CONTAINER FOR BEVERAGE OR FOODSTUFF PREPARATION MACHINE
TECHNICAL FIELD
The present disclosure relates generally to electrically operated beverage or foodstuff preparation systems, with which a beverage or foodstuff is prepared from a pre-portioned capsule.
BACKGROUND
Systems for the preparation of a beverage comprise a beverage preparation machine and a capsule. The capsule comprises a single-serving of a beverage forming precursor material, e.g. ground coffee or tea. The beverage preparation machine is arranged to execute a beverage preparation process on the capsule, typically by the exposure of pressurized, heated water to said precursor material. As part of this preparation process, the capsule interacts with the machine by a series of complex interactions to load, process and eject the capsule, by various mechanisms of the machine interacting principally with a flange portion of the capsule. Processing of the capsule in this manner causes the at least partial extraction of the precursor material from the capsule as the beverage.
This configuration of beverage preparation machine has increased in popularity due to 1 ) enhanced user convenience compared to a conventional beverage preparation machines (e.g. compared to a manually operated stove-top espresso maker) and 2) an enhanced beverage preparation process which is optimised in a manner specific to the capsule and to the precursor material.
Due to the complex interactions of the capsule with the machine and the exposure to pressurized, heated water, to date only an aluminium based capsule has been implemented with a high degree of reliability. Various attempts have been made to replace the Aluminium based material with alternative materials. For example, bioplastics made from corn-starch or dried pulp made from sugarcane fiber were proposed to be used as capsule materials. However, these materials have been found to be prone to sticking in the machine or to cause other material related errors or do not provide a reliable oxygen / moisture barrier for the precursor material in comparison to Aluminium. It would be desirable to be able to implement the capsule with other materials, particularly with a biodegradable and/or compostable material, with the associated advantages of the Aluminium material. It is therefore an object of the present invention to provide a capsule with a configuration and design that facilitates the use of biodegradable and/or compostable materials while maintaining and/or exceeding quality and continuity standards of the capsule itself and of the prepared beverage as set by a comparable Aluminium capsule.
SUMMARY
The present disclosure provides a container for containing a precursor material for use with a machine for preparing a beverage or foodstuff. In embodiments, the container comprises a body portion having a storage portion for storage of the precursor material and a flange portion coupled to the storage portion. In embodiments the flange portion is separate from the body portion.
In embodiments, a cavity of the storage portion is formed from extensible paper-based sheet material (e.g. a blank) by drawing to provide wrinkling portions in a drawn state, and the flange portion includes connecting members connected to the wrinkling portions to retain the drawn state.
By implementing the storage portion to be formed by drawing a blank of paper material to a drawn state, in which wrinkling portions are arranged at a periphery and these are fixed in position by the flange portion, two different materials may be implemented for the flange portion and the storage portion, which may enable optimisation of the container compared to the use of a single integral material. For example, the two materials may be implemented as a thin and/or high rigidity flange portion, which interacts with machine mechanisms for one or more of: loading; ejection; code reading, and; sealing, and a thicker storage portion for precursor material retention and preparation process/handling durability.
As used herein the term “extensible” in respect of the paper-based material may refer to a material which can undergo elongation, whilst becoming thinner (e.g. plastic deformation about a curved axis) when subject to tensile forces. A degree of extensibility may be limited by the tensile strength of the material. The degree of extensibility may be defined as a stretch at break in a machine direction of 1 .5 - 3 or 7%.
As used herein the term “drawing” in respect of the paper-based material may refer to the process of using tensile forces to elongate the paper-based material, so that it stretches and becomes thinner to achieve a desired shape. The drawing is in respect of sheet material and is defined as a plastic deformation over a curved axis. A blank of sheet material in an undrawn state (e.g., a planar state) may be subject to drawing to a drawn state, in which wrinkling portions may be present as a result of said drawing.
As used herein the term “sheet material” may refer to a material arrangement with a comparatively thin thickness and a large in-plane length and width. The sheet material may be supplied as individual sheets or as a continuous web. The sheet material may refer to a blank, or the blank may be formed by the sheet material (e.g. by cutting).
As used herein the term “blank” may refer to a sheet material formation from which portions (e.g. the storage portion and/or flange portion) of the container are formed. The blank may be cut from sheet material. The blank may be cut to size, e.g. so that no further cutting steps are required for implementation of the portion of the container.
