PORTION CAPSULE AND METHOD FOR PRODUCING A PORTION CAPSULE

Abstract

A portion capsule having a base element for receiving an extraction product, and a method for producing the portion capsule. The portion capsule has a bottom region and a circumferential side wall, wherein the bottom region and the circumferential side wall form an interior space. At least the circumferential side wall includes a cellulose-based sheet and is formed by a full winding of the cellulose-based sheet about a base element axis.

Claims

1. A portion capsule comprising a base element having a bottom region and a circumferential side wall, wherein the bottom region and the circumferential side wall form an interior space, the circumferential side wall comprising a cellulose-based sheet, and wherein the circumferential side wall is formed by a full winding of the cellulose-based sheet about a base element axis.

2. The portion capsule according to claim 1, wherein the base element is cup-like and has a rectangular, particularly square, basic shape.

3. The portion capsule according to claim 1, wherein the cellulose-based sheet comprises a sealing layer or a barrier layer, or a sealing layer and a barrier layer.

4. The portion capsule according to claim 3, wherein the sealing layer or the barrier layer, or the sealing layer and the barrier layer continuously covers an entire region facing toward the interior space.

5. The portion capsule according to claim 1, wherein the bottom region is formed from a cellulose-based bottom region sheet.

6. The portion capsule according to claim 5, wherein the bottom region is beaded to the circumferential side wall.

7. The portion capsule according to claim 1, wherein the bottom region is formed from the cellulose-based sheet.

8. The portion capsule according to claim 7, wherein the bottom region is formed by a folded region of the cellulose-based sheet.

9. The portion capsule according to claim 1, further comprising a capsule cover sealing off the interior space formed by the bottom region and the circumferential side wall, or being configured for sealing off the interior space formed by the bottom region and the circumferential side wall, wherein the capsule cover is formed from a cellulose-based capsule cover sheet.

10. The portion capsule according to claim 1, further comprising a capsule cover sealing off the interior space formed by the bottom region and the circumferential side wall, or being configured for sealing off the interior space formed by the bottom region and the circumferential side wall, wherein the capsule cover is formed from the cellulose-based sheet.

11. The portion capsule according to claim 9, wherein the cellulose-based sheet forming the capsule cover comprises a sealing layer or a barrier layer, or a sealing layer and a barrier layer.

12. The portion capsule according to claim 11, wherein the sealing layer or the barrier layer, or the sealing layer and the barrier layer continuously covers the entire region of the capsule cover facing toward the interior space.

13. A method for producing a portion capsule comprising a base element having a bottom region and a circumferential side wall, the method comprising the following steps: providing a cellulose-based sheet; forming the circumferential side wall from the cellulose-based sheet, and wherein the step of forming the circumferential side wall comprises forming a full winding of the cellulose-based sheet about a base element axis.

14. The method according to claim 13, further comprising at least one of the following steps: providing a cellulose-based bottom region sheet, forming the bottom region from the cellulose-based bottom region sheet, and beading the bottom region to the circumferential side wall, or processing the cellulose-based sheet so that the cellulose-based sheet comprises a side wall part by means of which the full winding can be formed and a bottom region part from which the bottom region can be formed; providing a cellulose-based capsule cover sheet and forming the capsule cover from the cellulose-based capsule cover sheet, or processing the cellulose-based sheet so that the cellulose-based sheet comprises a side wall part by means of which the full winding can be formed and a capsule cover part from which the capsule cover can be formed.

15. The method according to claim 14, comprising the step of applying a sealing layer or a barrier layer, or a sealing layer and a barrier layer to at least one of the following sheets: the cellulose-based sheet, the cellulose-based bottom region sheet, the cellulose-based capsule cover sheet.

16. The portion capsule according to claim 10, wherein the cellulose-based sheet forming the capsule cover comprises a sealing layer or a barrier layer, or a sealing layer and a barrier layer.

17. The portion capsule according to claim 16, wherein the sealing layer or the barrier layer, or the sealing layer and the barrier layer continuously covers the entire region of the capsule cover facing toward the interior space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0150] Embodiment examples of the invention are described below using figures. Shown are:

[0151] FIG. 1 a side view of an example of a portion capsule including a base element and a capsule cover;

[0152] FIG. 2 a detail view of the base element;

[0153] FIG. 3 a detail view of the capsule cover;

[0154] FIG. 4a-c a further example of a base element (FIG. 4a), and the cellulose-based sheet (FIG. 4b) and the cellulose-based bottom region sheet (FIG. 4c) from which said element is formed;

[0155] FIG. 5a-b an example of a cellulose-based sheet (FIG. 5a) and an example of a cellulose-based bottom region sheet (FIG. 5b) for a base element having a square basic shape;

[0156] FIG. 6 a method for producing a coffee portion capsule ready for consumption.

