METHOD AND APPARATUS FOR MAKING SINGLE-USE CAPSULES FOR BEVERAGES

Abstract

Described is a method for making single-use capsules for beverages including the steps of: providing an upper flange having at least one hole; providing a support having at least one seat for housing a rigid cup-shaped body; inserting a rigid cup-shaped body in said housing seat, said rigid cup-shaped body having an inner space and an open upper opening; providing a piece of filter material above the upper flange; actuating a first step of feeding, by means of a pushing element, a central portion of said piece of filter material towards said hole, up to an intermediate position; upon reaching said intermediate position of the pushing element, performing a main locking of said piece of filter material relative to said upper flange and making a main cut of the piece of filter material along a predetermined main closed cutting line, extending substantially circularly about said central portion, to define a filter for infusion of beverages.

Claims

1. A method for making single-use beverage capsules, said capsules having a rigid cup-shaped body equipped with a closed base and an upper opening, and a filter having a concave shape and positioned inside the rigid body to form a chamber for containing a dose of product, said method comprising the following steps: providing an upper flange having at least one hole; providing a support having at least one housing seat for housing said rigid cup-shaped body, said support being positioned under the upper flange with the housing seat aligned with the hole; inserting the rigid cup-shaped body into said housing seat with the upper opening close to the support; providing a piece of filter material above the upper flange; actuating a first step of feeding, using a pushing element, a central portion of said piece of filter material towards said hole, up to a first position; upon reaching said first position of the pushing element, a main locking of said piece of filter material relative to said upper flange is performed, the method being characterised in that it comprises the following further steps: making a main cut of said piece of filter material along a main closed cutting line, extending substantially circularly about said central portion, to obtain a filter for infusion of beverages; after the step of making the main cut, actuating a second step of feeding, using the pushing element, the filter towards said housing seat, from the first position to a desired final position, suitable for fixing said filter to an inner surface of said rigid cup-shaped body; then fixing a perimeter portion of the filter to said inner surface of the rigid cup-shaped body; wherein said first and/or second feeding step are performed in an adjustable way in such a way as to vary, respectively, a position of said filter relative to the main closed cutting line and/or to said desired final position.

2. The method according to claim 1, wherein said first and second feeding steps are performed in an adjustable manner in such a way as to vary the desired final position of the filter keeping unchanged the position where the perimeter portion of the filter is fixed to the inner surface of the rigid cup-shaped body.

3. The method according to claim 1, wherein the step of making a main cut of said piece of filter material to define said filter comprises a step of moving a main cutting device equipped with a cutting edge in the direction of the piece of filter material, until making contact with said piece of filter material and cutting it.

4. The method according to claim 1, wherein the following steps are carried out before the first feeding step: placing a sheet of filter material above said upper flange; carrying out a preliminary locking of said sheet of filter material above said upper flange; and performing a preliminary cutting of said sheet of filter material to obtain said piece of filter material.

5. He method according to claim 4, wherein the step of carrying out a preliminary cutting of said sheet of filter material to obtain said piece of filter material comprises: moving an additional cutting device provided with a cutting edge in the direction of said sheet of filter material, until making contact with said sheet of filter material and cutting it.

6. The method according to claim 1, comprising, simultaneously with the first feeding step, a step of generating radial folds on the piece of filter material and/or, simultaneously with the second feeding step, a step of generating radial folds on the filter.

7. An apparatus for making single-use beverage capsules, said capsules comprising a rigid cup-shaped body, having a closed base and an upper opening, and a filter having a concave cross section, positioned inside the rigid body to form a chamber for containing a dose of product, said apparatus comprising: a support comprising a seat for housing a rigid cup-shaped body; an upper flange comprising a hole, said upper flange being positioned above the support, positioning the hole aligned with the housing seat; a pushing element facing said hole and movable between a withdrawn position, outside the hole, and an advanced position, inside the hole, said pushing element having a shape suitable for intercepting a central portion of the piece positioned on the upper flange and pulling the piece of filter material into the hole; a main locking element configured to lock said piece of filter material against the upper flange; a main cutting device positioned above said upper flange and configured to make a main cut of said piece of filter material, whilst said piece is locked by the main locking element, along a main closed cutting line, having a substantially circular extension around said central portion, to obtain the filter or infusion of beverages; said main cut being performed when reaching an intermediate position, located between said withdrawn and advanced positions; a sealing element, configured to fix a perimeter portion of the filter along an inner surface of the rigid cup-shaped body inserted in said housing seat, after said pushing element has fed the filter towards said housing seat, moving the filter from the intermediate position to the advanced position; a control unit configured to actuate said main cutting device when the pushing element is in said intermediate position, in such a way that the cut on the piece of filter material occurs when the pushing element is at said intermediate position, said control unit also controlling the pushing element for actuating it in such a way as to vary, respectively, a position of said filter relative to said main closed cutting line and/or to the advanced position.

