Capsules

Patent metadata

Field	Value
Publication number	US-11155377-B2
Application number	US-201815922361-A
Country	US
Kind code	B2
Filing date	Mar 15, 2018
Priority date	Oct 19, 2012
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

The present invention provides a method of assembling a filter element (8) with a cup-shaped capsule body (2) using a combined weld-head (70) and former (80), comprising the steps of positioning the filter element (8) at or near a mouth of the cup-shaped capsule body (2), moving the combined weld-head (70) and former (80) so as to contact and drive the filter element (8) into the cup-shaped capsule body (2), wherein, the filter element (8) is deformed by a sprung-loaded former (80) of the combined weld-head (70) and former (80) to form a cup-shaped filter element (56), and using a weld-head (70) of the combined weld-head (70) and former (80) to bond the cup-shaped filter element (56) to the cup-shaped capsule body (2). The present invention further provides a method of making a beverage capsule and a beverage capsule produced using this method.

First claim

The invention claimed is:

1. A method of assembling a filter element with a cup-shaped capsule body using a combined weld-head and former, comprising the steps of:
a) positioning the filter element at or near a mouth of the cup-shaped capsule body;
b) moving the combined weld-head and former so as to contact and drive the filter element into the cup-shaped capsule body;
c) wherein, during step b), the filter element is deformed by a spring-loaded former of the combined weld-head and former to form a cup-shaped filter element; and
d) using a weld-head of the combined weld-head and former to bond the cup-shaped filter element to the cup-shaped capsule body;
wherein the spring-loaded former can move toward the weld-head against a spring bias; and wherein a distance between the weld-head and a bottom of the spring-loaded former can vary during step d) by allowing the spring-loaded former to move toward the weld-head against the spring bias to limit movement of the former into the cup-shaped capsule body;
wherein the spring-loaded former comprises a cup-shaped forming body, wherein a cup-shaped portion of the forming body is wholly formed from a flexible material, and wherein the forming body comprises a base and an upwardly extending side wall.

2. A method as claimed in claim 1 , wherein a magnitude of a peak force applied to the filter element by the spring-loaded former is limited by allowing the spring-loaded former to move relative to the weld-head against a spring bias.

3. A method as claimed in claim 2 , wherein the magnitude of the peak force applied to the filter element is less than the force required to tear the cup-shaped filter element.

4. A method as claimed in claim 2 , wherein the magnitude of the peak force applied to the filter element is less than 45N.

5. A method as claimed in claim 2 , wherein the magnitude of the peak force applied to the filter element is less than 40N.

6. A method as claimed in claim 2 , wherein the magnitude of the peak force applied to the filter element is less than 30N.

7. A method as claimed in claim 1 wherein, at the end of step b), a portion of the cup-shaped filter element is held in contact with the cup-shaped capsule body by the weld-head.

8. A method as claimed in claim 1 wherein the cup-shaped filter element is bonded to the cup-shaped capsule body such that the cup-shaped filter element is suspended within the cup-shaped capsule body, with a base of the cup-shaped filter element being out of contact with a base of the cup-shaped capsule body.

9. A method as claimed in claim 1 , wherein, during step d), a portion of the cup-shaped filter element is bonded to the cup-shaped capsule body by using a heated portion of the weld-head.

10. A method as claimed in claim 9 , wherein, during step d), at least a portion of the cup-shaped capsule body is softened by the heated portion of the weld-head, thereby allowing the weld-head to move further into the cup-shaped capsule body.

11. A method as claimed in claim 10 , wherein during said further movement of the weld-head into the cup-shaped capsule body, further movement of the spring-loaded former into the cup-shaped capsule body is limited or avoided by allowing the spring-loaded former to move relative to the weld-head against the spring bias.

12. A method as claimed in claim 1 , wherein the spring-loaded former is slidably coupled to the weld-head, with a compression spring extending between the spring-loaded former and the weld-head.

13. A method as claimed in claim 1 , comprising the further step of:
e) withdrawing the combined weld-head and former from the cup-shaped capsule body.

14. A method as claimed in claim 13 , wherein during step e) the spring-loaded former flexes to aid decoupling of the spring-loaded former from the cup-shaped filter element.

15. A method of making a beverage capsule, comprising the steps of:
i) filling a portion of one or more beverage ingredients into a cup-shaped capsule body having a filter element bonded thereto by the method of claim 1 ; and
ii) closing and sealing the cup-shaped capsule body using a lid.

16. A method as claimed in claim 1 , wherein step d) includes using the weld-head to bond the cup-shaped filter element to the interior of the cup-shaped capsule body.

17. A method as claimed in claim 1 , wherein the side wall of the forming body has a generally frusto-conical shape.

18. A method as claimed in claim 1 , wherein a compression spring extends between the spring-loaded former and the weld-head, and wherein the compression spring is arranged within the cup-shaped forming body.

19. A combined weld-head and former for use in assembling a beverage capsule, comprising a weld-head and a former, wherein the former is spring-loaded;
wherein the spring-loaded former comprises a cup-shaped forming body, wherein a cup-shaped portion of the forming body is wholly formed from a flexible material, and wherein the forming body comprises a base and upwardly extending side wall.

20. A combined weld-head and former as claimed in claim 19 , wherein the spring-loaded former is slidably coupled to the weld-head, with a spring extending between the spring-loaded former and the weld-head.

21. Use of a combined weld-head and former as claimed in claim 19 to assemble a filter element with a cup-shaped capsule body.

22. A combined weld-head and former as claimed in claim 19 , wherein the side wall of the forming body has a generally frusto-conical shape.

23. A combined weld-head and former as claimed in claim 19 , wherein a compression spring extends between the spring-loaded former and the weld-head, and wherein the compression spring is arranged within the cup-shaped forming body.

Assignees

• Intercontinental Great Brands Llc

Inventors

• Hansen Nicholas
• Norton Mark

Classifications

• B65D85/8061 Primary

  Filters · CPC title

• B65B61/20

  for adding cards, coupons or other inserts to package contents (adding unpacking elements B65B61/18) · CPC title

• Y10T156/1033

  Flexible sheet to cylinder lamina · CPC title

• B65B29/02 Primary

  Packaging of substances, e.g. tea, which are intended to be infused in the package · CPC title

• B65D85/8046 Primary

  Pods, i.e. closed containers made only of filter paper or similar material · CPC title