9) aligned with the transverse axis of symmetry (Lx) of the package, the vertical edges (9) extending downward to form downwardly extending tips (10), the extended vertical edges (9) having a height such that for each transverse cross-section of the cup-shaped bottom (3), measured along the entire transverse axis of symmetry (Lx) of the package, the sum of the two heights of the cup-shaped bottom and the width of the lower surface (7) of the cup-shaped bottom is constant.

3. 3. The package (1) according to claim 1 or 2, wherein the primary flat blank sheet (5) is made of a fiber-based material coated on its inner surface with a sealant layer, the fiber-based material being selected from the list of paper, cardboard, cabass-based, bamboo-based or starch-based material, cellophane or combinations thereof.

4. 4. The package (1) according to claim 3, wherein the primary flat blank sheet (5) further comprises a barrier coating sandwiched between the fiber-based material and the sealant layer, the barrier coating being an oxygen and / or moisture transmission preventing coating selected from the list of a metallized coating, a silicon oxide (SiOx) coating, an aluminum oxide (AlOx) coating, an atomic layer deposition (ALD) coating, or a combination thereof.

5. 5. The package (1) according to any one of claims 1 to 4, further comprising a secondary thickness stiffening sheet (11) arranged on at least the inner surface of the cup-shaped bottom (3) of the package, the secondary thickness stiffening sheet (11) being made of a fiber-based material coated with a sealant layer, the fiber-based material of the secondary thickness stiffening sheet (11) being selected from the list of paper, cardboard, birch-based, bamboo-based or starch-based material, cellophane, or combinations thereof.

6. 6. The package (1) according to any one of claims 1 to 5, comprising an identification means selected from the list of: a mechanical code, an optical code (including color codes and codes printed with invisible ink), an RFID tag, a one-dimensional barcode, a two-dimensional barcode, a magnetic code, a conductive code, a detection hole, or any combination thereof.

7. 7. A package (1) according to any one of claims 1 to 6, further comprising a centering cross-hole (12) located in the sealed side edge (4) of the package, the centering cross-hole (12) adapted to receive a centering pin of the beverage preparation machine, thereby preventing the package (1) from moving relative to the machine during beverage preparation.

8. The package (1) according to any one of the preceding claims, wherein the concave lower surface (7) comprises a flat portion aligned with the transverse and longitudinal axes of the cup-shaped bottom (3).

9. A package (1) according to any one of claims 1 to 8, which is a sachet or a pouch.

10. 10. The package (1) according to any one of claims 1 to 9, wherein the ingredient is a water-soluble powder or a soluble concentrate in liquid or semi-liquid form selected from the list of soup, fruit juice, vegetable juice, bouillon, coffee, chocolate, tea, dairy ingredients such as milk or creamer, smoothie, puree, coulis, cream, or combinations thereof, or the ingredient consists of plant leaves adapted for infusion in water.

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