ES2998746T3 - Single serve capsule for preparing a beverage in a beverage preparation machine, system for preparing a beverage and method and insallation for producing a single serve capsule - Google Patents

Abstract

The invention relates to a single-dose capsule for preparing a beverage in a brewing chamber of a beverage preparation machine, wherein the single-dose capsule has a base element having a hollow space for receiving a beverage raw material, and a capsule shell closing the hollow space, wherein the base element comprises a capsule bottom, a peripheral flange and a capsule wall extending between the capsule bottom and the peripheral flange, wherein the flange has a sealing element which is integral with the flange and is in the form of a sealing cord oriented away from the capsule shell, wherein the sealing cord comprises an inner flank and an outer flank, wherein the flange has a first flange region between the capsule wall and the inner flank and a second flange region between the outer free end of the flange and the outer flank, and wherein the capsule shell is fixed along a first peripheral fixing face on the first flange region and along a second peripheral fixing face. in the second flange region. (Automatic translation with Google Translate, no legal value)

Description

DESCRIPTION

Single-dose capsule for preparing a beverage in a beverage production machine, system for preparing a beverage, and method and installation for manufacturing a single-dose capsule

State of the art

The present invention is based on a single-dose capsule for preparing a beverage in a brewing chamber of a beverage production machine, the single-dose capsule having a base element with a cavity for receiving a beverage raw material and a capsule lid closing the cavity, the base element comprising a capsule bottom, a surrounding flange and a capsule wall extending between the capsule bottom and the surrounding flange, the flange having a sealing element configured integrally with the flange in the form of a sealing groove pointing away from the capsule lid, the sealing groove comprising an inner flank and an outer flank, the flange between the capsule wall and the inner flank having a first flange region and between the outer free end of the flange and the outer flank having a second flange region.

Such single-serve capsules are known from the prior art. For example, WO 2016/186 488 A1 discloses a generic single-serve capsule. This single-serve capsule is intended to be inserted into a brewing chamber, in which the capsule bottom is pierced to introduce scalding liquid in the form of hot water under pressure into the cavity. This increases the pressure inside the single-serve capsule, causing the capsule lid to be pressed against a relief or pyramidal plate in the brewing chamber and, upon reaching a predetermined pressure at the contact points, is pierced or burst open. The beverage formed by the interaction between the introduced water and the beverage raw material, in particular roasted and ground coffee, leaves the single-serve capsule through these piercing points in the capsule lid. In other words, the water or beverage flows through these single-serve capsules, passing the capsule bottom in the direction of the water capsule lid. This generic single-dose capsule therefore basically differs from other types of single-dose capsules in that the flow is in the opposite direction, i.e., the water enters the single-dose capsule through the capsule lid and the beverage leaves the single-dose capsule through the capsule bottom.

All single-serve capsules have in common the fact that a sufficient tightness between the brewing chamber and the single-serve capsule in the flange area is necessary so that the water inside the brewing chamber flows through the beverage raw material to form the beverage and does not flow out of the single-serve capsule, i.e. between a wall of the brewing chamber and the outside of the capsule wall, past the beverage raw material.

For this purpose, these single-dose capsules feature a sealing element in the flange area, which seals tightly against a brewing chamber element in the brewing chamber. In this case, it is desirable for the sealing element to be made of the same material as the capsule body (also known as the base element) to keep production costs for the single-dose capsule low and facilitate the disposal or recycling of used single-dose capsules.

Single-dose capsules with sealing elements are disclosed, for example, in WO 2016/186 488 A1 and WO 2016/041 596 A1. The single-dose capsules disclosed therein have a stamped sealing groove on their flange. The sealing effect is to be achieved between the sealing groove and the brewing chamber element by simple deformation of the sealing groove. Another single-dose capsule with a surrounding sealing element is known to those skilled in the art from EP 2872421 A1 or US 2016/159563 A1.

All of the above-mentioned single-serve capsules have in common that the sealing effect of their sealing elements is based on a significant deformation of the sealing elements. To achieve this, inner flanks with the shallowest possible angles are used, allowing the brewing chamber element to act on the flank during the closing of the brewing chamber, thus leading to a slight deformation of the sealing element.

A disadvantage of a sealing solution based on deformation of the sealing element is that it requires considerably high forces to close the brewing chamber. This significantly increases the ease of use and durability of the beverage preparation machine. Furthermore, the elements known from the prior art are designed asymmetrically. In the event of deformation, these sealing elements tilt laterally. Because of this, although a high sealing effect is achieved, the lateral inclination of the sealing elements often results in the brewing chamber element being trapped by the sealing element, such that the single-serve capsule, after the brewing process, can no longer be separated from the brewing chamber element without applying significant forces. This significantly hinders the ejection of used single-serve capsules from the brewing chamber and substantially impairs ease of use.

An alternative would be separate sealing elements made of a sealing material as known from EP 1654 966 A1 and EP 1839 543 A1. However, such sealing elements have the disadvantage already mentioned above that due to the use of separate materials, on the one hand, the production costs for the single-dose capsules are clearly higher and, on the other hand, the disposal or recycling of already used single-dose capsules is more complicated because the different materials must be separated from each other.

Another problem with known single-dose capsules lies in the attachment of the capsule lid to the flange. Capsule lids are generally made, at least in part, of aluminum and are usually sealed along a surrounding sealing surface on the flange. This is particularly problematic in the case of single-dose capsules with a continuous flange, where the capsule lid can be attached over the entire surface or at least without problems with a sufficiently large sealing surface.

This is different for single-dose capsules, which, as described above, have a sealing groove formed as a single piece with the flange. In this case, the flat surface of the flange available for sealing is limited, and it is difficult to achieve a reliable seal. If the capsule lid seal is also defective, liquid can escape through the capsule lid.

Furthermore, when the lid is sealed in a flange region located radially outside the sealing groove, as in the aforementioned WO 2016/041 596 A1, liquid may flow into the cavity of the sealing groove and remain there as a dead volume. On the one hand, this amount of liquid is missing from the desired total beverage volume, and on the other hand, the liquid may also escape from the sealing groove after the brewing process, thus causing unwanted dripping from the single-serve capsule.

Disclosure of the invention

An objective of the present invention is to provide a single-dose capsule of the type mentioned at the outset that does not present the problems outlined in connection with the prior art. In particular, a single-dose capsule must be provided that ensures secure attachment of the capsule cap even when the single-dose capsule has a sealing groove. Furthermore, a method for preparing said single-dose capsule must be provided, as well as a system for manufacturing said single-dose capsule.

The object of the present invention is achieved by a single-dose capsule according to claim 1. Preferably, the first and/or second fixing surface is a smooth plane. Particularly preferably, the first and/or second fixing surface is crown-shaped, with the first fixing surface and the second fixing surface, in particular, having substantially the same radial extent.

The single-dose capsule according to the invention has the advantage over the prior art in that by securing the capsule lid in at least two distinct areas relative to each other, a pressure-resistant and secure fixation of the capsule lid is achieved. Particularly advantageously, no liquid can flow into the cavity formed by the sealing groove. For those skilled in the art, it was surprising and also unexpected that a secure fixation is possible even on two distinct and small surfaces observed individually.

Advantageous designs and improvements of the invention can be gleaned from the dependent claims and from the following description with reference to the drawings. These advantageous designs and improvements also relate to other subjects according to the invention and vice versa.

According to a preferred embodiment of the present invention, the base element is provided as a single piece of aluminum. Those skilled in the art understand that the sealing element, which is provided according to the invention as a single piece with the flange, is also made of aluminum. Aluminum within the scope of this invention should also include aluminum laminates and other materials containing at least aluminum. In particular, materials that additionally also have enameling and/or coatings should also be included, and these may also include, for example, plastic materials. Aluminum is the preferred material for the single-dose capsule according to the invention; alternatively, however, the base element can also be made of plastic and/or a biologically degradable material. It is crucial that the sealing element is designed as a sealing groove integral with the flange and that a secure attachment of the capsule lid to the first flange region and the second flange region is possible. Preferably, the base element is produced by hot or cold forming, in particular by deep drawing, in which the sealing groove is printed on the flange. The single-dose capsule is preferably designed as a truncated cone or cylinder.

