METHOD FOR MANUFACTURING A COMPOSTABLE POD
20250171178 ยท 2025-05-29
Inventors
- Christophe Sebastien Paul Heydel (Chez Le Bart, CH)
- CAMILLE MARIE-ROSE ELIANE DAGANAUD (Pully, CH)
- Frederic Doleac (Vaux et Chantegrue, FR)
Cpc classification
B65B9/00
PERFORMING OPERATIONS; TRANSPORTING
B65B9/045
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65B29/02
PERFORMING OPERATIONS; TRANSPORTING
B65B9/00
PERFORMING OPERATIONS; TRANSPORTING
B65B9/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention relates to a method for manufacturing a pod (100) for preparing a beverage in a beverage production machine, the machine having opening elements for opening the pod (100) under the effect of rising pressure of fluid being injected into the pod (100). In the method, two formable sheet elements (200) are provided, into one of which an opening (210) is cut. A second sheet material (300) is provided and connected with the respective sheet element (200) at a connection area (230) that circumferentially surrounds the opening (210). The so connected sheet material (300) forms a delivery wall (110) of the pod (100), through which during the beverage preparation process the prepared beverage is dispensed from the pod (100). The two sheet elements (200) are formed into the shape of a half-shell (101, 102), respectively, whereby the connection area (230) is pinched from opposite sides of the sheet element (200) when forming the respective half-shell (101, 102). An injection wall (120) for injecting a fluid into the pod (100) is formed. A substance (105) for the beverage is provided and the two half-shells (101, 102) are connected to form a pod body (130) around the substance (105). Therein, the pod body (130) together with the delivery wall (110) and the injection wall (120) delimit a chamber containing the substance (105). The delivery wall (110) is configured to be opened upon interaction with the opening elements of the beverage production machine under the effect of rising pressure of the fluid being injected into the pod (100).
Claims
1. A method for manufacturing a pod for preparing a beverage in a beverage production machine, comprising the steps of: providing two sheet elements each being made of a formable material; cutting an opening into one of the sheet elements; covering the opening with a sheet material and connecting the sheet material and the respective sheet element at a connection area circumferentially surrounding the opening, the so connected sheet material forming a delivery wall; forming the two sheet elements into the shape of a half-shell, respectively; forming an injection wall of the pod for injecting a fluid into the pod; providing a substance required for the preparation of the beverage; connecting the two half-shells to form a pod body around the substance to form the pod, the pod body together with the delivery wall and the injection wall defining a chamber containing the substance for preparing the beverage upon interaction of the substance with the fluid injected through the injection wall, and the delivery wall being adapted to be opened upon interaction with opening elements of the beverage production machine under the effect of rising pressure of the fluid being injected into the pod to dispense the prepared beverage from the pod, and wherein the connection area is pinched from opposite sides of the sheet element when forming the respective half-shell.
2. The method according to claim 1, wherein the sheet elements are formed into the shape of a half-shell, respectively, by drawing at least part of the respective sheet element into a forming die.
3. The method according to claim 1, wherein pinching the connection area is obtained by a punch positioned on one side of the sheet element and a counter-punch positioned on the other side of the sheet element with respect to the punch.
4. The method according to claim 3, wherein the counter-punch is configured to dampen and/or to resist a displacement force applied by the punch onto the connection area, and the counter-punch is elastically supported in the forming die, preferably by an elastic element, like a spring.
5. The method according to claim 3, wherein the counter-punch is spring-elastically biased towards the punch so as to apply a defined clamping force to the connection area during the forming step.
6. The method according to claim 1, wherein each of the two half-shells comprises a circumferential flange.
7. The method according to claim 6, wherein the two half-shells are connected to each other via the circumferential flanges.
8. The method according to claim 1, wherein the two sheet elements are provided by cutting or punching a sheet made of a formable and biodegradable material.
9. The method according to claim 1, wherein the half-shells are configured such that the two half-shells are separated by a gap when surrounding the substance before the step of connecting the two half-shells.
10. The method according to claim 1, wherein the injection wall is formed when forming one of the half-shells.
11. The method according to claim 1, wherein the half-shells are formed before or after cutting the opening into the sheet element.
12. The method according to claim 1, wherein at least one or both of the sheet elements have a disc shape.
13. The method according to claim 1, wherein the half-shells are identical.
14. The method according to claim 1, wherein the substance is provided as a tablet made of compressed beverage powder.
15. The method according to claim 1, wherein the two half-shells are connected under the application of vacuum and under the application of heat sealing or ultrasonic sealing.
Description
4. BRIEF DESCRIPTION OF DRAWINGS
[0060] Further features, advantages and objects of the invention will become apparent for the skilled person when reading the following detailed description of embodiments of the invention and when taking in conjunction with the figures of the enclosed drawings. In case numerals have been omitted from a figure, for example for reasons of clarity, the corresponding features may still be present in the figure.