As used herein the term “cellulosic material” or “cellulose-based material” may refer to conventionally woody (from soft wood and/or hard wood species) and/or non-woody materials. Examples of softwood are Pine, Spruce, Redwood etc. Examples of hardwood are Maple, Oak, Ash, Eucalyptus, Maple, Birch, Walnut, Beech etc. Examples of non-woody origin cellulose-based material are rice, manila hemp, sisal, jute, bamboo, maize, sugar cane, sugar cane residues (bagasse), banana peels, coffee ground. These cellulosic materials may be bleached and unbleached and may include a regenerated or reconstituted cellulose. As used herein the term “natural cellulosic material” may refer to conventionally woody materials or non-woody materials, which are not regenerated. As used herein the term “reconstituted or regenerated cellulosic material” may refer natural cellulosic material subject to processing that comprises reconstitution or regeneration, examples include rayon and lyocell.
As used herein the term “paper-based” may refer to a paper cellulose-based material. Said material may be produced by mechanically and/or chemically processing cellulose. The fibres maybe derived from one or more of: wood; rags; grasses, or; other vegetable sources. The material may be formed by the fibres in water by draining the water through a fine mesh leaving the fibre evenly distributed on the surface, followed by pressing and drying. The paper-based material may be a non-laminated material, e.g. when implemented for drawing.
As used herein the term “wrinkling portions” or “crimped portions” may refer to portions that are: wavy; bent; creased, and; pinched, in an overlapping manner without cutting. The wrinkling portions are formed as a result of drawing. As used herein the term “storage portion” may refer to a portion of the container that comprises a cavity for storage of the precursor material. The storge portion may be hemispherical in shape, including partially hemisphere.
As used herein the term “flange portion” may refer to a portion of the container that comprises a flange (e.g. a thin ring) for one or more processes implemented by the machine comprising: loading; processing, including sealing, and; and ejection. The flange portion may present as a thin, rigid gasket.
As used herein the term “closing member” may refer to an arrangement that closes the storage portion and may comprises a flexible membrane or other rigid body. An example of a suitable membrane is provided in WO2021/145763.
In embodiments, an entire periphery of the storage portion comprises wrinkling portions. By arranging, in the drawn state, the wrinkling portions to extend fully around the edge of the blank (e.g. with an even size and/or distribution) an evenly shaped hemisphere may be formed. The wrinkling portions may be formed without cutting and be evenly distributed, which may improve a strength of the storage portion.
In embodiments, the wrinkling portions extend from the periphery to at least 40% or 50% or 60% or 80% (e.g. in a depth direction) of the depth of the storage portion. By having the wrinkling portions to extend a substantial depth (e.g. at least 40% or 50% or 60% or 70% or 80% of the depth to either the full depth or 90% or 95% depth), a suitable hemispherical shape may be created by the drawing process.
In embodiments, the cavity is entirely formed by drawing without individual flaps. Individual flaps defined by cuts and folds may reduce strength of the storage portion or may provide a less representative hemispherical shape.
In embodiments, the storage portion is drawn directly (e.g. without an intermediate of subsequent step of folding) from the blank. By drawing the storage portion from sheet material, it maybe conveniently formed, e.g. by cutting multiple blanks from the same sheet.
In embodiments, the paper-based material of the storage portion (formed by drawing) has a thickness of 60 - 150 or 200 micron and between 80 and 180 gsm and may have a stretch at break in a machine direction of 1 .5 - 7%.
In embodiments, the paper-based material is pressed to the drawn state by 500 - 1500 N. In embodiments, the connecting members are arranged as individual flaps that extend from a periphery of the storage portion. In embodiments, the flaps extend from the periphery of the storage portion to at least 40% or 50 % or 60% of a depth of the wrinkling portions. By arranging the flaps to extend over a substantial portion of the wrinkling portions, the wrinkling portions may be conveniently held in the drawn state by the flaps. In embodiments, the flaps extend 3 mm to 20 mm in the depth direction. In embodiments, there are 5 - 15 flaps.
In embodiments, the connecting members include cut-out portions. By having cut-out portions that define enclosed regions within each connecting member, material usage may be reduced and/or the cut-out regions may facilitate improved adhesion of the connecting members to the storage portion, e.g. by a liner member.
In embodiments, the connecting members are adhesively bonded to the storage portion. By adhering the connecting members directly to the storage portion, e.g. by ultrasonic welding or a contact adhesive, a strong connecting may be provided, which retains the cripped portions of the drawn state.