According to a preferred embodiment of the present invention, the capsule lid is provided with an aluminum foil. Here again, the term "aluminum foil" is also understood to mean a laminated aluminum foil and/or an aluminum foil with a coating and/or enamel. The capsule lid can be provided with one or more layers and, in particular, can also comprise a laminated structure.

Preferably, the beverage raw material provided in the cavity formed by the base element and closed by the capsule lid, in particular in an airtight manner, comprises roasted coffee beans, instant coffee, chocolate powder, tea mix, milk powder and/or the like.

According to a preferred embodiment of the present invention, it is provided that the outer free end of the flange is rolled, in particular flanged such that it forms a circumferential flange, the flange preferably having a vertical extension relative to the flange greater than zero, particularly preferably on both sides of the flange, where very particularly preferably the vertical extension of the flange on the side of the flange facing away from the capsule lid is smaller than the vertical extension of the sealing groove and/or where the vertical extension of the flange on the side of the flange facing away from the capsule lid is smaller than on the side of the flange facing away from the capsule lid. In other words, it is preferably provided that the flange is smaller than the sealing groove, particularly preferably on both sides of the flange. Very particularly preferably, the flange is substantially and in particular designed symmetrically with respect to its vertical extension. Alternatively, it is also possible for the vertical extension of the flange on the side of the flange facing away from the capsule lid to be greater than the vertical extension of the sealing groove and/or for the vertical extension of the flange on the side of the flange facing away from the capsule lid to be greater than on the side of the flange facing away from the capsule lid. Very particularly preferably, the flange is provided such that no sealing effect is exerted during beverage preparation. Such a flange advantageously protects a user from unintentional injuries, particularly when the base element is made of aluminum. However, even in the case of single-serve capsules made of plastic materials, the free outer end of the flange may be sharp and/or have manufacturing defects that pose a risk of injury to the user. Providing a flange, i.e., a rounded free outer end of the flange, particularly advantageously prevents this. The rim is formed in particular by rolling the flange edge, the flange edge preferably being rolled in the direction of the capsule bottom.

According to a preferred embodiment of the present invention, the inner flank and the outer flank are designed symmetrically. In particular, they have the same angles and the same material thicknesses. This advantageously enhances the stable and reliable sealing effect according to the invention.

According to a preferred embodiment of the present invention, it is provided that both the outer flank and the inner flank are oriented at an angle of greater than 80 to less than 90 degrees, preferably from 81 to 89 degrees, particularly preferably from 83 to 87 degrees, very particularly preferably from 84 to 86 degrees, and in particular substantially 85 degrees, relative to a horizontal plane extending through the first flange region or the second flange region. A person skilled in the art understands that horizontal, within the scope of the present invention, in particular refers to a typical arrangement of the capsule in which the central longitudinal axis of the preferably rotationally symmetrical capsule is arranged vertically and the first and/or second flange regions are arranged perpendicular to this capsule axis. Particularly preferably, the horizontal extent of the first and/or second flange region coincides with a horizontal extent of the first and/or second fastening surface. It has been shown that in this angular range, on the one hand, the deformation of the sealing groove can be reduced and the rigidity of the sealing groove can be increased because the angle is as acute as possible and the sealing groove therefore ensures high stability with respect to forces acting on the sealing groove perpendicular to the first and/or second fixing surface (also referred to as the vertical direction and therefore in particular parallel to the median longitudinal axis of the single-dose capsule). On the other hand, the production of the single-dose capsule is made possible and affordable because the angle is always smaller than a right angle. In the case of a right angle on both flanks of the sealing groove, the inner flank and the outer flank, the demolding of the single-dose capsule outside of the molding or stamping tool would be significantly more complicated in the production of the single-dose capsule.

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

According to a preferred embodiment of the present invention, the sealing groove is designed such that, when the brewing chamber is closed, it deforms only parallel to the first and/or second fastening surface to such an extent that its radius relative to a central longitudinal axis (about which the rotationally symmetrical flange is arranged) of the single-serve capsule is displaced by only a maximum of 10%, preferably a maximum of 8%, particularly preferably a maximum of 5%, and very particularly preferably a maximum of 4% parallel to the first and/or second fastening surface. Advantageously, this prevents the brewing chamber element from becoming trapped by the laterally inclined sealing groove, so that the prepared single-serve capsule can always be removed from the brewing chamber easily and without requiring significant force.

The sealing groove is therefore particularly rigid and stable in such a way that when a force is applied perpendicular to the first and/or second fixing surface, i.e. along the vertical direction, parallel to the median longitudinal axis of the single-dose capsule, centrally to the sealing groove with a force of in particular up to 100 N, acting in particular flat at the tip of the sealing groove or on the inner and/or outer flank of the sealing groove or in a flat transition plane of the sealing groove, a small deformation of the sealing groove occurs. The sealing groove should be variable in height in particular by a maximum of 30%, preferably a maximum of 20%, particularly preferably a maximum of 10% and very particularly preferably a maximum of 5%. Furthermore, it is conceivable that only a lateral displacement or deformation occurs along a direction parallel to the first and/or second fixing surface, i.e., in particular in the radial direction R as viewed from the median longitudinal axis of the concentrically configured single-dose capsule. In this case, too, it is provided that the tip of the sealing groove, i.e., the transition region of the sealing groove, is displaced or deformed by a maximum of 10%, preferably a maximum of 8%, particularly preferably a maximum of 5%, and very particularly preferably a maximum of 4% of its total radius from the central median longitudinal axis of the single-dose capsule. The total radius can be taken, for example, as the radius as viewed from the center of the sealing groove.

It is preferably provided that the angle between the inner flank and outer flank preferably amounts to 5 to 15 degrees, particularly preferably 8 to 12 degrees and very particularly preferably essentially 10 degrees.

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

According to a preferred embodiment of the present invention, it is provided that the base element has a preferably constant, but at least average, material thickness of between 0.05 mm and 0.3 mm, preferably between 0.08 mm and 1.8 mm, particularly preferably between 0.09 mm and 1.5 mm and very particularly preferably substantially 0.11 mm. Preferably, the base element has the aforementioned material thickness at least in the region of the sealing groove, the capsule wall, the capsule bottom and/or the flange, in particular the first and/or second flange region.

According to a preferred embodiment of the present invention, the first fastening surface and the second fastening surface are provided at a vertical distance from one another, with the first fastening surface preferably having a smaller vertical distance from the capsule bottom than the second fastening surface. This particularly preferably also applies to the first and second flange regions. This provides a single-dose capsule whose flange has two sections, in particular horizontal ones, at different heights. This is particularly advantageous since, for manufacturing reasons, a minimal deviation between the first flange region and the second flange region often cannot be avoided. It was extremely surprising and unexpected for those skilled in the art that a secure fastening of the capsule lid was also possible in two regions located at different heights relative to the median longitudinal axis. In particular, the available first fastening surface of the first flange region is very small, such that a secure fastening could not be expected. Alternatively, the first flange region and the second flange region are located at the same height. This has the advantage that, when the scalding chamber is closed, there is no indirect displacement or deformation of the sealing groove due to the deformation or displacement of the first flange region and the second flange region relative to each other in the vertical direction. Instead, both flange regions bear on the scalding chamber closure element, thereby creating a suitable counterforce to prevent significant deformation of the sealing groove.