8. The apparatus according to claim 7, wherein said main cutting device comprises a first cylindrical blade.

9. The apparatus according to claim 8, comprising an additional cutting device, positioned outside the main cutting device and configured to cut a sheet of filter material along a preliminary cutting line, in such a way as to obtain said piece of filter material, said preliminary cutting line of the additional cutting device preferably having a substantially circular shape.

10. The apparatus according to claim 9, further comprising an additional locking element, acting in conjunction with the additional cutting device, for locking said sheet of filter material relative to said upper flange.

11. The apparatus according to claim 7, wherein the sealing element comprises a sonotrode with a hollow tubular shape, positioned about said pushing element and movable axially towards and away from the housing seat, preferably independently of the pushing element.

12. The apparatus according to claim 7, comprising a guide element above the upper flange and movable from, and towards, the upper flange, and having a central cavity sized to allow the passing through of said pushing element.

13. The apparatus according to claim 12, wherein the guide element has radial grooves relative to said central cavity, positioned to favour the formation of wrinkles on said piece of filter material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Further features and advantages of the invention are more apparent in the non-limiting description which follows of a preferred non-limiting embodiment of a method for making single-use beverage capsules an a relative apparatus, as illustrated in the accompanying drawings, in which:

[0038] FIG. 1 shows a partly simplified cross section of an apparatus for making single-use beverage capsules made according to the invention;

[0039] FIG. 2 shows a cross section of a single-use capsule for beverages;

[0040] FIGS. 3 to 10 show the apparatus for making capsules of FIG. 1 in different operating configurations according to different steps of the method according to the invention;

[0041] FIGS. 11a to 11d show a portion of filter material in different configurations according to different steps of the method according to the invention;

[0042] FIG. 12 shows the step of FIG. 11c in an alternative embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0043] With reference to FIG. 1, the numeral 100 generically indicates an apparatus for making single-use beverage capsules according to the invention.

[0044] A capsule of the type which can be produced by the apparatus 100 is illustrated in a longitudinal cross section in FIG. 2 and is labelled 1. In the simplest form, it comprises a rigid cup-shaped body 2, a closing element 3 made of perforatable material, and a filter 4 containing a dose of product “D” for extraction or infusion beverages, preferably ground coffee.

[0045] The rigid body 2 is made of plastic and/or paper material and comprises a side wall 2a, preferably substantially frustoconical, and a closed bottom 2b, the latter made of perforatable material.

[0046] At the top of it, the rigid body 2 has an upper opening 2c which is accessible before closing.

[0047] The filter 4 comprises a portion of filter material, preferably filter paper for beverages. The filter 4 is made from a sheet “F” of filter material, to which reference is hereinafter made to denote a strip or web or other semifinished piece of thin filter paper.

[0048] A perimeter portion of the filter 4 is fixed to the inner side of the side wall 2a, preferably continuously along its circumference, to define a chamber for containing a dose of product “D”. Advantageously, the filter 4 is fixed to the rigid body 2 in such a way as to have a concave surface designed to contain the dose of product “D” and allow the filtering relative to a flow of water coming from the upper opening 2c.

[0049] The closing element 3 (also called “lid”) is a film or other type of cover positioned to occlude the upper opening 2c, in such a way as to hermetically seal it to allow a good conservation of the dose of product “D” contained in the capsule 1 and prevent a contamination with extraneous agents, and the closing element 3 also makes it possible to contain the water dispensed for the infusion. Preferably, the closing element 3 is configured to be perforated by a nozzle which supplies liquid under pressure of a dispensing machine.

[0050] In its simplest embodiment, the apparatus 100 comprises: a main cutting device 110, a pushing element 115 and a sealing element 120.

[0051] In the embodiment illustrated, there is an upper flange 107 which defines a central hole 108, extending about an axis of extension “X” and having an inlet section 108a, preferably flared, and an outlet section 108b. Close to the inlet section 108a, the central hole 108 may have radial inner grooves.

