Abstract
The invention relates to a portioning container (1) made of biodegradable fiber material (11), to a molded fiber system (100), and to a method (200) for manufacturing such portioning containers (1), comprising a receptacle (2) for holding a consumable (G, G) and a cover (6) for closing the receptacle to produce a sealed volume (V) within the portioning container (1), wherein at least the receptacle (2), preferably also the cover (6), is manufactured from biodegradable fiber material (11) using a molded fiber system (100) by means of a molded fiber process, from a pulp (7, 7a, 7b) as a liquid solution containing the biodegradable fiber material (11), wherein at least the receptacle (2), preferably also the cover (6), is provided with a barrier layer system (8) which has a barrier effect at least against penetration of moisture, water, aromatic substances, flavoring agents, odorants, and/or non-food-grade substances.
Claims
1-38. (canceled)
39. A portioning container, comprising: a receptacle for holding a consumable, wherein the receptacle is manufactured from a biodegradable fiber material, wherein the receptacle is formed from a first molded part made of a first fiber material and a second molded part made from a second, different fiber material, wherein the first and second molded parts are interconnected via their respective mutually facing surfaces by pre-compression pressure applied during a pre-forming process; and a cover for closing the receptacle to produce a sealed volume within the portioning container.
40. The portioning container of claim 39, wherein the receptacle includes a partition that divides the sealed volume into at least a first volume and a second volume.
41. The portioning container of claim 40, wherein the cover includes a plurality of outlets such that both the first volume and the second volume are associated with one or more of the plurality of outlets.
42. The portioning container of claim 39, wherein the portioning container further comprises: a barrier layer applied to at least one surface of the receptacle or the cover, wherein the barrier layer prevents penetration of one or more of: moisture, water, aromatic substances, flavoring agents, odorants, or non-food-grade substances.
43. The portioning container of claim 42, wherein the barrier layer includes one or more of: a wax layer, a coating layer, a layer of polytetrafluoroethylene (PTFE), or a ceramic layer.
44. The portioning container of claim 42, wherein the barrier layer is a ceramic layer having a thickness of between 0.0005 mm and 0.02 mm.
45. The portioning container of claim 42, wherein the barrier layer is applied to an inner surface of the receptacle and an inner surface of the cover.
46. The portioning container of claim 39, wherein the biodegradable fiber material includes no organic binders.
47. A portioning container constructed from biodegradable fiber material, the portioning container comprising: a receptacle for holding a consumable, wherein the receptacle is manufactured, from the biodegradable fiber material, using a pulp as a liquid solution containing the biodegradable fiber material, wherein the receptacle is provided with a barrier layer system that provides a barrier against penetration of one or more of moisture, water, aromatic substances, flavoring agents, odorants, or non-food-grade substances; and a cover for closing the receptacle to produce a sealed volume within the portioning container.
48. The portioning container of claim 47, wherein the receptacle is formed from a first molded part made of a first fiber material, and a second molded part made from a second, different fiber material.
49. The portioning container of claim 47, wherein the barrier layer system is applied to an inner surface of the receptacle.
50. The portioning container of claim 47, wherein the biodegradable fiber material has a liquid solution content of less than 10%.
51. The portioning container of claim 47, wherein the receptacle is shaped such that one or more wall surfaces of the receptacle have an angle of at least 3 degrees with respect to an axis of symmetry that is oriented perpendicularly to a bottom surface of the receptacle.
52. The portioning container of claim 47, wherein the receptacle includes a partition that divides the sealed volume into at least a first volume and a second volume, and wherein the cover includes at least one outlet for the consumable in the sealed volume.
53. The portioning container of claim 52, wherein the cover divides an incoming liquid flow into the sealed volume into at least a first liquid flow into the first volume and a second liquid flow into the second volume, and wherein a bottom surface of the portioning container includes at least one tap.
54. A molded part manufactured from biodegradable fiber material, the molded part comprising: a receptacle for holding a consumable, wherein the receptacle is manufactured from the biodegradable fiber material; a cover for closing the receptacle to produce a sealed volume within the molded part, wherein the cover is manufactured from the biodegradable fiber material; and a barrier layer applied to an inner surface of the receptacle, wherein the barrier layer includes one or more of: a wax layer, a coating layer, a layer of PTFE, or a ceramic layer.