DETAILED DESCRIPTION OF THE INVENTION

[0157] Identical reference numerals in the figures indicate identical or analogous elements.

[0158] The example of a portion capsule 1 according to FIG. 1 includes a base element 11 having a base element axis 15. The base element 11 shown has the shape of a cup, wherein the base element axis 15 is a cup axis. The portion capsule 1 further includes a capsule cover 21 attached along a circumferential flange 14 of the base element (cup) 11, wherein the base element 11 and the capsule cover 21 together form an outer capsule wall and define a capsule interior space. The base element 11 shown forms a slightly domed bottom region (capsule base) 16 and a circumferential side wall 12, as is per se known. The flange 14 shown is implemented as a flange on the circumferential side wall 12.

[0159] In the embodiment shown, the base element 11 and capsule cover 21 are formed from a cellulose-based sheet, more precisely a paper sheet, wherein the base element 11 is formed from a first cellulose-based sheet 2 and wherein the capsule cover 21 is formed from a second cellulose-based sheet, the cellulose-based capsule cover sheet 25.

[0160] In the embodiment shown, the capsule cover 21 is attached to the base element 11 by means of ultrasonic welding or gluing. Alternatively, thermal welding is also conceivable, for example. Thermal welding can take place, for example, using an embossment supporting the welding process. The embossment can be disposed particularly on a surface to be welded of the welding partners, that is, of the capsule cover 21 and/or of the base element 11.

[0161] For the case of ultrasonic welding, at least the area of the flange 14 facing toward the capsule cover 21 or at least one area of a circumferential cover flange 22 facing toward the flange 14 includes a material for becoming flowable under ultrasound and pressure. The material is disposed and/or the areas are shaped so that, no later than during ultrasonic welding, the material disposed on one piece (flange 14 or cover flange 22) makes at least partial contact with the facing area of the other piece (cover flange 22 or flange 14). If, for example, only the flange 14 of the base element 11 includes the material, then the material makes contact with the area of the cover flange 22 facing the flange 14 of the base element 11 no later than during the ultrasonic welding of the capsule cover 21 to the base element 11.

[0162] For example, the material can be disposed on the surface of the flange and/or on the surface of the circumferential cover flange 22. The material can, however, also be covered by at least one further layer through which the material penetrates during the ultrasonic welding process, or through which at least a part of the facing surface of the counterpart (flange 14 if the cover flange 22 includes the covered material, cover flange 22 if the flange 14 includes the covered material) penetrates during the ultrasonic welding process. The part can be a circumferential protrusion, for example.

[0163] The material can particularly be the liquid sealing layer (sealing layer 3 for short) described below. The barrier layer described below, being a gas transmission barrier layer in the embodiments shown, more specifically an oxygen barrier layer 4, can be a layer covering the material in the above sense.

[0164] FIG. 2 shows a detail view of the base element 11. The base element 11 is cup-like and has a square basic shape. That is, the base element 11 substantially has the shape of a cube, one of the six sides of the cube being missing and forming an opening 13. Extraction product can be introduced into the interior space of the base element 11 and thus into the interior capsule space via said opening 13. Other basic shapes, such as a round basic shape (base element having substantially the shape of a cylinder open on one flat side), are conceivable.

[0165] In the embodiment shown, the circumferential edge 14 to which the capsule cover 21 can be attached, the rounded edges, and at most slightly domed sides primarily deviate from the shape of a cube. Depending on how the bottom region 16 is connected to the circumferential side wall 12, further deviation from the shape of a cube is possible. This is particularly the case if the bottom region 16 is beaded to the circumferential side wall 12 or if the bottom region is applied to the circumferential side wall 12 analogously to the capsule cover. If, however for example, the bottom region 16 is formed by a simple folding over of the cellulose-based sheet 2 in comparison with beading, including an attaching area in any case and optionally a sealing area (e.g., in the area of the corners), then the additional deviation from the shape of a cube may be relatively small.

[0166] The circumferential side wall 12 of the base element 11 shown is implemented as a full winding of the cellulose-based sheet 2 about the base element axis 15. That is, the cellulose-based sheet 2 is disposed about the base element axis 15 so that a starting region and an end region of the cellulose-based sheet 2 overlap in a fixing region 9 of the winding. The starting region is permanently connected to the end region, for example in that the regions are glued to each other or connected by means of ultrasonic welding. The permanent winding thus implemented forms the circumferential side wall 12 of the base element 11.