[0052] The main cutting device 110 is located above the upper flange 107 and is equipped with a cutting edge configured to cut a piece “S” from the sheet “F” of filter material, interposed between the main cutting device 110 and the upper flange 107.

[0053] According to another aspect, there is a movable support 105 equipped with a seat 106 for housing a rigid cup-shaped body 2.

[0054] The support 105 is moved by an external device (not illustrated).

[0055] In use, the outlet section 108b faces the housing seat 106 in such a way that, when the rigid cup-shaped body 2 is positioned below, the outlet section 108b is substantially aligned with the upper opening 2c of the rigid body 2.

[0056] Preferably, the above-mentioned piece “S” of filter material consists of filter paper for coffee or tea. The main cutting device 110 is configured to cut the piece “S” along a predetermined, substantially circular main cutting line 10 to obtain a filter disc designed for inserting in a rigid cup-shaped body 2, for making a single-use capsule of the type described above.

[0057] The main cutting line 10 made by the main cutting device 110 is substantially circular and has a diameter greater than 75 mm when the filter material is positioned flat. The above-mentioned diameter must make it possible to obtain a filter 4 to be inserted correctly in the rigid body 2.

[0058] The main cutting device 110 comprises a first cylindrical blade 111, having a diameter preferably between 75 and 190 mm. For simplicity, the drawings show only the part in cross-section of the cylindrical blade 111. The choice of the diameter of the cylindrical blade 111 is a function of the minimum dimension of the filter 4 to be made.

[0059] The first cylindrical blade 111 is movable away from, and towards, the upper flange 107, preferably driven by a linear actuator, not illustrated, connected to it. In the embodiment illustrated, the first cylindrical blade 111 is movable along the axis of extension “X”.

[0060] Preferably, the apparatus 100 comprises a main locking element 110a, for example a pressing element, associated with the main cutting device 110 and configured to lock the piece “S” of filter material to favour its cutting by the main cutting device 110. For simplicity, the drawings show only the part in cross section of the main locking element 110a.

[0061] Preferably, the apparatus 100 comprises an additional cutting device 112, positioned outside the main cutting device 110 in such a way as to surround it.

[0062] Advantageously, the additional cutting device 112 is equipped with a cylindrical cutting edge configured to make a preliminary cut of the sheet “F” of filter material, interposed between the main cutting device 110 and the upper flange 107, along a preliminary cutting line 12. The above-mentioned preliminary cut is aimed at obtaining the piece “S” of filter material, designed for the subsequent cuts by the first cylindrical blade 111.

[0063] Preferably, the preliminary cutting line 12 of the additional cutting device 112 is substantially circular and has a diameter greater than that obtained subsequently with the first cylindrical blade 111 of the main cutting device 110.

[0064] In the embodiment illustrated, the additional cutting device 112 comprises a second cylindrical blade 113 having a diameter preferably between 470 and 570 mm. For simplicity, the drawings show only the part in cross-section of the cylindrical blade 113.

[0065] Preferably, the apparatus 100 comprises an additional locking element 112a, associated with the additional cutting device 112 and configured to lock the sheet “F” of filter material to favour its cutting by the additional cutting device 112. For simplicity, the drawings show only the part in cross section of the main locking element 110a.

[0066] In the embodiment illustrated, the upper flange 107 has respective contact grooves for the main cutting device 110 and for the additional cutting device 112.

[0067] The pushing element 115 is movable, preferably along the axis of extension “X”, towards and away from the central hole 108 between a withdrawn position (illustrated in FIG. 3), above the upper flange 107, and a forward position (illustrated in FIG. 10), wherein the hole 108 is completely crossed to reach the inside of the rigid body 2. In the passage from the withdrawn position to the advanced position, the pushing element 115 strikes a central portion of the piece “S” of filter material interposed between the main cutting device 110 and the upper flange 107 and pulls the piece “S” of filter material into the hole 108. Preferably, the pushing element 115 comprises a head 116, configured to enter the rigid cup-shaped boy 2 after passing through the central hole 108, and a stem 117 connected to the head 116.

[0068] More specifically, the head 116 is designed to pull the piece “S” of filter material, located on the upper flange 107, through the central hole 108 and, after being cut further by the main cutting device 110, inside the rigid cup-shaped body 2 located in the housing seat 106. The above-mentioned pulling is performed by applying a pressure on the central portion of the piece “S” of filter material in such a way as to fold the piece “S” of filter material to obtain a concave shape with the cavity facing upwards, designed to contain a dose of product “D” (for example coffee powder).