55. The molded part of claim 54, wherein the biodegradable fiber material does not include any organic or non-organic binders.
56. The molded part of claim 54, the receptacle is formed from a first molded part made of a first fiber material, and a second molded part made from a second, different fiber material.
57. The molded part of claim 54, wherein the molded part is a portioning container, and wherein the cover has a resealable tap.
58. The molded part of claim 54, wherein the molded part is a hot-beverage capsule, wherein the cover is configured to divide an incoming liquid flow into at least two liquid flows into two separate volumes within the sealed volume, and wherein a bottom surface of the hot-beverage capsule includes at least two separate taps.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0082] In addition, further features, effects, and advantages of the present invention are explained with reference to the attached drawings and the following description. Components which correspond at least substantially in terms of their function in the individual figures are identified by the same reference symbols, it not being necessary for the components to be numbered and explained in all the figures.
[0083] In the drawings:
[0084] FIG. 1: is a schematic representation of a portioning container according to the invention;
[0085] FIG. 2: shows different embodiments of the receptacle and the cover with a barrier layer system on the (a) outside, (b) inside, and (c) on both sides of the receptacles and covers;
[0086] FIG. 3: shows an embodiment of the receptacle formed from first and second molded parts made of fiber material;
[0087] FIG. 4: shows an embodiment of the portioning container with two separate volumes filled with respective consumables;
[0088] FIG. 5: shows an embodiment of the molded fiber system according to the invention;
[0089] FIG. 6: shows another embodiment of the molded fiber system according to the invention having two pulp reservoirs containing different pulps for manufacturing receptacles and/or covers from first and second molded parts; and
[0090] FIG. 7: shows an embodiment of the method according to the invention.
EXEMPLARY EMBODIMENTS
[0091] FIG. 1 is a schematic representation of a portioning container 1 according to the invention, comprising a receptacle 2 for holding a consumable G, G and a cover 6 for closing the receptacle to produce a sealed volume V within the portioning container 1, wherein the receptacle 2 and the cover 6 are produced from biodegradable fiber material 11, for example produced from a pulp 7, 7a, 7b as a liquid solution containing the biodegradable fiber material 11 using a molded fiber system 100 (see FIGS. 5 and 6) by means of a molded fiber process, wherein at least the receptacle 2, preferably also the cover 6, is provided with a barrier layer system 8 which has a barrier effect at least against penetration of moisture, water, aromatic substances, flavoring agents, odorants, and/or non-food-grade substances (see, inter alia, FIG. 2). The biodegradable fiber material 11 of the portion receptacle 1 has a liquid solution proportion of less than 10%, preferably less than 7%, in the molded fiber process after the final shaping of the receptacle 2. The biodegradable fiber material 11 of the portion container 1 is correspondingly compacted by a double-pressing process consisting of pre-pressing in a pre-forming station 20 and hot-pressing in a hot-pressing station 30 at a temperature higher than during pre-pressing. The biodegradable fiber material 11 preferably contains no organic binder, preferably likewise no non-organic binder, and consists substantially of fibers with a fiber length of less than 5 mm. In the portioning container shown, a wall thickness WD of the receptacle 2, preferably also of the cover 6, varies over all surfaces of the receptacle 2 by less than 7% with respect to a target thickness. In this regard, the receptacle 2 is shaped in such a way that all surfaces 21 of the receptacle 2 have an angle of at least 3 degrees with respect to an axis of symmetry S which is oriented perpendicularly to a bottom surface 21b of the receptacle 2. The same applies to the cover 6. The thickness of the cover 6 in the direction of symmetry S is not regarded as a surface. The receptacle 2 is integrally formed from a wall surface 21w and the bottom surface 21b, which makes it easier to assemble the portioning container. The portioning container 1 or its components 2, 6 can additionally be stacked. For this purpose, the receptacle 2 comprises, at its end 21e opposite the bottom surface 21b, a circumferential flat receptacle edge 21r, which functions as a stacking edge 21s. Furthermore, the portioning container 1 can be manufactured from a consumable fiber material. The cover 6 in this case comprises an outlet 6a for the consumable in the volume V, as a result of which the portioning container can serve as a cup. For better stability, the receptacle 2 has, on its bottom surface 21b, a base ring 5 at the transition between the bottom surface 21b and the wall surface 21w. Furthermore, the receptacle 2 has a transition from the bottom surface 21b to the wall surface 21w, which transition is rounded or has one or more discrete contours 9a, preferably ribs or beads. In addition, the receptacle 2 has one or more discrete contours 9b, preferably ribs or beads, within the wall surface 21w. These measures make the receptacle 2 mechanically more robust. The receptacle 2 has a wall surface 21w with different thicknesses. The bottom surface 21b can also be designed as a hollow base 21hb (shown in dashed lines). Furthermore, the bottom surface 21b can be roughened with or without a base ring or have corrugations. In an embodiment not shown here, the receptacle 2, preferably the entire portioning container 1, can also be spherical in shape. The finished portioning container 1 encompasses the consumable G, with the cover 6 closing the receptacle 2. In one embodiment, the portioning container 1 is a hot-beverage capsule, preferably a coffee capsule.