[0167] In the fixing region 9, both the starting region and the end region include an area for bringing into contact with each other during fixing. For the case of fixing by means of ultrasonic welding, at least one of the areas includes a material for becoming flowable under ultrasound and pressure. The material is disposed and/or the areas are shaped so that, no later than during ultrasonic welding, the material disposed on one piece (starting region or end region) makes at least partial contact with the facing area of the other piece (end region or starting region). If, for example, only the end region includes the material, then the region makes contact with the area of the starting region facing toward the end region no later than during fixing by means of ultrasonic welding.

[0168] The material can be disposed, for example, on the surface of the starting region and/or on the surface of the end region. The material can, however, also be covered by at least one further layer through which the material penetrates during the ultrasonic welding process, or through which at least a part of the facing surface of the counterpart (starting region if the end region includes the covered material, end region if the starting region includes the covered material) penetrates during the ultrasonic welding process. The part can be a protrusion, for example.

[0169] The cellulose-based sheet 2, from which the circumferential side wall 12 is formed, includes a sealing layer 3 and an oxygen barrier layer 4 in the embodiment shown.

[0170] In the embodiment shown, the sealing layer 3 is a PLA layer and the oxygen barrier layer 4 is an SiO.sub.x layer.

[0171] The sealing layer 3 is—other than a potentially present bonding layer—directly disposed on the cellulose-based sheet 2, while the oxygen barrier layer 4 is—other than a potentially present bonding layer—directly disposed on the sealing layer 3.

[0172] The sealing layer 3 and oxygen barrier layer 4 are disposed, or the cellulose-based sheet 2 carrying the layers is wound about the base element axis 11, so that the sealing layer 3 and the oxygen barrier layer 4 are disposed toward the interior space of the base element 11 on the cellulose-based sheet 2.

[0173] The sealing layer 3 and oxygen barrier layer 4 are disposed so that the entire interior space bounded by the base element 11 is continuously coated by both of said layers.

[0174] Such an implementation of the cellulose-based sheet 2 and the layers present thereon can lead to only the end region including the material for becoming flowable under ultrasound and pressure, such that the material can make contact with the starting region no later than during the ultrasonic welding.

[0175] This is particularly the case when—as in the embodiment according to FIG. 2—the material for becoming flowable during the ultrasonic welding process is the material of the sealing layer 3. The oxygen barrier layer 4 is then a layer penetrated by the liquefied material of the sealing layer 3 and/or penetrated by the material of the counterpart (the starting region) during the ultrasonic welding process.

[0176] FIG. 3 shows a detail view of the capsule cover 21. In the embodiment shown, the capsule cover 21 is formed from the cellulose-based capsule cover sheet 25 and is separate from the cellulose-based sheet 2 from which the circumferential side wall 12 is formed prior to attaching the capsule cover 21 to the base element 11.

[0177] The capsule cover 21 shown includes the layer sequence of sealing layer 3 and oxygen barrier layer 4 shown in conjunction with the base element 11, wherein the layers are disposed on the cellulose-based capsule cover sheet 25 so that the closed interior space of the portion capsule 1 formed after attaching the capsule cover 21 to the base element 11 is continuously coated by said layers.

[0178] The capsule cover 21 includes a circumferential flange 22 matched to the flange 14 of the base element 11, so that the capsule cover 21 can seal off the base element 11 in a fluid-tight manner when appropriately attached.

[0179] The capsule cover 21 shown in FIG. 3 is not implemented as a simple sheet representing a two-dimensional object, other than the thickness of the sheet. Such two-dimensional capsule covers are known from the prior art in the form of films or plates.

[0180] Instead, the capsule cover 21 shown in FIG. 3 includes an outward dome 23. The dome 23 forms a flat region in the center thereof. The flat region is offset outward relative to a plane defined by the circumferential cover flange 22. The dome 23 and cover flange 22 are connected to each other by means of a transition region 24.

[0181] FIG. 4 shows an example of a base element 11 having the shape of a cup having a round basic shape. That is, the base element 11 substantially has the shape of a cylinder, wherein one flat side of the cylinder is open. The open, flat side defines the opening 13 for introducing the extraction product into the interior space of the base element 11 and thus into the interior capsule space. The cup is oriented along the base element axis 15, to be considered as the cup axis in the embodiment shown.