According to a preferred embodiment of the present invention, it is provided that the vertical distance between the fastening surfaces and/or the first and/or second flange regions is less than three times the thickness of the flange in the region of the first and/or second fastening surface or the first and/or second flange regions, preferably less than 0.035 mm, particularly preferably less than 0.030 mm, in particular at most 0.025 mm. Very particularly preferably, the vertical deviation is less than twice the material thickness and even more preferably less than one material thickness. The material thickness in this case is in particular the material thickness of the base element in the region of the first and/or second flange regions, in particular measured vertically in the extension in the aforementioned region. This makes it particularly advantageous to allow for a certain tolerance in the heights of the flange areas due to production, yet still ensure a secure and leak-proof attachment of the capsule lid.

According to a preferred embodiment of the present invention, the first fastening surface and the second fastening surface are arranged such that there is no fluid connection between the cavity of the single-dose capsule and the cavity between the capsule lid and the sealing groove. This means that, in particular, the fastening of the capsule lid in the first flange region is designed to be fluid-tight along the first fastening surface. This advantageously provides a single-dose capsule that is water- and air-tight.

According to a preferred embodiment of the present invention, a transition region extends between the inner flank and the outer flank. The transition region is preferably designed to be curved or has a transition plane extending parallel to the first flange region and/or the second flange region. In particular, the transition plane is designed horizontally. The curved configuration of the transition region has the advantage that the sealing groove is more stable, and deformation can therefore be prevented even more effectively. In contrast, the flat configuration of the transition region has the advantage that the sealing groove is flatter and, therefore, affects the gap in the sealing contour of the receiving element of the brewing chamber to a lesser extent, so that less force must be exerted on the sealing groove when the brewing chamber is closed. Furthermore, the risk of the brewing chamber part becoming jammed by the flat sealing groove is reduced. According to the invention, the transition region has a radial extension of 0.05 mm to 0.20 mm, preferably 0.07 mm to 0.17 mm, particularly preferably 0.10 mm to 0.14 mm, in particular 0.12 mm. This means in particular that in the radial cross-section of the surrounding sealing groove, the transition region has a straight connecting region having a width of 0.05 mm to 0.20 mm, preferably 0.07 mm to 0.17 mm, particularly preferably 0.10 mm to 0.14 mm, and in particular 0.12 mm.

According to a preferred embodiment of the present invention, it is provided that the single-dose capsule has a radius of 0.03 mm to 0.20 mm at the transition from the outer flank to the second flange region and/or at the transition from the inner flank to the first flange region, particularly preferably 0.06 mm to 0.15 mm, particularly preferably 0.09 mm to 0.13 mm, in particular 0.11 mm. The preferred dimensioning of the sealing groove described above results in the sealing groove having sufficient stability so that no deformation thereof occurs during the closing of the brewing chamber and/or during brewing of the capsule in the brewing chamber.

Preferably, in the radial cross-section of the surrounding sealing groove, both the inner flank and the outer flank each have a straight contact area extending between the flange and the transition area. The term "in radial cross-section" means a sectional representation of the flange contour along the circumferential direction of the surrounding flange contour. The plane of the sectional representation therefore extends through the vertical direction and the radial direction, as illustrated in Figures 3 to 5.

According to a preferred embodiment of the present invention, the straight contact area has a length of 0.1 mm to 1.5 mm, preferably 0.3 mm to 1.3 mm, particularly preferably 0.5 mm to 1.0 mm, and very particularly preferably 0.7 mm to 0.9 mm. It has been shown in simulations and experiments that with a straight contact area of the aforementioned lengths, an optimal seal between the sealing contour of the scalding chamber element and the flange can be achieved. In other words: A planar contact in form and force interaction of the inner flank with a sealing protrusion flank of the sealing contour of the brewing chamber element over a length of 0.1 mm to 1.5 mm, preferably 0.3 mm to 1.3 mm, particularly preferably 0.5 mm to 1.0 mm and very particularly preferably 0.7 mm to 0.9 mm is sufficient to achieve a sufficient sealing effect (in the area of the inner flank) without requiring extensive deformation of the sealing groove across the sealing contour.

According to a preferred embodiment of the present invention, the single-dose capsule has a radius of 0.05 mm to 0.35 mm, preferably 0.10 mm to 0.30 mm, and particularly preferably 0.21 mm, at the transition from the straight contact region to the transition region on the side facing the capsule lid. According to a preferred embodiment of the present invention, the single-dose capsule has a radius of 0.05 mm to 0.35 mm, preferably 0.10 mm to 0.30 mm, and particularly preferably 0.21 mm at the transition from the outer flank to the transition region on the side facing the capsule lid. According to a preferred embodiment of the present invention, the height of the sealing groove perpendicular to the sealing plane is provided between 0.6 mm and 1.3 mm, preferably between 0.3 mm and 0.6 mm, and particularly preferably between 0.9 and 1.0 millimeters. The preferred dimensioning of the sealing groove described above results in the sealing groove having sufficient stability so that severe deformation thereof does not occur when the brewing chamber is closed and/or the capsule is removed from the brewing chamber.

According to a preferred embodiment of the present invention, the single-serve capsule has one or more, preferably two, three, four, five, six, seven, or eight, concentrically extending grooves on its capsule wall, in particular on the outside of the capsule wall. The grooves can be designed as inwardly or outwardly directed notches and/or ridges. Advantageously, such grooves serve to stiffen or reinforce the capsule wall so that the single-serve capsule can withstand the pressures occurring during beverage preparation.

According to a preferred embodiment of the present invention, the single-dose capsule comprises a filter in the region of the capsule bottom. Particularly preferably, the filter comprises a nonwoven material and/or a fleece material. Very particularly preferably, the filter is designed as a single or multi-layered filter. Preferably, the filter is designed as a disc, in particular a round filter. Alternatively, the filter is designed as a polygonal filter, for example, quadrangular, hexagonal, octagonal, or decagonal filter. Preferably, the filter is arranged in the region of the bottom. Very particularly preferably, the filter is fixed, in sections or encircling the capsule bottom region, to the capsule and/or to the capsule wall and/or in a transition region between the capsule bottom and the capsule wall.

Another object of the present invention is a system for preparing a beverage comprising a beverage production machine and a single-dose capsule according to the invention, wherein the beverage production machine comprises a brewing unit with a first brewing chamber part and a second brewing chamber part, wherein the first and/or second brewing chamber part is movable relative to the other brewing chamber part between an approximate position in which the first and second brewing chamber parts form a closed brewing chamber and an open position in which the first and second brewing chamber parts are spaced apart from each other for inserting or ejecting a single-dose capsule, wherein the first brewing chamber part comprises a receiving element for at least partially receiving the single-dose capsule and the second brewing chamber part comprises a closing element for the receiving element, wherein in the closed position the flange of the single-dose capsule is form-fittingly and tightly received between a sealing region. edge of the housing element and the closing element.

The single-dose capsule according to the invention is part of the system according to the invention, so that all the advantages and improvements explained in relation to the single-dose capsule apply equally to the system according to the invention - and to the other objects of the present invention - and vice versa.

According to a preferred embodiment of the present invention, a sealing contour is provided in the edge region of the receiving element for sealing engagement with the sealing groove, the sealing contour comprising a surrounding recess and a surrounding sealing projection formed adjacent to the recess, the recess preferably being arranged outside the sealing projection in the radial direction, and an outer sealing projection flank forms an inner wall of the recess, the sealing projection engaging in the first flange region in the closed position, and the sealing groove engaging in the recess such that the sealing projection flank forms a linear contact with the inner flank in the radial cross-section. Such a configuration of the brewing chamber part is particularly advantageous since the sealing of the system is improved. In particular, the path extension for any ingressing water is achieved.

According to a preferred embodiment of the present invention, it is provided that in the closed position, the sealing groove across the sealing contour is deformed by only a maximum of 30%, preferably a maximum of 20%, particularly preferably a maximum of 10%, and very particularly preferably a maximum of 5% of its height perpendicular to the first and/or second fixing surface. This advantageously limits the active forces and thus reduces the risk of damage to the beverage production machine and/or the single-dose capsule.