[0092] FIG. 2 shows different embodiments of the receptacle 2 and the cover 6 with barrier layer systems 8 on the (a) outside, (b) inside, and (c) on both sides of the receptacles 2 and covers 6. In this case, the receptacle 2 and the cover 6 are each provided with a barrier layer system 8 which has a barrier effect at least against penetration of moisture, water, aromatic substances, flavoring agents, odorants, and/or non-food-grade substances. The barrier layer system 8 can be made of biocompatible materials. In FIG. 2a, the barrier layer system 8 is applied to both the outer surface 2a of the receptacle 2 and the cover 6, which prevents substances from penetrating the fiber material 11 from the outside or escaping from the fiber material 11 to the outside. However, substances can get from the fiber material 11 into the consumable G or, vice versa, from the consumable G into the fiber material 11. This type of coating is particularly expedient if the fiber material 11 has to be protected against external influences, for example water, so that the fiber material 11 does not unintentionally dissolve. In FIG. 2b, the barrier layer system 8 is applied to both the inner surface 2i of the receptacle 2 and the cover 6, which protects the consumable G against all substances from the environment and the fiber material 11 and prevents the release of substances from the consumable G. This type of coating in particular protects the consumable G from external impairments and, for example, from a loss of aroma to the outside. In FIG. 2c, the barrier layer system 8 is applied to both sides of the receptacle 2 and the cover 6, which combines the advantages of the two previous variants but requires greater effort in terms of coating. The barrier layer system 8 can comprise a wax layer, a coating layer, a layer of PTFE, or a ceramic layer, preferably a SiOx layer or a glass-ceramic material. The barrier layer system 8 applied to the outside can consist of a material that can be printed on.
[0093] FIG. 3 shows an embodiment of the receptacle 2 made of first and second molded parts 10-1, 10-2 made of fiber material 11. In this case, the receptacle 2 made of biodegradable fiber material 11 is formed from a first molded part 10-1 made of a first fiber material 11 from a first pulp 7a, as the outer part of the receptacle 2, and from a second molded part 10-2 made of a fiber material 11 from a second or further pulp 7b that is different from the first pulp 7a, as the inner part of the receptacle 2. The first and second molded parts 10-1, 10-2 are firmly interconnected at an interface 10i by means of a pre-compression pressure VD in the pre-forming station 20 via their respective mutually facing surfaces. What is stated above for the receptacle 2 of the portioning container 1 applies equally to the cover 6, which can likewise be manufactured from a first molded part 10-1 and a second molded part 10-2.
[0094] FIG. 4 shows an embodiment of the portioning container 1 having two separate volumes V1, V2 filled with respective consumables G, G, so that the portioning container 1 can hold at least one second consumable G. For this purpose, the sealed volume V shown in FIG. 1 is divided here into two separate volumes V1, V2 by virtue of the receptacle 2 having a partition 3 between the separate volumes V1, V2. The cover 6 here comprises an outlet 6a for the consumables in the volumes V1, V2; the outlet takes the form of an individual outlet for each volume V1, V2. This outlet 6a can be used, for example, as a drinking cup for portioning containers 1 (arrows pointing upward). Alternatively, the cover 6 can divide an incoming liquid flow into the volume V into at least two liquid flows in respective separate volumes V1, V2 (arrows pointing downward). For this purpose, the cover 6 can have a resealable tap 4w, which is shown here as the same part as the outlet 6a for the sake of clarity. In the alternative embodiment, the bottom surface 21b can have two separate taps 4, 4, one for each of the separate volumes V1, V2. In this embodiment, the portioning container 1 can be used, for example, as a coffee capsule for two different types of coffee or for a coffee with additives, wherein one of the volumes V1 is filled with the coffee powder to be brewed, for example, as one consumable G, and the other volume V2 is filled with milk powder, for example, as the other consumable G for a white coffee. After brewing, the two consumables G, G can be dispensed for consumption via the two taps 4, 4 into a vessel. The hot water for brewing reaches the two volumes V1, V2 via the tap 4w in the cover 6, with the tap 4w being designed to divide the water flow into separate water flows for the respective volumes V1, V2 (see arrows), with the strength of the respective divided water flows being preset by the design of the tap 4w.