[0069] In at least one embodiment, the head 116 has radial grooves on the outer surface (not illustrated) designed to favour the formation of a predetermined wrinkle on the piece “S” of filter material during its feeding through the hole 108.

[0070] Preferably, the pushing element 115 is moved by an actuator (not illustrated) connected to the stem 117.

[0071] Advantageously, the pushing element 115 is configured to adopt a predetermined intermediate position (FIG. 7), between the withdrawn and advanced positions.

[0072] The sealing element 120 is configured for sealing a perimeter portion of the filter 4 to a lateral inner surface of the rigid cup-shaped body 2. In the embodiment illustrated, the sealing element 120 is configured for sealing the filter 4 along a predetermined fixing line 14 on the side wall 2a located at a distance from the upper opening 2c which is fixed and identical for all the dimensions of the filter 4.

[0073] The sealing element 120 preferably comprises a sonotrode 121, positioned outside the pushing element 115 and coaxial with it. Preferably, the sealing element 121 can be moved axially away from and towards the housing seat 106 between a raised position and a lowered position where it is suitable for performing the above-mentioned sealing, preferably independently of the pushing element 115. In the embodiment illustrated, the sealing element 121 can be moved along the axis of extension “X”. Preferably, the central hole 108 of the upper flange 107 is configured to allow simultaneous movements of the pushing element 115 and of the sealing element 120 towards and away from the housing seat 106.

[0074] The sealing element 120 is positioned at the fixing line 14 when the pushing element 115 is in the advanced position.

[0075] Preferably, a sonotrode may be used as sealing element to perform an ultrasonic sealing.

[0076] Advantageously, the apparatus 100 comprises a control unit, configured to operate the main cutting device 110 when the pushing element 115 is in the above-mentioned predetermined intermediate position. The control unit is also active on the pushing element 115 for varying the intermediate position and/or the advanced position.

[0077] Adjusting the intermediate position has the effect of varying the position of the piece “S” of filter material at the moment of cutting by the main cutting device 110 to obtain the filter 4. Consequently, the size of the filter 4 after cutting along the predetermined main cutting line 10 depends advantageously on the choice of the intermediate position.

[0078] In other words, although the diameter of the main cutting device 110 is fixed, the dimensions of the piece cut by it vary according to the intermediate position made to adopt the pushing element 115, when the main cutting device 110 performs the cut.

[0079] At the intermediate position, the pushing element 115 pauses and the main cutting device 110 cuts the piece “S” of filter material.

[0080] FIGS. 11c and 12 schematically illustrate a cut made along the main cutting line 10 at different intermediate positions to obtain different dimensions of the filter 4.

[0081] The adjustment of the advanced position of the pushing element 115 has the effect of controlling the final position of the filter 4 in the rigid cup-shaped body 2 and defines the position in which the sealing occurs on the side wall 2a of the rigid cup-shaped body 2.

[0082] Preferably, the control unit is designed to activate the sealing element 120 when the above-mentioned pushing element 115 is in the advanced position. Advantageously, the control unit adjusts the position of the advanced position of the pushing element 115 in such a way as to position a perimeter portion of the filter 4 on the predetermined fixing line 14.

[0083] In at least one embodiment, the apparatus 100 comprises an interface for adjusting the intermediate and/or advanced position by part of a user.

[0084] Preferably, the apparatus 100 comprises a guide element 125, above the upper flange 107 and able to be moved towards and away from the latter along the axis of extension “X”. The guide element 125 has a central cavity positioned aligned with the central hole 108 of the upper flange 107 and configured to allow the pushing element 115 and the sealing element 120 to pass through it. The guide element 125 defines with the upper flange 107, in a configuration close to the upper flange 107, a gap for slidably housing the piece “S” of filter material. The guide element 125 may also have grooves, radial in the above-mentioned central cavity, at least in a zone ending in the central cavity for generating radial folds on the piece “S” of filter material during its pushing by the pushing element 115, in such a way as to favour a wrinkle on the filter 4.

[0085] The invention also relates to a method for making single-use beverage capsules of the type described above, preferably using the apparatus 100 described above.

[0086] The above-mentioned method comprises a step of providing a rigid cup-shaped body 2 of the type described above.

[0087] The method according to the invention also comprises a step of preparing a piece “S” of filter material, preferably of filter paper for coffee or tea, on top of an upper flange 107 having a central hole 108.