According to a preferred embodiment of the present invention, the sealing contour is provided with a further surrounding sealing projection, the recess being arranged in the radial direction between the sealing projection and the further sealing projection, the sealing projection being longer than the further sealing projection, and the further sealing projection forming a contact point with the outer flank in the radial cross-section in the closed position. This further improves the sealing in a particularly advantageous manner.

Another subject of the present invention is a method for producing a single-serve capsule according to the invention, wherein in a first step a base element is produced with a capsule bottom, a surrounding flange, and a capsule wall extending between the capsule bottom and the surrounding flange, wherein in a second step a sealing groove is formed in the flange, wherein in a third step the cavity of the base element is filled with at least one beverage raw material, wherein in a fourth step the base element is closed with a capsule lid, wherein the capsule lid is secured, in particular sealed, to the flange along a first securing surface and along a second securing surface. By means of the method according to the invention, a single-serve capsule is provided which offers all of the aforementioned advantages in connection with the single-serve capsule according to the invention.

The advantages and improvements explained in relation to the method according to the invention apply equally to the other objects of the present invention and vice versa.

According to a preferred embodiment of the method according to the invention, the fourth step comprises at least a first sub-step and a second sub-step, wherein in the first sub-step, a fixing, in particular a sealing, is carried out along the second fixing surface by means of a fixing means, in particular a sealing tool, and wherein in the second sub-step, a fixing, in particular a sealing, is carried out along the first fixing surface and preferably the second fixing surface by means of a fixing means, in particular a sealing tool. Those skilled in the art understand that the fixing is always carried out over the entire surrounding fixing surface in order to achieve the required tightness. In particular, the first sub-step corresponds to a pre-sealing. In this context, "pre-sealing" means that a first fixing is carried out which, for example, is less robust compared to the fixing of the second sub-step, i.e., for example, is carried out with less force and/or in a shorter time. Preferably, the fixing means of the first and second sub-steps are at least partially identical. Partially identical in this regard means, for example, that individual elements of the fixing means are replaced, for example, in the case of a sealing tool, the sonotrode and/or the receiving element are replaced. Alternatively, a first fixing means, in particular a first sealing tool, is used in the first sub-step, and a second fixing means, in particular a second sealing tool, is used in the second sub-step.

Preferably, the fixing takes place in the first sub-stage at a sealing temperature of between 160°C and 260°C, more preferably between 190°C and 230°C, and in particular 210°C. Preferably, the fixing takes place in the first sub-stage with a sealing time of between 200 ms and 300 ms, more preferably between 230 ms and 270 ms, and in particular 250 ms. Preferably, the fixing in the first sub-stage takes place with a sealing force of between 250 N and 350 N, more preferably between 280 N and 320 N, and in particular 300 N.

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

According to a preferred embodiment of the method according to the invention, it is provided that in a further sub-step of the fourth step, before the first step, the capsule lid is produced, preferably cut and/or punched out from a web material. Those skilled in the art understand that, in the case of aluminum foil as the material for the capsule lid, a capsule lid, particularly a round one, is preferably punched out from aluminum foil. In this regard, the further sub-step is particularly preferably also carried out by means of a clamping means, in particular in one operation. For example, the capsule lid is punched out from aluminum foil in one movement and then sealed onto the base element. Alternatively, the capsule lid, in particular as a round sheet, is fed into the clamping means. This simplifies the production of the single-dose capsule and shortens the production time. Possible positioning errors are also advantageously avoided.

According to a preferred embodiment of the method according to the invention, it is provided that the first step comprises a first sub-step, a second sub-step and preferably a third sub-step, wherein in the first sub-step a basic shape is created, in particular punched out from a web material, wherein in the second sub-step a preform is created such that the base element is molded from the basic shape, wherein in the third sub-step a flange is molded, in particular rolled and/or flanged from the outer free end of the flange. Preferably the second sub-step is carried out by means of a punch.

Preferably, in another sub-stage, surrounding concentric grooves are molded into the capsule wall, at least on the outside.

According to a preferred embodiment of the method according to the invention, it is provided that the third step is carried out under a modified atmosphere and/or that a layer of nitrogen is applied to the bed of beverage raw material, in particular in such a way that after the fourth step there is no oxygen in the single-dose capsule.

According to a preferred embodiment of the method according to the invention, it is provided that in a fifth step, which is carried out after the first step and before the third step, a filter is introduced into the cavity and preferably secured to the base element, particularly in the area of the capsule bottom. Particularly preferably, the filter comprises a nonwoven material and/or a fleece material. Very particularly preferably, the filter is designed as a single or multi-layered filter. Preferably, the filter is designed in the form of a disc, particularly round. Alternatively, the filter is designed polygonal, for example quadrangular, hexagonal, octagonal, or decagonal. Preferably, the filter is arranged in the area of the bottom. Very particularly preferably, the filter is secured, in sections or encircling the capsule bottom and/or the capsule wall and/or in a transition area between the capsule bottom and the capsule wall, in a sealed manner. Particularly preferably, the filter is cut by a tool in one operation, brought into the cavity, and secured, in particular sealed, there.

Another subject of the present invention is an installation for the production of a single-dose capsule according to the invention, in particular according to a method according to the invention, with a moulding station for moulding a base element, a filling station for filling a cavity of the base element with at least one beverage raw material and a closing station for closing the base element with a capsule lid, the closing station being a sealing station according to the invention.

The embodiments that apply to this object of the present invention also apply to the rest of the objects according to the invention and vice versa.

Other details, features, and advantages of the invention are apparent from the drawings, as well as from the following description of preferred embodiments based on the drawings. The drawings here illustrate only exemplary embodiments of the invention, which do not limit the fundamental inventive idea.

Brief description of the drawings

Figures 1 and 2

show schematic sectional views of a single-dose capsule and a system for preparing a beverage according to a first exemplary embodiment of the present invention.

Figures 3 to 5

show detailed schematic views of the single-dose capsule according to the different exemplary embodiments of the present invention.

Figures 6 to 15

show different schematic perspective views of sealing tools according to different exemplary embodiments of the present invention.

Figure 16

shows a schematic detailed view of the single-dose capsule according to another exemplary embodiment of the present invention in cross-section.

Embodiments of the invention

Some illustrations contain measurement data. These illustrations correspond to technical drawings from which measurements and/or proportions can be extracted. This applies in particular to figures 3 to 5 and 12 to 15.

Figures 1 and 2 show a schematic side view of a single-dose capsule 1 and a sectional view of a system formed by the single-dose capsule 1 and a part of a beverage production machine 13 for preparing a beverage according to a first exemplary embodiment of the present invention.

The single-dose capsule 1 has a base element 2, which is exemplarily cup-shaped and truncated cone-shaped, and which has a capsule base 5 in its closed portion and a surrounding flange 6 in its open portion. Between the capsule base 5 and the flange 6, a capsule wall 7 extends around a hollow space 3. The single-dose capsule 1 is rotationally symmetrical in structure about its central median longitudinal axis M, which defines a vertical direction Y. In the radial direction R, the flange 6, which is circular and therefore surrounding in the circumferential direction, projects outwardly over the capsule wall 7.

The flange 6 is firmly connected to a capsule lid 4 in the form of a lid foil, in particular an aluminum foil which closes the cavity 3 in the open part of the base element 2. For this purpose, the flange 6 has, according to the invention, a first fastening surface 100 facing the capsule lid 4 and a second fastening surface 200 which preferably extend more or less at right angles to the vertical direction Y. The capsule lid 4 in its edge region at the first and second fastening surfaces 100, 200 is sealed, welded or glued onto the flange 6.

The capsule lid 4 is preferably made of aluminum or plastic, which may also comprise laminates. Formed within the base element 2 is the cavity 3, which is filled with beverage raw material, e.g., roasted coffee beans, instant coffee, chocolate powder, tea mix, powdered milk, and/or the like (for clarity, the beverage raw material is not shown), and which is sealed by the capsule lid 4.