In embodiments, the connecting members are adhesively bonded via a heat activated lacquer applied to the connecting members and/or to the storage portion. Such an adhesion may aid in positioning the connecting members relative the storage portion prior to adhesion with the liner member and/or may enhance a strength of a connection of the connecting members to the storage portion.
In embodiments, the container comprises a liner member, which is arranged to line an interior of the storage portion (e.g. over the entire interior, that may comprise the interior surface of the storage portion and the connecting members) and to bond (e.g. to further bond) the connecting members to the storage portion. By arranging a liner member over the interior of the storage portion, the container may be lined with a material which is food safe, moreover, the liner may be used to fix adhesively the connecting members to the storage portion, whilst retaining the wrinkling portions of the drawn state.
In embodiments, the container comprises a closing member arranged to connect to the flange portion (e.g. over the liner member rather than directly) to close the storage portion.
In embodiment, wherein the container is axis symmetric (e.g. fully axis symmetric) about an axis of rotation. In embodiments, the container is configured to withstand a maximum rotation of 7000 rpm and typically 3500 - 6000 rpm and/or a centripetal force of 500 N, which is applied to the storage portion by liquid and the precursor material during processing by the machine. In embodiments, the body portion is configured to withstand an extraction pressure (from the pump and from centrifugation) of about 2.5 bar.
In embodiments, the container comprises a separate (e.g. a separate component) stiffening ring arranged connected to the flange portion to stiffen a periphery of the flange portion. By implementing a separate stiffening ring, rather than for example a stiffening ring that is integral to the flange portion and may be is rolled therefrom, the flange portion can be formed from an alternative material that most suited to stiffening the flange portion, hence less material restrictions are imposed. The stiffening ring may provide additional stiffness to the flange portion and storage portion (e.g. for handling, processing and/or ejection from the machined. The stiffening ring may provide a surface for sealing in the processing unit of the machine.
As used herein the term “stiffen” may refer to an increase in flexural rigidity of the container due to a presence of the stiffening ring compared to an equivalent container absent the stiffening ring. For example, a container with out a stiffening ring may have a flexural rigidity of less than 2N, and with the stiffening ring a flexural rigidity may be about 6N, hence an increase of at lest 2 - 4N or at least 100%.
In embodiments, the stiffening ring is adhesively bonded to the flange portion, e.g. by a heat activated lacquer applied to the flange or ultrasonic welding or a contact adhesive. By adhesively fixing the stiffening ring to the flange portion, a convenient assembly process may be implemented, moreover, load transfer between the stiffening ring and flange portion may be effective.
In embodiments, the stiffening ring is connected to an upper surface of the flange portion, wherein the upper surface faces away from the storage portion. Such an arrangement may define a cavity for receiving a closing member and/or may provide a strong bond, e.g. compared to an arrangement with the stiffening ring on and peripheral edge of the flange portion.
In embodiments, the container comprises a liner member, which is: arranged to line an interior of the storage portion; arranged over an upper face of the flange portion that faces away from the storage portion arranged over the stiffening ring. By arranging a liner member to cover the stiffening ring and flange portion, the capsule may be food safe, in particular the stiffening ring and its bonding are not required to be food safe since they are not exposed. Moreover, the liner member may bond (e.g. further bond) the stiffening ring to the flange portion. In embodiments, . In embodiments, the liner member is arranged so as not to extend over an opposed lower face of the flange portion that faces the storage portion.
In embodiments, the liner member extends around the stiffening ring and to the upper surface of the flange portion at a periphery of the flange portion. By arranging the liner member to extend from the upper surface proximal the storage portion, around the stiffening ring, and back to the upper surface at proximal a peripheral edge, the stiffening ring may be fully sealed by the liner member and the liner member may provide additional securing of the stiffening ring to the flange portion.
In embodiments, the liner is not arranged over an opposed lower face of the flange portion that faces the storage portion. Such an arrangement may interfere with a code arranged on said lower surface or may introduce material wastage.
In embodiments, the flange portion is formed of a paper-based material. In embodiments, the paper-based material of the flange portion has a thickness of less than 200 or 190 microns with an optional minimum of above 50 or 100 microns and/or a grams per square metre (GSM) of 80 -120. Such an arrangement may ensure compatibility with machines that are designed for aluminium based capsules, which are comparatively thin due to the strength of said material being greater.