[0182] The base element 11 shown further includes a flange 14 circumferentially enclosing the opening 13. The flange 14 can be implemented in any one of the ways described above, except for the shape thereof (circular instead of square basic shape).

[0183] A capsule cover 21 can be implemented in any one of the ways described above, except for being matched to the shape of the flange 14 and the opening 13. The capsule cover 21 can be attached or attachable to the base element 11 in any one of the ways described above.

[0184] The circumferential side wall 12 of the base element 11 is formed by a cellulose-based sheet 2 forming a full winding about the base element axis 15. The cellulose-based sheet 2, the winding, and the fixing thereof in a fixing region 9 can—except for differences caused by the different shape of the base element 11—be implemented in one of the ways described above.

[0185] The bottom region 16 of the base element 11 is formed by a cellulose-based bottom region sheet 17 separate from the cellulose-based sheet 2 prior to forming the base element 11.

[0186] In the embodiment shown, the base element 11 includes a bead 8 on the side of the base element 11 opposite the opening 13.

[0187] The bead 8 is a bead between the cellulose-based sheet 2 forming the circumferential side wall 12 and the cellulose-based bottom region sheet 17 forming the bottom region 16. The bead 8 is implemented so that the bottom region 16 permanently closes off the base element 11 without openings or “leaks”.

[0188] In other words, the base element shown in FIG. 4a is a wound cup having a bottom region beaded to the circumferential side wall of the wound cup.

[0189] FIG. 4b shows the cellulose-based sheet 2 prior to winding about the base element axis 15.

[0190] The cellulose-based sheet 2 includes a side wall region 10 forming the circumferential side wall 12 after winding.

[0191] The side wall region 10 can include the starting region 31 described above and the end region 32 described above for fixing the winding in the fixing region 9.

[0192] At least the side wall region 10 includes the sealing layer 3 and the barrier layer 4 in the embodiment shown.

[0193] The end region 32 and/or the starting region 31 can include a different layer or sequence of layers than the remaining side wall region.

[0194] The cellulose-based sheet 2 shown includes a flange region 5 disposed and shaped so that the region forms the circumferential flange 14 after winding.

[0195] The cellulose-based sheet 2 shown includes a bead region 6 disposed and shaped so that the region, together with a corresponding bead region 18 of the cellulose-based bottom region sheet 17, can form the bead described above.

[0196] FIG. 4c shows the cellulose-based bottom region sheet 17 prior to beading to the cellulose-based sheet 2.

[0197] The cellulose-based bottom region sheet 17 includes a region 19 for forming the actual bottom region 16 of the base element 11 after beading.

[0198] The cellulose-based bottom region sheet 17 shown further includes the bead region 18. The region is disposed and shaped so that said region, together with the bead region 6 of the cellulose-based sheet 2, can form the bead described above.

[0199] In the embodiment shown, at least the region 19 forming the actual bottom region 16 of the base element 11 after beading includes the sealing layer 3 described above and the oxygen barrier layer 4 described above.

[0200] FIG. 5a shows a cellulose-based sheet 2 prior to winding about the base element axis 15, as an alternative shape to the cellulose-based sheet 2 shown in FIG. 4b. The cellulose-based sheet 2 shown is configured so that the sheet forms the circumferential side wall 12 and the circumferential flange 14 of a base element 11 having a square basic shape after winding, as shown as an example in FIG. 2.

[0201] In comparison to the cellulose-based sheet 2 shown in FIG. 4b, the cellulose-based sheet 2 shown in FIG. 5a includes a side wall region 10 subdivided into four partial regions by intended folds 7. The four partial regions are disposed so that the regions form the four flat sides of the circumferential side wall 12 after winding.

[0202] The flange region 5 is further divided into four parts matched to the four partial regions of the side wall region 10. The four parts are disposed and configured so that the parts can run at an angle, not equal to zero, relative to the base element axis 15 and can form the circumferential flange 14 after winding the cellulose-based sheet 2 about the base element axis 15.

[0203] The circumferential flange 14 typically runs at about 90° from the base element axis 15, as shown in FIGS. 1, 2, and 4a. That is, the circumferential flange 14 is disposed at least approximately in one plane, the normal thereof running parallel to the base element axis 15.

[0204] FIG. 5b shows a cellulose-based bottom region sheet 17, not to scale, matched to the cellulose-based sheet 2 shown in FIG. 5a and able to be attached to the same by means of a bead 8.

[0205] The cellulose-based bottom region sheet 17 shown includes a square region 19 for forming the actual bottom region 16 of the base element 11 after beading.