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

The single-serve capsule 1 is inserted into a brewing unit in a beverage production machine 13 during use. The brewing unit comprises a first brewing chamber portion and a second brewing chamber portion, wherein the first or second brewing chamber portion is movable relative to the other brewing chamber portion between an approximate position in which the first and second brewing chamber portions form a closed brewing chamber 12, and an open position in which the first and second brewing chamber portions are spaced apart from one another for inserting or ejecting the single-serve capsule 1.

The first brewing chamber part is designed as a cup-shaped receiving element 21, which substantially accommodates the single-dose capsule 1, particularly when the brewing chamber 12 is in the closed position. The second brewing chamber part is designed as a closing element 22 for the receiving element 21. In the closed position illustrated in FIG. 2, the flange 6 of the single-dose capsule 1 is tightly clamped between an edge region 23 of the receiving element 21 and the closing element 22.

In this closed position, the capsule lid 4 and the capsule bottom 5 are pierced successively or simultaneously. The one or more piercing openings in the capsule bottom 5 are formed in particular by one or more piercing tips in the receiving element 21 during the closing of the brewing chamber 13, while the piercing openings in the capsule lid 4, preferably through piercing structures in the bottom of the closing element 22, are created already during the closing of the brewing chamber 12 or until the pressure inside the single-dose capsule 1 is not built up during the beverage production process.

An extraction liquid is introduced under pressure into the cavity 3 through one or more perforations in the capsule base 5. The interaction of the extraction liquid with the beverage raw material produces the desired beverage, which leaves the single-serve capsule 1 through the perforations in the capsule lid 4 and is fed into a beverage container. An optional filter medium can filter any particles of the beverage raw material from the beverage and retain them in the single-serve capsule 1. However, the multi-perforated capsule lid 4 preferably functions as a filter element.

Detailed views of the single-dose capsule 1 illustrated in FIGS. 1 and 2 are shown in FIGS. 3 to 5, according to the exemplary embodiment of the present invention. The figures herein show an enlarged view of the sectional representation of the flange 6 on the right side of FIG. 1 and 2. FIGS. 3 to 5 are shown to scale and provide a more accurate representation of the angular and longitudinal proportions.

The illustrated flange 6 extends essentially horizontally, i.e. parallel to the radial direction R, from the upper end of the capsule wall 7 to its free outer end where the flange 6 ends with a rim 8. The rim 8 comprises in particular a flange end rolled in the direction of the capsule bottom 5.

Furthermore, the flange 8 protrudes in the vertical direction Y in particular on both sides of the flange 6, whereby the flange 6 in the lower part projects from the flange 6 less than a sealing groove 9 and in addition in the upper part protrudes less or the same as in the lower part through the flange 6.

Between the shoulder 8 and the end of the capsule wall 7, the flange 6 has the sealing groove 9, which is designed in the form of a slit directed in the vertical direction Y opposite the capsule lid 4 and concentrically surrounding the central longitudinal member M in the circumferential direction. The sealing groove 9 has an inner flank 10 facing the capsule wall 7 and an outer flank 11 facing the shoulder 8. The sealing groove 9 is molded in one piece from the flange 6 and, as can be seen from the figures, has substantially the same thickness as the capsule wall 7 and/or a first flange region 18 between the capsule wall 7 and the inner flank 10 and/or a second flange region 19 between the shoulder 8 and the outer flank 11.

Between the inner flank 11 and the outer flank 12, a transition region 14 extends in the form of the transition plane 15, which runs in particular flat (i.e., straight) and parallel to the first and/or second flange regions 18, 19. The outer flank 11 runs at an angle p of approximately 85 degrees toward the second flange region 19. The outer flank 11 has in particular a straight flank section 20, which preferably has a length between 0.5 mm and 0.9 mm. The second flange region 19 preferably has a length of 0.2 mm to 0.8 mm. Between the inner flank 10 and the upper end of the capsule wall 7, the flange 6 has a first flange region 18. In the present example, the first flange region 18 is configured in the radial cross-section at least by straight and horizontal sections. The rectilinear zone has in particular a length of 0.07 mm to 0.09 mm.

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

According to the invention, the angle a between the inner flank 10 or the straight contact area 16 and the first flange area 18 is essentially 85 degrees.

The angle between the inner and outer flank 10, 11 is therefore preferably 5 to 15 degrees, particularly preferably 8 to 12 degrees and very particularly preferably essentially 10 degrees.

The first flange region 18 and the second flange region 19 are located in this case in the vertical direction Y at the same height. The height 17 of the sealing groove 9 corresponds to the total extension of the sealing groove 9 from the bottom of the first and/or second flange regions 18, 19 to the bottom of the flange 6 in the area of the transition plane 15. This height 17 perpendicular to the first or second flange regions 18, 19 amounts to between 0.9 mm and 1.0 mm.

The material thickness of the aluminium in the area of the flange 6 is preferably between 0.1 mm and 0.13 mm, in particular essentially 0.11 mm or 0.12 mm.

In Figures 3 to 5, for the sake of clarity, the edge region 23 of the receiving element 21, which is sealingly engaged with the flange 6 of the single-dose capsule 1, is not shown. The edge region 23 comprises a sealing contour for sealing engagement with the sealing groove 9. For this purpose, the sealing contour has a circumferential recess and a sealing projection formed adjacent to the recess, which also surrounds it in the circumferential direction. When viewed in the radial direction R, the recess is arranged outside the sealing projection such that an outer sealing projection flank of the sealing projection forms an inner wall of the recess.

In the closed position illustrated in Figure 2, the sealing protrusion engages in the first flange region 18, while the sealing groove 9 engages in the recess. A contact 16 is thus formed between the flank of the sealing protrusion and the inner flank 10 in the radial cross-section. This contact 16 is preferably present circumferentially in the circumferential direction and thereby forms the actual seal between the flange 6 and the receiving element 21, such that hardly or no extraction liquid can pass through the beverage raw material to the outlet of the brewing chamber 12. The apex of the sealing protrusion optionally touches the lower part of the first flange region 18, while the lower part of the transition plane 15 optionally touches the bottom of the recess.

The above-described configuration and dimensioning of the sealing groove 9 means that the sealing groove 9 does not deform significantly when the brewing chamber 12 is closed and/or when the beverage is brewed. The sealing is achieved primarily by the surrounding contact 16, which, due to the rigidity of the sealing groove 9, is subjected to relatively high forces.

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

It is conceivable that the sealing groove 9 in the closure of the brewing chamber 12 and/or brewing of the single-dose capsule 1 may vary in its height 17 in particular by a maximum of 0.2 mm, preferably a maximum of 0.15 mm, particularly preferably a maximum of 0.1 mm and very particularly preferably a maximum of 0.05 mm in the vertical direction Y. Alternatively, however, the sealing groove 9 is displaced only in the radial direction R and not in the vertical direction Y.

Preferably, the sealing groove 9 is also designed to be rigid, such that there is no excessive lateral displacement or deformation in the radial direction R. Provision is made for the sealing groove 9 to be designed such that, when the brewing chamber 12 is closed, it is preferably deformed or displaced only parallel to the first and/or second flange region 18, 19 to such an extent that its radius relative to a central longitudinal axis M of the single-dose capsule 1 is displaced by only a maximum of 5% parallel to the first and/or second flange region 18, 19, so that the single-dose capsule 1 can be easily removed from the brewing chamber 12 again after brewing and the sealing projection does not become jammed by the laterally inclined sealing groove 9.

It is conceivable that in the case of the sealing groove 9 in the closure of the brewing chamber 12 and/or brewing of the single-dose capsule 1, it is preferably provided that the tip of the sealing groove 9, i.e. the transition region 14 of the sealing groove 9, is displaced or deformed by a maximum of 0.2 mm, preferably a maximum of 0.15 mm, particularly preferably a maximum of 0.1 mm and very particularly preferably a maximum of 0.05 mm in the radial direction R.