In embodiments, wherein the stiffening ring is formed of: a solid strip of paper-based material, which may be cut from a tube, e.g. it may have a rectangular section. By forming the stiffening ring from a solid piece of material, it may have comparable strength to a rolled aluminium ring. By forming the stiffening ring by cutting from a tube, it may be conveniently/precisely formed.
In embodiments, the stiffening ring has an outer diameter of 55 - 65 mm, a thickness of 1 .2 - 2.5 mm, and a depth of 1 .2 - 2.5 mm.
In embodiments, the container is axis symmetric (e.g. fully axisymmetric); and has a machine- readable code arranged on a lower surface of the flange portion, which faces towards the storage portion, for reading by relative rotation about said axis between the container and a code reader of the machine. By arranging a code on a lower surface and the stiffening ring on an upper surface, the stiffening ring and its bonding to the flange portion may not disrupt a code area.
In embodiments, the container comprises a closing member arranged to connect (e.g. via the liner member) to the flange portion to close the storage portion, wherein the closing member is arranged to extend up to and sit within a cavity defined by the stiffening ring. By arranging the closing member in a lined cavity defined by the stiffening ring, a secure bonding of the closing member to the storage portion may be achieved.
In embodiments, the storage portion is formed from a paper-based material and comprises in a hemispherical state a hemispherical cavity formed of flaps. In embodiments, the flaps extend in a depth direction, and adjoin each other in a hemispherical state. In embodiments, the flange portion includes connecting members to retain the storage portion in the hemispherical state. By arranging flaps that extend in a depth direction, which adjoin each other in a hemispherical state, a hemisphere may conveniently be formed from a blank of sheet material, which is retained in said configuration by the connecting members of the flange portion.
As used herein the term “hemispherical” may refer to a geometric arrangement that is shaped like half a sphere. The curvature may be exactly spherical or generally spherical. Hence hemispherical may refer to cup shaped but without a flat bottom or with a relatively small flat bottom e.g. any such flat bottom may be less than 40% or 30% or 20% of the total radii. Hence hemispherical may refer to cup shaped but without a flat sides or with a relatively small flat sides proximal the flange portion e.g. any such flat sides may be less than 40% or 30% or 20% of the total depth.
In embodiments, there are more than 8 flaps of the storage portion, e.g. 10 - 15. By having a large number of flaps, a hemispherical shape may be accurately formed.
In embodiments, the flaps extend from distal a height of a base of the storage portion to a periphery of the storage portion.
In embodiments, the hemispherical shaped cavity is formed by bending of the flaps without forming fold lines. By forming the hemispherical shape by bending without introducing fold lines, the hemispherical shape may be more accurate.
In embodiments, the hemispherical shape is formed by pressing the paper-based material to have a flat or curved base.
In embodiments, the hemispherical shape is formed by pressing the paper-based material to have a flat or curved base, e.g. by pressing the fibres in a mould which may facilitate folding of the flaps. In embodiments, the blank comprises a circular central portion to form a base of the hemisphere, the circular central portion delineated by vertices; the flaps extending radially at proximal ends from the vertices, to a distal end at the periphery of the blank, wherein cut-out region interpose the flaps which have a v-shape. Such an arrangement of blank may be conveniently cut from sheet material and processed to the hemispherical shape.
In embodiments, the periphery of the blank at a distal end of the flap comprises linear peripheral edge. With such an arrangement a hemispherical shape may be accurately formed and/or a convenient connection to the flange portion may be achieved.
In embodiments, proximal the distal end the flap comprises parallel edges to provide a region for selecting a depth dimension of the hemispherical shaped cavity. Such an arrangement of blank may enable convenient sizing of a depth of the storage portion and consequently its capacity.
In embodiments, the storage portion (formed by pressing flaps) is formed of a paper-based or compact board-based material and may have a thickness of 100 microns to 1 mm, and may be from 100 gsm to 1000 gsm.
In embodiments, the connecting members of the flange portion are adhesively bonded (e.g. via a heat activated lacquer applied to the connecting or ultrasonic welding or a contact adhesive) to the flaps.
In embodiments, the connecting members are connected to the flaps of the storage portion in the hemispherical state by a liner member arrange to line the interior of the storage portion. The liner member may bond (e.g. further bond) the flaps and connecting members in the hemispherical state.