[0206] The bead region 18 is further divided into four partial regions, matched to the four partial regions of the side wall region 10. The four partial regions of the bead region 18 are disposed and configured so that the partial regions can be folded away from the square region 19.

[0207] The four partial regions of the bead region 18 are disposed and shaped so that the regions, together with the bead region 6 of the cellulose-based sheet 2, can form the bead described above.

[0208] FIG. 6 shows schematically an example method for producing a portion capsule 1 ready for consumption. Optional steps are also shown in the schematic.

[0209] The example method shown according to FIG. 6 relates particularly to a portion capsule 1 ready for consumption and including a bottom region 16 beaded to the circumferential side wall 12 and a capsule cover 21 applied by means of ultrasonic welding to a circumferential flange 14 of the circumferential side wall 12.

[0210] In a first phase of the method, the elements required for producing a non-filled portion capsule are provided. In particular: [0211] The cellulose-based sheet 2 is provided from which the circumferential side wall 12 and the circumferential flange are ultimately formed. [0212] The cellulose-based bottom region sheet 17 is provided from which the bottom region 16 is ultimately formed. [0213] The cellulose-based capsule cover sheet 25 is provided from which the capsule cover 21 is ultimately formed. [0214] The sealing layer 3 and the oxygen barrier layer 4 are applied to the cellulose-based sheets.

[0215] Prior to or after applying the sealing layer 3 and the oxygen barrier layer 4, the cellulose-based sheets can be cut to size, provided with fold regions (if needed), preformed (if needed, such as capsule covers), and/or provided with an additionally processed starting region 31 and/or end region 32 (if needed). In addition or alternatively, one or more attaching areas and/or one or more sealing areas can be prepared.

[0216] In a second phase of the method, the base element 11 is formed. To this end, the method includes a step wherein the cellulose-based sheet 2 is deformed so as to form a full winding about an axis. The axis is the base element axis 15 hereafter.

[0217] Depending on the shape of the portion capsule to be produced and depending on the cut of the cellulose-based sheet 2 and the cellulose-based bottom region sheet 25, the second phase of the method includes a beading step prior to, during, or after the step of winding. In the beading step, the cellulose-based bottom region sheet 17 is beaded to the cellulose-based sheet 2, so that after the step of winding, the bottom region 16 closes off one end of the circumferential wall 12.

[0218] The second phase of the method further typically includes a step wherein the winding is stopped so that the winding is permanent. This step is typically in addition to the step of beading.

[0219] In a third phase of the method, the base element 11 available after the second phase is filled with extraction product, for example coffee.

[0220] In a fourth phase of the method, the capsule cover 21 is attached to the filled base element 11 in order to seal off the same and to produce the portion capsule 1 ready for consumption.

[0221] To this end, the fourth phase includes a step wherein the capsule cover 21, potentially preformed as described in conjunction with FIG. 3, is positioned on the base element 11 so that the cover seals off the opening 13 and that the circumferential flange 14 of the base element 11 makes contact circumferentially with the cover flange 22.

[0222] The fourth phase further includes a step wherein the flanges of the base element 11 and of the capsule cover 21 contacting each other are subjected to pressure and ultrasound between an anvil and a sonotrode, so that a weld circumferential to the former opening 13 arises between the flange 14 of the base element 11 and the cover flange 22.

[0223] The method can include further phases and steps. For example, a cleaning step, applying inscriptions and/or codes, coloring, etc.

REFERENCE NUMERALS

[0224] 1. Portion capsule

[0225] 2. Cellulose-based sheet (paper)

[0226] 3. Liquid sealing layer (PLA)

[0227] 4. Gas transmission barrier layer (SiO.sub.x)

[0228] 5. Flange region

[0229] 6. Bead region

[0230] 7. Intended fold

[0231] Bead

[0232] 9. Fixing region (of the winding)

[0233] 10. Side wall region

[0234] 11. Base element

[0235] 12. Circumferential side wall

[0236] 13. Opening

[0237] 14. Flange of the circumferential side wall

[0238] 15. Base element axis

[0239] 16. Bottom region (capsule base)

[0240] 17. Cellulose-based bottom region sheet

[0241] 18. Bead region

[0242] 19. Region forming bottom region 16 after beading

[0243] 21. Capsule cover

[0244] 22. Circumferential cover flange

[0245] 23. Dome

[0246] 24. Transition region

[0247] 25. Cellulose-based capsule cover sheet

[0248] 31. Starting region

[0249] 32. End region