The remaining measures shown with numbers in Figure 3 can preferably also be regarded as essential to the invention.

A detailed view of the single-dose capsule 1 shown in FIGS. 1 and 2 according to a further exemplary embodiment of the present invention is shown in FIG. 4 shows an enlarged view of the sealing groove 9 in section (in the same orientation as in FIG. 3, i.e., the capsule wall 7 on the left and the rim 8 on the right).

This embodiment essentially resembles the embodiment illustrated and explained in relation to Figure 3 so that all the previous explanations apply analogously.

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

The angle between the inner and outer flanks 10, 11 is preferably from 5 to 15 degrees, particularly preferably from 8 to 12 degrees, and very particularly preferably essentially from 10 degrees. 5 shows a detailed view of the single-dose capsule 1 illustrated in FIGS. 1 and 2 according to a further exemplary embodiment of the present invention. FIG. 5 shows a sectional view of the sealing groove 9 (in the same orientation as in FIGS. 3 and 4, i.e., the capsule wall 7 on the left and the rim 8 on the right) in an enlarged view.

This embodiment essentially resembles the embodiments illustrated and explained in relation to Figures 4 and 5 so that all the previous explanations apply analogously.

The measurements shown above deviate slightly in this embodiment; these can be seen from the drawing. Angles a and p, however, are equal.

According to the embodiment shown here, the radius at the transition between the capsule wall 7 and the first flange region 18 is between 0.49 mm and 0.51 mm, in particular 0.50 mm.

The first flange region 18 comprises a first fastening surface 100, on which the capsule lid 4 is connected to the flange 6, in particular is sealed thereto. In addition, however, the second flange region 19 also comprises a second fastening surface 200, on which the capsule lid 4 is connected to the flange 6, in particular is sealed thereto. Accordingly, according to the invention, the capsule lid 4 is connected to the flange 6 on at least two fastening surfaces 100, 200. These fastening surfaces 100, 200 are preferably unequal, i.e., distinct from one another, in particular without intersecting, and are arranged in the first and second flange regions 18, 19, i.e., in flange regions on both sides of the sealing groove 9.

Preferably, the first and second mounting surfaces 100, 200 are essentially circular in shape. According to the exemplary embodiment shown here, the rings have essentially the same diameter.

In this case, the fastening surfaces 100, 200, corresponding to the flange regions 18, 19, are arranged horizontally and essentially at the same height. Alternatively, however, it is also possible for the first flange region 18 and the second flange region 19 to be arranged at different heights. This is possible, among other things, due to manufacturing. Thus, for example, the first flange region 18 is between 0.020 mm and 0.030 mm, in particular up to 0.025 mm, lower, i.e., it is arranged at a smaller distance from the capsule bottom 5 than the second flange region 19.

Also in this case, i.e. in the case of particularly horizontal flange regions 18, 19, the capsule lid 4 is connected to the flange 6 both via the first fixing surface 100 and the second fixing surface 200.

The radius at the transitions between the first flange region 18 and the inner flank 10 and the second flange region 19 and the outer flank 11 is between 0.10 mm and 0.12 mm, in particular 0.11 mm, while the radius at the transitions between the inner flank 10 and the transition region 14 is also flat in this case, and the outer flank 11 is preferably between 0.20 mm and 0.22 mm, in particular 0.21 mm. In this context, the radii described above, according to the figure, are in each case measured on the side facing away from the capsule lid 4. The difference to the radii associated with the side facing the capsule lid 4, as explained by those skilled in the art, lies in the material thickness at this point, in this case in particular 0.11 mm or 0.12 mm.

The transition between the second flange region 19 and the shoulder 8 preferably amounts to between 0.19 mm and 0.21 mm, in particular 0.20 mm.

The height 17 of the sealing groove 9 according to this embodiment in the area of the first flange area is between 0.90 mm and 0.98 mm, in particular 0.90 mm and in the area of the second flange area between 1.00 mm and 0.90 mm, in particular 0.90 mm.

The flange 8 has in particular a vertical extension of between 1.20 mm and 1.40 mm, in particular 1.30 mm.

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

A sealing tool, in particular a first sealing tool 24, is shown in Figure 6 according to an exemplary embodiment of the present invention. Said sealing tool is used to seal the capsule lid 4 to the flange 6 of the single-dose capsule 1.

In order to achieve a seal according to the invention on both sides of the sealing groove 9, a special sealing tool is required in this regard.

The sealing tools 24, 25 of this type are already known in principle in this respect, so that in the following only the differences with the known sealing tools will be discussed, in particular with regard to the single-dose capsule according to the invention 1.

The sealing tool 24 comprises, inter alia, a sonotrode 28, which generates heat in a targeted manner and thus locally heats the material of the capsule lid 4 and the flange 6, creating a material bond between the two. This creates a fluid-tight connection between the base element 2 and the capsule lid 4. Since pressure also plays a decisive role in addition to heat, the sealing tool 24 comprises a receiving element 26, which receives the base element 2 and, on the underside of the flange 6, provides a counteracting force, via suitable retaining means 27 in the region of the first and/or second fastening surfaces 100, 200, relative to the force exerted by the sonotrode 28, so that no deformation of the flange and, consequently, no defective single-dose capsule 1 and/or incomplete sealing of the capsule lid 4 occurs.

The sealing tool 24 is explained in more detail in relation to the following images.

It is now decisive for the invention that the sealing process is carried out in two steps, where in a first sub-step the capsule lid 4 is connected to the flange 6 first only in the second flange area 19 along the second fixing surface 200, and where in a second sub-step the capsule lid 4 is connected both in the first flange area 6 along the first fixing surface 100 and in the second flange area 19 along the second fixing surface 200.

In this respect, the first sub-stage in particular corresponds to a pre-sealing, i.e. a sealing process that is carried out in comparison with the second sub-stage with at least one parameter reduced in quantity, namely sealing temperature, sealing time and/or sealing force.

In this regard, a combination of a sealing temperature of preferably between 200°C and 220°C, in particular 210°C, a sealing time of preferably between 220 ms and 280 ms, in particular 250 ms, and a sealing pressure of preferably between 100 N and 500 N, in particular 300 N, which in a preferred sealing tool 24 corresponds to a sealing pressure of approximately 2 bar, has proven successful in tests.

Basically, it is possible to carry out both sub-stages with the same sealing tool 24. In this respect, for example, it is possible to selectively not make any changes between the sub-stages, i.e. to work with the same elements, but with modified parameters, and/or to replace the sonotrode 28 and/or the housing element 26.

Alternatively, both sub-steps are executed in different sealing tools, in this case a first sealing tool 24 and a second sealing tool 25.

Merely by way of example, this embodiment is explained by means of Figures 6 to 15. Thus, in this case the external diameter of the sonotrode 28 of the first sealing tool 24 is preferably between 34.0 mm and 35.0 mm, in particular 34.5 mm.

A detailed schematic drawing of the first sealing tool 24 in the area relevant here is shown in Figure 7. Compared to known sealing tools, the first sealing tool 24 differs in that the retaining means 27 has two protruding regions, the upper surfaces of which are located below either the first flange region 18 or the second flange region 19.

In this respect, the retaining means 27 can be provided in one piece or in several pieces. In particular, the retaining means 27 comprises two pushers.

Surprisingly, it turns out that the best sealing results are achieved when, for a single-dose capsule 1, as described in connection with FIG. 5, two pushers with different heights are used. In this regard, in particular, the inner pusher, i.e., the pusher associated with the first flange region 18 and the first fixing surface 100, is between 0.05 mm and 0.25 mm, preferably between 0.10 mm and 0.20 mm, and in particular 0.15 mm higher than the outer pusher, associated with the second flange region 19 and the second fixing surface 200. This is not shown to scale here, but rather clearly exaggerated. Both pushers have upper surfaces that are in contact with the first flange region 18 and the second flange region 19 and thus define the first and second fixing surfaces 100, 200.