In embodiments, the connecting members are positioned to expose connecting edges between the flaps (e.g. directly adjoining flaps), and a liner member is arranged to line the interior of the storage portion and the connecting edges. By exposing the connecting edges directly to the liner, structural strength may be optimised.
In embodiments, the storage portion includes crushed regions formed in the flaps of the paperbased material. The crushed regions can be arranged to facilitate curving of the flaps to the hemispherical state, e.g. they may reduce a flexural rigidity of the flaps, which may be achieved by a thickness reduction, e.g. by at least a 10% or 20% reduction. In embodiments the container is biodegradable as defined with reference to EN 13432:2000 (including anaerobic conditions, disintegration etc) and/or ISO 14852:1999 (aerobic conditions).
The present disclosure provides a system comprising one or more containers of any preceding embodiment or another embodiment disclosed herein, and a machine for preparing a beverage and/or foodstuff from the containers. In embodiments, the machine includes: a processing unit for processing precursor material of the container, and; electrical circuitry to control the processing unit to process the container.
The present disclosure provides a set of containers according to any preceding embodiment or another embodiment disclosed herein, wherein the storage portions of the containers have a different depth dimension to enable containment of different volumes of precursor material. The set may be implemented as part of the preceding system.
The present disclosure provides use of the container of any of any preceding embodiment, or another embodiment disclosed herein for a machine for preparing a beverage and/or foodstuff.
[Method of forming body portion]
The present disclosure provides a method of forming a body portion of a container. The method may implement the features of any preceding embodiment, or another embodiment disclosed herein.
In embodiments, the method comprises: arranging an extensible paper-based sheet material over a former; drawing the paper-based sheet material over the former to a drawn state in which crimped portions form a storage portion; connecting a separate flange portion with connecting members to the wrinkling portions to retain the storage portion in the drawn state.
In embodiments, the method comprises adhesively connecting the connecting members to the storage portion via an adhesive, e.g. a heat activated lacquer applied to the connecting members or ultrasonic welding or a contact adhesive.
In embodiments, the method comprises connecting the connecting members arranged as individual flaps to extend from a periphery of the storage portion into the storage portion.
In embodiments, the method comprises retaining the storage portion in the drawn state with low pressure (e.g. a vacuum) as the connecting members are connected to the storage portion. In embodiments, the method comprises applying a liner member to line an interior of the storage portion and the connecting members to connect the connecting members to the storage portion.
In embodiments, the method comprises: arranging a blank of paper-based sheet material (which may comprise flaps) over a former; pressing the blank into the former to a hemispherical state in which flaps which extend in a radial direction and directly adjoin each other, and; connecting a flange portion with connecting members to the flaps to retain the storage portion in the hemispherical state.
In embodiment, the method comprises forming crushed regions prior to pressing into the former. The crushed regions may be arranged to facilitate forming with the former, e.g. to make the flaps more flexible, and may be arranged as one or more rings.
[Method for of forming a container]
The present disclosure provides method of forming a container. The method/container may implement the features of any preceding embodiment, or another embodiment disclosed herein. The method may implement the preceding method (or other method disclosed herein) of forming a body portion of a container.
In embodiments, the method comprises: connecting a flange portion to a storage portion, and; connecting a stiffening ring to the flange portion to stiffen the flange portion (e.g. before or after connecting a flange portion to a storage portion).
In embodiments, the method comprises cutting the stiffening ring from a tube of material.
In embodiments, the method comprises arranging a liner member to line an interior of the storage portion and over the flange portion and the stiffening ring. In embodiments, the method comprises terminating the liner member so as not to extend over an opposed lower face that faces the storage portion.
In embodiments, the method comprises filling the storage portion with precursor material.
In embodiment, the method comprises arranging a closing member over the liner member, e.g. to close the storage portion.
In embodiments, the method comprises arranging the closing member to extend up to and sit within a cavity defined by the stiffening ring. In embodiments, the method comprises arranging the liner member to extend around the stiffening ring and back to the flange portion at a periphery of the flange portion.
The present disclosure provides a container formed by the method of any preceding embodiment or another embodiment disclosed herein.
The present disclosure provides a manufacturing line arranged to form a container by the method of forming a container according to any preceding embodiment or another embodiment disclosed herein.