[0061]
[0062]
[0063]
[0064]
[0065]
[0066]
[0067]
5. DETAILED DESCRIPTION
[0068]
[0069] A first aspect of the invention relates to said method for manufacturing a pod for preparing a beverage in a beverage production machine, such as the mentioned pod 100. The method for manufacturing the pod 100 comprises a number of steps, some of which are exemplarily assigned reference signs S1, S2, S3, S4, S5 and S6 in
[0070] In the method, two sheet elements 200 are provided.
[0071] Each of the sheet elements 200 is made of a formable and preferably biodegradable and/or preferably (home-) compostable material. For example, the sheet 201 may be made of a formable and/or biodegradable and/or compostable material. For example, the material of the sheet elements 200 (or the sheet 201) may be formable by being stretchable (and/or deformable permanently) in traverse and longitudinal directions. For example, a suitable material for this purpose may be a formable paper material. The material of the sheet elements 200 (or the sheet 201) may comprise a formable paper material, preferably having a grammage between 80 g/m.sup.2 to 150 g/m.sup.2. For example, the formable paper material may be a Kraft paper. Preferably, the formable paper material may be exclusively made of cellulose fibres. The material of the sheet elements 200 may have a tensile strength between 2000 MPa and 30 000 MPa, preferably 26 000 MPa in the cross-direction of the paper material, and/or preferably 2600 MPa in the machine-direction of the paper material. Preferably, the sheet elements 200 may be configured to have an elongation at break in the range between 8% and 15% at a tensile strength between 2000 MPa to 40 000 MPa. Therein, elongation at break may generally be understood as the ratio between changed length and initial length after breakage of the test specimen, and can be used as a measure to quantify the resistance of a material to changes of the shape without breaking or crack formation. For example, the elongation at break can be determined by tensile testing following EN ISO 527. The work up to break of the material of the sheet elements 200 may be between 100 Nmm and 200 Nmm. For example, by providing the sheet elements 200 (or the sheet 201) with any of the aforementioned configurations, it is possible to provide the pod 100 with sufficient rigidity, stiffness and/or form-stability to build up pressure inside the pod 100 during the preparation of a beverage.
[0072] Preferably, the material of the sheet elements 200 may have a (laminated) multi-layer structure, which preferably may comprise at least one additional layer 212 (in addition to a formable paper layer 211). This exemplarily illustrated in the schematic cross-section of
[0073] Further, in the method, an opening 210 is cut (and/or punched) into at least one of the sheet elements 200. This is exemplarily shown in step S2 of
[0074] Moreover, in the method, the opening 210 is covered with a sheet material 300.
[0075] The sheet material 300 and the respective sheet element 200 (having the opening 210) are connected at a connection area 230. The connection may be established by sealing the respective elements to each other, for example by heat sealing or ultrasonic sealing. The state, in which the sheet element 200 (or sheet 201) is connected to the sheet material 300, is exemplarily shown in all Figures.
[0076] Preferably, the sheet material 300 may have any size, shape or form. For, example, in
[0077] The so connected (sealed) sheet material 300 forms a delivery wall 110 of the pod 100. Through the delivery wall 110 the beverage is dispensed from the pod 100 during the process of preparing the beverage. The delivery wall 110 is exemplarily shown in all Figures, but highlighted in
[0078] The sheet material 300 may be provided as a continuous foil, film, sheet or membrane or as a layered structure. Preferably, the sheet material 300 may be a biodegradable and/or (home-) compostable material. For example, the sheet material 300 may comprise a paper material, preferably having a grammage between 20 g/m.sup.2 and 100 g/m.sup.2 and/or more preferred comprising an aerated structure to provide softness to facilitate the sheet material's 300 perforation. Moreover, the sheet material 300 may comprise paper, parchment paper, (coated) cellophane, a (home- or industrial-) compostable film and/or a filter paper for filtering particles and residues of the substance from the prepared beverage. Alternatively or additionally, the sheet material 300 may comprise an oxygen barrier (e.g. less than 5 cc/m.sup.2-day) and/or moisture barrier. Preferably, the sheet material 300 may be configured to have an elongation at break in the range between 2% and 25% at a tensile strength between 250 MPa to 15 000 MPa.
[0079] The two sheet elements 200 are formed into the shape of a half-shell 101, 102, respectively, as exemplarily shown in step S4 of
[0080] The half-shells 101, 102 may have any shape or form. Preferably, the shape of the half-shells 101, 102 may correspond with the geometry of the pod holder. Examples for the geometry and design of the half-shells 101, 102 can be taken from
[0081] However, as exemplified by the Figures, before being formed into the shape of a half-shell, at least one of the sheet elements 200 (or at least one section of the sheet 201) may have a configuration where the opening 210 may be covered by the sheet material 300 and where the sheet element 200 (or at least one section of the sheet 201) and the sheet material 300 may be connected to each other.