The retaining means 27 can be arranged in a height-variable or fixed manner.

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

The heat evacuation means 29 ensures that the heat increase resulting from the two different sealing processes does not adversely affect the beverage raw material and/or the capsule lid 4 in this area.

Since in the first sub-stage only a sealing is carried out via the second fixing surface 200, the internal pusher for the housing element 26 of the first sealing tool 24 is optional.

8 now shows a second sealing tool 25, which triggers the main sealing process (also known as post-sealing). In this respect, the second sealing tool 25 essentially corresponds to the first sealing tool 24, referring to the embodiments of FIGS. 6 and 7. This applies to both FIGS. 8 and 9.

In this respect, the sonotrode 28 of the second sealing tool 25 preferably has a larger diameter than the sonotrode 28 of the first sealing tool 24, particularly preferably between 34.3 mm and 35.2 mm and in particular 34.8 mm.

The sealing process of the second sub-stage is now carried out with at least one parameter higher in quantity, where a combination of a sealing temperature of preferably between 200°C and 220°C, in particular 210°C, a sealing time of preferably between 420 ms and 480 ms, in particular 450 ms, and a sealing pressure of preferably between 700 N and 1100 N, in particular 900 N, which in the preferred embodiment of the sonotrode 28 of the second sealing tool 25 corresponds to a sealing pressure of approximately 6 bar, has proven to be particularly successful.

As already mentioned in this second sub-stage, the capsule lid is fixed to the flange 6 firmly and in particular fluid-tight and pressure-tight, specifically both along the first fixing surface 100 and the second fixing surface 200.

A perspective sectional representation of a first and/or second sealing tool 24, 25 is shown in Figure 10. Reference is made to the previous embodiments with respect to Figures 6 to 9.

In Figure 10 it can be clearly seen that the retaining means 27 only provides a counteracting force in the area of the first and/or second flange region 18, 19. In the area of the sealing groove 9, as in the area of the capsule bottom 5, the receiving element 26 is clearly spaced from the base element 2.

Furthermore, in Figure 10 the structure of the sonotrode 28 can be distinguished, in particular with regard to the heat evacuation means 29, according to the embodiment shown in this case.

11 shows a schematic detailed view of a cross-section of the sealing tool 24, 25 according to an exemplary embodiment of the present invention similar to the representations in FIGS. 7 and 9. Reference is made in this respect to the previous embodiments. In this case, grooves, four in this case, can be distinguished on the capsule wall 7 of the single-dose capsule 1, by way of example.

Figures 12 and 13 show technical drawings of the receiving element 26 or the sonotrode 28 of the first sealing tool 24 according to the exemplary embodiment of the present invention explained above. The external diameter of the receiving element 26 is preferably substantially 35 mm and the height preferably 36 mm.

The sonotrode 28 in turn, according to the embodiment shown here, has an external diameter of in particular 34.5 mm, whereby the heat dissipation means 29 in the sonotrode 28 has an external diameter of 29.7 mm.

Figures 14 and 15 show technical drawings of the housing element 26 or of the sonotrode 28 of the second sealing tool 25 according to the exemplary embodiment explained above of the present invention, as well as a detailed drawing of the retention means 27. In the detailed drawing the height difference between the pushers has been drawn, where the inner pusher associated with the first flange area 18 is located 0.15 mm higher than the outer pusher.

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

A schematic detailed view of the single-dose capsule 1 according to another exemplary embodiment of the present invention is shown in Figure 16 in cross-section. The embodiment shown in Figure 16 corresponds in this respect essentially to the embodiments explained in relation to Figures 3 to 5 and in particular to the embodiment shown in Figure 5, so that reference is made to the relevant embodiments.

5, Figure 16 differs in particular in its dimensions and/or associated tolerances. Depending on the embodiment shown, the following measurements can be taken from left to right according to the illustration in this regard. The transition from the capsule wall 7 to the first flange region 18 on the capsule lid 4 side preferably has a radius of 0.30 mm to 0.50 mm. The transition between the first flange region 18 and the inner flank 10, in particular on the side facing away from the capsule lid 4, has a radius of preferably 0.11 mm to 0.36 mm. The sealing groove 9 between the transition region 14, which in this case is also a transition plane 15, therefore has a planar extension, at least in sections, in particular 0.12 mm long, and the first flange region 18 preferably has a height of 0.82 mm to 0.90 mm.

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

Particularly preferably, the sealing groove 9 is constructed symmetrically in this case. The virtual internal angle at an imaginary extension of the tip of the sealing groove 9 is therefore 10°. Furthermore, the transition from the transition plane 15 to the outer flank 11, in particular on the side facing away from the capsule lid 4, preferably has a radius of 0.23 mm to 0.33 mm. The angle between the straight section of the outer flank 11 and a horizontal section of the second flange region 19 is preferably 85°.

The transition between the outer flank 11 and the second flange region 19, in particular on the side facing away from the capsule lid 4, preferably has a radius of 0.11 mm to 0.36 mm. The sealing groove 9 between the transition plane 15 and the second flange region 19 preferably has a height of 0.90 mm to 1.00 mm. The person skilled in the art understands that, within the tolerances, the first flange region 18 and the second flange region 19 preferably lie in a horizontal plane, but due to the tolerances, a slight horizontal deviation of at most 0.18 mm may also occur, i.e., in particular, slightly more than a material thickness.

The transition between the second flange region 19 and the flange 8 preferably has a radius of 0.20 mm to 0.45 mm, the flange 8 according to the embodiment shown having a radial extent of approximately 1 mm and a vertical extent, i.e. a total height, of preferably 1.25 mm to 1.45 mm, in particular 1.35 mm.

List of references

1 single-dose capsule

2 Base element

3 Cavity

4 Capsule lid

5 Capsule bottom

6 Flange

7 Capsule wall

8 Flange

9 Sealing groove

10 Inner flank

11 External flank

12 Scalding chamber

13 Beverage production machine

14 Transition zone

15 Transition plane

16 Contact zone

17 Height of the sealing groove

18 First flange area

19 Second flange area

20 Flank section

21 Accommodation element

22 Closing element

23 Border Zone

24 First sealing tool

25 Second sealing tool

26 Sealing tool housing element

27 Retention medium

28 Sonotrode

29 Heat evacuation medium

100 First fixing surface

200 Second fixing surface

Angle

Angle

R Radial direction

And Vertical Direction

M Median longitudinal axis

Claims (22)