[0088] Preferably, the step of preparing a piece “S” of filter material comprises a step of preparing a sheet “F” of filter material above the upper flange 107 (FIG. 3), performing a preliminary locking of the sheet “F” of filter material above the upper flange 107 (FIG. 4) and performing a preliminary cut of the sheet “F” of filter material (FIG. 5).

[0089] Preferably, the step of performing a preliminary locking of the sheet “F” of filter material above the upper flange 107 is performed by a lowering of an additional locking element 112a of the type described above.

[0090] Preferably, the step of performing a preliminary cutting of the sheet “F” of filter material comprises moving an additional cutting device 112 provided with a cutting edge in the direction of the sheet “F” of filter material, until coming into contact with the sheet “F” and cutting it along a preliminary cutting line 12 (illustrated in FIG. 11a), preferably substantially circular, thus obtaining the piece “S” of filter material. More specifically, this preliminary cutting step may be carried out by punching the sheet “F”.

[0091] Preferably, the additional cutting device 112 comprises a second cylindrical blade 113.

[0092] The step of preparing a piece “S” of filter material is illustrated, in one embodiment, in FIGS. 3 to 5 and 11a, the piece “S” of resulting filter material is illustrated in FIG. 11b.

[0093] In a different embodiment, the sheet “F” is cut into a different cutting station and the piece “S” ready is conveyed and positioned above the central hole 108 of the upper flange 107.

[0094] Subsequently, the method according to the invention comprises actuating a first step of feeding (FIG. 6), using a pushing element 115, a central portion of the piece “S” of filter material towards the housing seat 106, up to a predetermined intermediate position (FIGS. 7 and 8). The pushing element 115 is actuated in such a way as to pull the piece “S” of filter material along the central hole 108 towards the rigid cup-shaped body 2 making it slide on the upper flange 107.

[0095] Subsequently, upon reaching the predetermined intermediate position of the pushing element 115, the method according to the invention comprises a step of carrying out a main locking of the piece S of filter material relative to the upper flange 107 and performing a main cut of the piece “S” of filter material along the main cutting line 10 (FIG. 8), thus obtaining a filter 4 of the desired size.

[0096] Preferably, the step of locking the main piece S of filter material relative to the upper flange 107 is accomplished by a main locking element 110a of the type described above.

[0097] Preferably, the step of performing a main cut of the piece “S” of filter material comprises moving a main cutting device 110, of the type described above, provided with a cutting edge, towards the piece “S” of filter material, until making contact with the piece “S” and cutting it along a predetermined main closed cutting line 10 to define the filter 4 of the type described above (FIG. 8).

[0098] The main cutting line 10 extends substantially in a circular fashion around the central portion of the piece “S”. Moreover, the filter 4 is cut in such a way as to be provided with a surface and a perimeter shape suitable for insertion into the rigid body 2 described above.

[0099] Advantageously, the predetermined intermediate position of the pushing element 115 described above is adjustable, in such a way as to be able to adjust the size of the filter 4.

[0100] After the main cutting step, this method comprises actuating, preferably using the pushing element 115, a second step of feeding the filter 4 (FIG. 9) inside the rigid body 2, until reaching a desired final position (illustrated in FIG. 10). More specifically, the desired final position is suitable for fixing a perimeter portion of the filter 4 to the inner surface of the rigid cup-shaped body 2 along a fixing line 14.

[0101] Preferably, the method according to the invention comprises a step of generating radial folds on the piece (S) of filter material and on the filter 4. More specifically, the step of generating radial folds is performed using a guide element 125 of the type described above. Advantageously, it is designed to create a wrinkle on the surface of the filter 4.

[0102] After the second feeding step, the method according to the invention comprises the step of fixing, preferably by sealing, a perimeter portion of the filter 4 to the inner surface of the rigid cup-shaped body 2, in particular along the above-mentioned predetermined fixing line 14, shown in FIG. 11d. Advantageously, the final position is adjustable.

[0103] The invention achieves the set aim by overcoming the drawbacks of the prior art, since the method and the apparatus 100 described above allow adjusting the cutting of a piece “S” of filter material in such a way as to make, with a single machine, filters for single-use capsules for beverages of the type described above of different sizes. The invention therefore increases the flexibility of the machinery for the production of single-use capsules and allows a greater diversification of the production compared with the prior art. The invention also allows the use of filters with different sizes without increasing the number of cutting stations.