[0095] FIG. 5 shows an embodiment of the molded fiber system 100 according to the invention for manufacturing portioning containers 1 according to the invention, comprising a reservoir 15 for providing a pulp 7 as a liquid solution containing biodegradable fiber material 11; a molding station 20 having a suction tool 20s with a large number of suction heads adapted to the contour of the receptacle 2 and/or cover 6 of the portioning container 1 to be manufactured, in order to integrally mold the receptacle 2 and/or covers 6 by sucking the pulp 7 into the respective suction heads, wherein the suction tool 20s is mounted on a moving unit 20b, for example a robot with a robot arm; a pre-forming station 30 for pre-pressing the molded receptacles 2 and/or cover 6 of the portioning container 1 comprising the pulp reservoir 15; a hot-pressing station 40 for producing the final shape of the pre-formed receptacles 2 and/or covers 6 of the portioning containers 1, wherein the portioning containers or the receptacles 2 and/or the covers 6 are transferred to a pre-press lower die 41 by means of the suction tool 20s and are hot-pressed in the hot-pressing station 40 between the hot-press lower die 41 and a correspondingly shaped hot-press upper die (not shown here in detail); a coating station 50 for applying a barrier layer system 8 to the integrally molded, pre-formed, or final-shaped receptacles 2 and/or covers 6 of the portioning containers 1; and a dispensing station 60 for dispensing the final-shaped receptacles 2 and/or covers 6 or the portioning containers 1 from the molded fiber system 100. The molded fiber system 100 in this case also comprises one or more assembly stations 70, 80 for filling the receptacles 2 with consumables G, G and/or for closing the receptacles 2 with the respective covers 6.
[0096] FIG. 6 shows another embodiment of the molded fiber system 100 according to the invention having two pulp reservoirs 15 containing different pulps 7a, 7b for producing receptacles 2 from first and second molded parts 10-1, 10-2. In this case, the first, second, and optionally further pulps 7a, 7b differ in terms of their compositions, their solvents, their fiber materials, their concentrations, and/or in proportions and/or in terms of their type of dopant, if any. The molded fiber system 100 here comprises a second reservoir 15 containing a second pulp 7b, in order to, via a partial second immersion 300 of the suction tool 20s with or without molded parts 10-1 already molded from the first pulp 7a in the suction heads, fill said parts with a second fiber layer as a second molded part 10-2. So that the two pulp reservoirs 15 are supplied with pulp 7a, 7b for the ongoing production process, the pre-forming station 20 comprises a pulp processing and subsequent delivery station 35. In addition, the pre-press lower die 31 is arranged as a multi-tool on the pre-forming station 30 in such a way that the solution or pulp pressed out during pre-forming can be collected and fed back directly to the two pulp reservoirs 15. In this case, the suction tool 20s is arranged on a robot arm of the moving unit 20b, since the robot arm can reliably approach the two pulp reservoirs 15 with the suction tool 20s. For this purpose, the robot arm first immerses the suction tool 20s, for example, into the first pulp reservoir 15 containing the first pulp 7a so that the first molded part 10-1 is integrally molded from the first pulp 7a. The suction tool 20s is then immersed a second time into the second pulp reservoir 15 containing the second pulp 7b so that further fiber material 11 from the second pulp 7b is molded onto the previously molded first molded part 10-1 as a second molded part 10-2 as a result of the suction process.