1. Single-dose capsule (1) for preparing a beverage in a scalding chamber (12) of a beverage production machine (13), the single-dose capsule (1) having a base element (2) with a cavity (3) for receiving a beverage raw material and having a capsule lid (4) closing the cavity (3), the base element (2) comprising a capsule bottom (5), a surrounding flange (6) and a capsule wall (7) extending between the capsule bottom (5) and the surrounding flange (6), the flange (6) having a sealing element integrally configured with the flange (6) in the form of a sealing groove (9) pointing away from the capsule lid (4), the sealing groove (9) comprising an inner flank (10) and an outer flank (11), the flange (6) between the capsule wall (7) and the inner flank (10) has a first flange region (18), and between the outer free end of the flange (6) and the outer flank (11) it has a second flange region (19), the capsule lid (4) being fastened in the first flange region (18) along a surrounding first fastening surface (100) and fastened in the second flange region (19) along a surrounding second fastening surface (200), characterized in that a transition region (14) extends between the inner flank (10) and the outer flank (11), the transition region (14) extending in a radial direction from 0.05 mm to 0.20 mm, preferably from 0.07 mm to 0.17 mm, particularly preferably from 0.10 mm to 0.14 mm, in particular from 0.12 mm. 2. Single-dose capsule (1) according to claim 1, characterized in that the outer free end of the flange (6) is rolled up, in particular flanged in such a way that it forms a surrounding flange (8), the flange (8) preferably having a vertical extension with respect to the flange (6) greater than zero, particularly preferably on both sides of the flange (6), very particularly preferably the vertical extension of the flange (8) on the side of the flange (6) opposite the capsule lid (4) is smaller than the vertical extension of the sealing groove (9) and/or the vertical extension of the flange (8) on the side of the flange (6) facing the capsule lid (4) is smaller than on the side of the flange (6) opposite the capsule lid (4). 3. Single-dose capsule (1) according to one of the preceding claims, characterized in that both the inner flank (10) and the outer flank (11) are oriented at an angle (a, p) of greater than 80 to less than 90 degrees, preferably from 81 to 89 degrees, particularly preferably from 83 to 87 degrees, very particularly preferably from 84 to 86 degrees and in particular substantially 85 degrees, with respect to a horizontal plane extending through the first flange region (18) or the second flange region (19). 4. Single-dose capsule (1) according to one of the preceding claims, characterized in that the first fixing surface (100) and the second fixing surface (200) each have an essentially horizontal extension. 5. Single-dose capsule (1) according to one of the preceding claims, characterized in that the first fixing surface (100) and the second fixing surface (200) are spaced vertically apart from each other, preferably the first fixing surface (100) having a smaller vertical distance from the capsule bottom (5) than the second fixing surface (200). 6. Single-dose capsule (1) according to claim 5, characterized in that the vertical distance between the fixing surfaces (100, 200) is less than three times the thickness of the flange (6) in the region of the first and/or second fixing surface (100, 200), preferably less than 0.35 mm, particularly preferably less than 0.30 mm, very preferably less than 0.25 mm, even more preferably less than 0.20 mm, in particular at most 0.018 mm. 7. Single-dose capsule (1) according to one of the preceding claims, characterized in that the first fixing surface (100) and the second fixing surface (200) are provided in such a way that there is no fluid connection between the cavity (3) of the single-dose capsule and the cavity between the capsule lid (4) and the sealing groove (9). 8. Single-dose capsule (1) according to one of the preceding claims, characterized in that the inner flank (10) and the outer flank (11) are configured symmetrically with respect to each other. 9. Single-dose capsule (1) according to one of the preceding claims, characterized in that the transition zone (14) is configured curved or has a transition plane (15) extending parallel to the first flange zone (18) and/or the second flange zone (19). 10. Single-dose capsule (1) according to one of the preceding claims, characterized in that the base element (2) is made in a single piece of aluminum. 11. Single-dose capsule (1) according to one of the preceding claims, characterized in that the single-dose capsule (1) has a filter in the area of the capsule bottom (5). 12. System for preparing a beverage comprising a beverage production machine (13) and a single-dose capsule (1) according to one of the preceding claims, wherein the beverage production machine (13) comprises a brewing unit with a first brewing chamber part and a second brewing chamber part, the first and/or second brewing chamber part being movable relative to the other brewing chamber part between an approximate position in which the first and second brewing chamber parts form a closed brewing chamber (12) and an open position in which the first and second brewing chamber parts are spaced apart from one another for inserting or ejecting a single-dose capsule (1), the first brewing chamber part comprising a receiving element (21) for at least partially receiving the single-dose capsule (1) and the second brewing chamber part comprising a closing element (22) for the receiving element (21). wherein in the closed position the flange (6) of the single-dose capsule (1) is housed between an edge area (23) of the housing element (21) and the closing element (22) in a form-fitting and tight manner. 13. System according to claim 12, characterized in that a sealing contour for sealing engagement with the sealing groove (9) is formed in the edge region (23) of the receiving element (21), the sealing contour comprising a surrounding recess and a surrounding sealing projection formed adjacent to the recess, the recess preferably being arranged outside the sealing projection in the radial direction (R) and an outer sealing projection flank forms an inner wall of the recess, and/or in the closed position the sealing projection engages in the first flange region (18) and the sealing groove (9) engages in the recess such that the sealing projection flank forms a linear contact (16) with the inner flank (10) in the radial cross section. 14. Method for producing a single-dose capsule according to one of claims 1-11, wherein in a first step a base element (2) is created with a capsule bottom (5), a surrounding flange (6) and a capsule wall (7) extending between the capsule bottom (5) and the surrounding flange (6), wherein in a second or the first step a sealing groove (9) is molded into the flange (6), wherein in a third step the cavity (3) of the base element (2) is filled with at least one beverage raw material, wherein in a fourth step the base element (2) is closed with a capsule lid (4), wherein the capsule lid (4) is fixed, in particular sealed, on the flange (6) along a first fixing surface (100) and along a second fixing surface (200). 15. Method according to claim 14, wherein the fourth step comprises at least a first sub-step and a second sub-step, wherein in the first sub-step a fixing, in particular a sealing, is carried out by means of a fixing means, in particular a sealing tool (24, 25), along the second fixing surface (200) and wherein in the second sub-step a fixing, in particular a sealing, is carried out by means of a fixing means, in particular a sealing tool (24, 25), along the first fixing surface (100) and preferably the second fixing surface (200). 16. Method according to claim 15, wherein in another sub-step of the fourth stage before the first sub-step the capsule lid (4) is created, preferably cut and/or punched from a web material. 17. Method according to one of claims 14-16, wherein the first step comprises a first sub-step, a second sub-step and preferably a third sub-step, wherein in the first sub-step a basic shape is created, in particular punched out, from a web material, wherein in the second sub-step a preform is created such that the base element (2) is molded from the basic shape, wherein in the third sub-step a flange (8) is molded, in particular rolled and/or flanged from the outer free end of the flange (6), wherein preferably the molding of the sealing groove is carried out in the second or third sub-step. 18. Method according to one of claims 14-17, wherein in a fifth step which is carried out after the first step and before the third step a filter is introduced into the cavity (3) and preferably fixed to the base element (2), in particular in the area of the capsule bottom (5). 19. Installation for the production of a single-dose capsule (1) according to one of claims 1 to 11, in particular according to a method according to one of claims 14-18, with a molding station for molding a base element (2), a filling station for filling a cavity (3) of the base element (2) with at least one beverage raw material and a closing station for closing the base element (2) with a capsule lid (4), characterized in that the closing station is a sealing station for closing a single-dose capsule (1) with a capsule lid (4) for producing the single-dose capsule (1) according to one of claims 1 - 11 with at least a first sealing tool (24), wherein the first sealing tool (24) is configured to seal the capsule lid (4) along the second fixing surface (200) on the flange (6) and wherein the first sealing tool (24) or a second sealing tool (25) is configured to seal the capsule lid (4) to the flange (6) along the first fixing surface (100) and preferably the second fixing surface (200). 20. Installation according to claim 19, characterized in that the first sealing tool (24) and/or the second sealing tool (25) each comprise at least one sonotrode (28) and at least one receiving element (26), the receiving element (26) having an open cavity for receiving the single-dose capsule (1), the receiving element (26) further having at least one retaining means (27), the retaining means (27) being provided to provide a counteracting force on the side of the flange (6) opposite the capsule lid (4), in particular in the area of the first fixing surface (100) and/or the second fixing surface (200), with respect to the force exerted by the sonotrode (28). 21. Installation according to claim 20, characterized in that the receiving element (26) has at least one retaining means (27) in the area of the first fixing surface (100), wherein an upper surface of the retaining means (27) in comparison with an upper surface of the retaining means (27) of the first sealing tool (24) and/or second sealing tool (25) in the area of the second fixing surface (200) is arranged at least 0.05 mm, preferably at least 0.10 mm, in particular at least 0.15 mm higher. 22. Installation according to one of claims 20 or 21, characterized in that the sonotrode (28) of the first and/or second sealing tool (24, 25) has a heat dissipation means (29), in particular arranged centrally.