[0082] The connection area 230 is pinched from opposite sides of the sheet element 200 when forming the respective half-shell 101, 102. Preferably, pinching the connection area 230 may be obtained by the aforementioned punch 410 being positioned on one side of the sheet element 200 and a counter-punch 420 being positioned on the other side of the sheet element 200 with respect to the punch 410. The punch 410 and the counter-punch 420 may be relatively movable with respect to each other and/or the sheet element 200 (sheet 201). This is exemplarily illustrated in
[0083] An injection wall 120 of the pod 100 for injecting a fluid into the pod 100 is formed. The injection wall 120 may interact or engage with injection elements of the beverage production machine during the beverage preparation process, through which a (hot, e.g. 60 to 120 degree Celsius) fluid (under pressure, e.g. 1 to 20 bar) may be injected into the pod 100. The injection wall 120 may be formed when forming one of the half-shells 101, 102 and preferably may be the one half-shell 101, 102 other than the half-shell 101, 102 comprising the opening 210 or the delivery wall 110. This is exemplarily shown in
[0084] A substance 105 required for the preparation of the beverage is provided. This is exemplarily illustrated in
[0085] The two half-shells 101, 102 are connected. By connecting the two half-shells 101, 102 they form a pod body 130 around the substance 105 to form the pod 100. The pod body 130 together with the delivery wall 110 and the injection wall 120 delimit a chamber containing the substance 105 for preparing the beverage upon interaction of the substance 105 with the fluid injected through the injection wall 120. This is exemplarily shown in
[0086] It has been surprisingly been found that it is also possible to configure the half-shells 101, 102 such that-at first-the two half-shells 101, 102 are separated (radially and/or axially) by a gap when surrounding the substance 105 before the step of connecting the two half-shells 101, 102. Therein, the size of the gap may depend on the volume of the substance 105. However, the half-shells 101, 102 may be configured such that the volume of the pod 100 corresponds to the volume of the substance 105 after the step of connecting the two half-shells 101, 102 so that the gap may be reduced or even eliminated upon connection of the two half-shells 101, 102. This may be a result of the pod manufacturing method of the invention comprising the step of pinching the connection area 230 since the material forming the pod body 130 is primarily stretched at portions thereof that are between the flange 140 and the opening 230. In comparison, the connection area 230 and delivery wall 110 have not undergone mechanical stress and thus, higher forces are required to stretch and plastically deform this section of the pod 100. Thereby, it is possible that the two half-shells 101, 102 stretch to match the volume and dimensions of the substance 105 under conditions typically present during the filling and connection process, which include the application of a vacuum during the connecting process. This effect may be advantageously supported by the substance 105 being compacted as it may act as a bending edge for stretching the half-shells 101, 102. In experiments, a gap extending up to 2 mm, preferably between 0.1 mm and 2 mm, was successfully reduced or even eliminated at the end of the connecting process. Therein, the configuration of the half-shells 101, 102, the substance 105 and/or the connection process may be such that at least one of the half-shells 101, 102, preferably the half-shell 101, 102 comprising the injection wall 120, may follow in shape and dimension at least a part of the contour of the compacted substance 105, to which it is adjacent in the pod 100. It is also conceivable that, before the step of connecting the two half-shells 101, 102, the half-shells 101, 102 may be formed such that they differ in height. Preferably, the half-shell 101, 102 comprising the injection wall 120 may have a greater height than the half-shell 101, 102 comprising the delivery wall 110. Naturally, it is also conceivable that no gap (0 mm) exists between the two half-shells 101, 102 at the beginning of the connecting process. In this configuration, the substance 105 may be (additionally) compacted during the connecting process.
[0087] A further aspect of the present invention relates to a pod, such as the above described pod 100, being produced in the above described method. The pod 100 is suitable and/or configured for preparing a beverage in a beverage production machine. The beverage production machine may comprise elements for opening the pod 100 under the effect of rising pressure of a fluid that is injected into the pod 100.
[0088] A further aspect of the present invention relates to a use of a pod, such as the above described pod 100, which is produced in the above described method, for preparing a beverage in a beverage production machine having a pod holder. Therein, the pod 100 may be placed inside the pod holder of the beverage production machine. The pod holder may be closed and the beverage may be prepared in the above-described way and may be released from the pod 100 by interaction of the delivery wall 110 with the opening elements of the beverage production machine.
[0089] The invention is not limited by the embodiments as described hereinabove, as long as being covered by the appended claims. All the features of the embodiments described hereinabove can be combined in any possible way and be provided interchangeably.