[0097] FIG. 7 shows an embodiment of the method 200 according to the invention for producing portioning containers 1 according to the invention using a molded fiber system 100 according to the invention, comprising the steps of providing 210 a reservoir 10 of pulp 7 as a liquid solution containing biodegradable fiber material 11; integrally molding 220 receptacles 2 and/or covers 6 of the portioning containers 1 to be manufactured in a molding station 20 having a suction tool with a large number of suction heads adapted to the contour of the receptacle 2 and/or cover 6 by sucking the pulp 7 into the respective suction heads; pre-pressing 230 the integrally molded receptacles 2 and/or covers 6 of the portioning containers 1 in a pre-forming station 30; producing the final shape 240 of the pre-formed receptacles 2 and/or covers 6 of the portioning containers 1 in a hot-pressing station 40; applying 250 a barrier layer system 8 to the integrally molded, pre-formed, or final-shaped receptacles 2 and/or covers 6 of the portioning containers 1 in a coating station 50; and dispensing 260 the final-shaped receptacles 2 and/or covers 6 or the portioning containers 1 from the molded fiber system 100 by means of a dispensing unit 60. The different points in time at which the barrier layer system 8 can be applied is represented by a number of application steps 250. In this case, the components are not necessarily coated several times but can be coated at any point 250 shown. The method can also (shown in dashed lines) comprise the step of filling 270 the receptacles 2 with consumables G, G in an assembly station 70 and/or closing 280 the receptacles 2 with the respective covers 6 in another assembly station 80.
[0098] At this point, it should be explicitly pointed out that features of the solutions described above or in the claims and/or drawings can also be combined, if necessary, in order to be able to cumulatively implement or achieve explained features, effects, and advantages.
[0099] It goes without saying that the exemplary embodiment explained above is merely a first embodiment of the present invention. In this respect, the embodiment of the invention is not limited to this exemplary embodiment.
LIST OF REFERENCE SIGNS
[0100] 1 portioning container [0101] 2 receptacle [0102] 2i inner surface of the receptacle [0103] 2a outer surface of the receptacle [0104] 21 surface of the receptacle [0105] 21b bottom surface of the receptacle [0106] 21hb bottom surface as hollow base [0107] 21e end of receptacle opposite the bottom surface [0108] 21r circumferential edge of the receptacle [0109] 21s stacking edge of the receptacle [0110] 21w wall surface of the receptacle [0111] 3 partition [0112] 4, 4 taps of the bottom surface [0113] 4w resealable tap [0114] 5 base ring [0115] 6 cover [0116] 6a outlet for the consumable [0117] 7 pulp [0118] 7a first pulp [0119] 7b second pulp [0120] 8 barrier layer system [0121] 9a discrete contour, for example rib or bead, at the transition from the bottom surface to the wall surface [0122] 9b discrete contour, for example rib or bead, within the wall surface [0123] 10-1 first molded part of the receptacle (or cover) [0124] 10-2 second molded part of the receptacle (or cover) [0125] 10i interface between the first and second molded part [0126] 11 fiber material [0127] 15 reservoir of pulp [0128] 20 molding station [0129] 20s suction tool [0130] 20b moving unit [0131] 30 pre-forming station [0132] 31 pre-press lower die [0133] 35 pulp preparation and subsequent delivery unit [0134] 40 hot-pressing station [0135] 41 hot-press lower die [0136] 50 coating station [0137] 60 dispensing station [0138] 70 assembly station for filling the receptacle with consumables [0139] 80 assembly station for closing the receptacle with the cover to complete the portioning container [0140] 90 control unit [0141] 100 molded fiber system [0142] 200 method for producing portioning containers [0143] 210 providing a reservoir of pulp [0144] 220 integrally molding receptacles and/or covers of the portioning containers to be manufactured [0145] 230 pre-pressing the integrally molded receptacles and/or cover of the portioning container [0146] 240 producing the final shape of the pre-formed receptacles and/or cover of the portioning container [0147] 250 applying a barrier layer system to the integrally molded, pre-formed, or [0148] 260 final-shaped receptacles and/or cover of the portioning containers dispensing the final-shaped receptacles and/or cover or the portioning containers from the molded fiber system [0149] 270 filling the receptacles with consumables [0150] 280 closing the receptacles with the respective covers [0151] G, G consumables [0152] S axis of symmetry [0153] V sealed volume [0154] V1, V2 separate volumes [0155] VD pre-compression pressure [0156] WD wall thickness