[Method of preparing a beverage]
The present disclosure provides a method of preparing a beverage and/or foodstuff using the machine and container of any preceding embodiment, or another embodiment disclosed herein. The method may comprise control of a processing unit to process the container, e.g. to extract the beverage and/or foodstuff therefrom.
The preceding summary is provided for purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the abovedescribed features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description of Embodiments, Brief Description of Figures, and Claims.
BRIEF DESCRIPTION OF FIGURES
Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following detailed description of embodiments in reference to the appended drawings in which like numerals denote like elements.
Figure 1 is a block system diagram showing an embodiment system for preparation of a beverage or foodstuff or a precursor thereof.
Figure 2 is a block system diagram showing an embodiment machine of the system of figure 1 .
Figure 3 is an illustrative diagram showing an embodiment fluid conditioning system of the machine of figure 2. Figures 4A and 4B and 5 are illustrative diagrams showing an embodiment container processing system of the machine of figure 2.
Figure 6 is a block diagram showing embodiment control electrical circuitry of the machine of figure 2.
Figure 7 is a side view of an illustrative diagram showing embodiment container of the system of figure 1.
Figure 8 is a plan view showing embodiment blank for forming the container of figure 7.
Figure 9 is a perspective view showing an embodiment storage portion for the container of figure 7.
Figure 10 is an exploded perspective assembly view showing an embodiment of the container of figure 7.
Figure 1 1 is a perspective view showing an embodiment assembly of a storage portion, flange portion and stiffening ring of the container of figure 7.
Figure 12 is a side view showing an embodiment connecting member of the container of figure 7.
Figure 13 is a perspective view showing an embodiment assembly of a storage portion, flange portion and stiffening ring of the container of figure 7.
Figure 14 is an exploded perspective assembly view showing an embodiment of the container of figure 7.
Figure 15 is a plan view showing an embodiment of the container of figure 7.
Figures 16 - 25 are illustrative diagrams showing embodiment manufacturing processes for the container of figure 7.
Figure 26 is a perspective view showing embodiment blank for forming the container of figure 7.
Figure 27 is a perspective view showing an embodiment storage portion for the container of figure 7.
Figure 28 is an exploded perspective assembly view showing an embodiment of the container of figure 7. Figure 29 is a perspective view showing an embodiment assembly of a storage portion, flange portion and stiffening ring of the container of figure 7.
DETAILED DESCRIPTION OF EMBODIMENTS
Before describing several embodiments of the system, it is to be understood that the system is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the system is capable of other embodiments and of being practiced or being carried out in various ways.
The present disclosure may be better understood in view of the following explanations:
As used herein, the term “machine” may refer to an electrically operated device that: can prepare, from a precursor material, a beverage and/or foodstuff, or; can prepare, from a pre-precursor material, a precursor material that can be subsequently prepared into a beverage and/or foodstuff. The machine may implement said preparation by one or more of the following processes: dilution; heating; cooling; mixing; whisking; dissolution; soaking; steeping; extraction; conditioning; infusion; grinding, and; other like process. The machine may be dimensioned for use on a work top, e.g. it may be less than 70 cm in length, width and height. As used herein, the term “prepare” in respect of a beverage and/or foodstuff may refer to the preparation of at least part of the beverage and/or foodstuff (e.g. a beverage is prepared by said machine in its entirety or part prepared to which the end-user may manually add extra fluid prior to consumption, including milk and/or water).
As used herein, the term "container" or “capsule” may refer to any configuration to contain the precursor material, e.g. as a single-serving, pre-portioned amount. The container may have a maximum capacity such that it can only contain a single-serving of precursor material. The container may be single use, e.g. it is physically altered after a preparation process, which can include one or more of: perforation to supply fluid to the precursor material; perforation to supply the beverage/foodstuff from the container; opening by a user to extract the precursor material. The container may be configured for operation with a container processing unit of the machine, e.g. it may include a flange portion for alignment and directing the container through or arrangement on said unit. The container may include a rupturing portion, which is arranged to rupture when subject to a particular pressure to deliver the beverage/foodstuff. The container may have a closing member, e.g. a membrane, for closing the container. The container may have various forms, including one or more of: frustoconical; cylindrical; disk; hemispherical; other like form. The container may be formed from various materials, such as metal or plastic or paper a combination thereof. The material may be selected such that it is: food-safe; it can withstand the pressure and/or temperature of a preparation process. The container may be defined as a capsule, wherein a capsule may have an internal volume of 10 - 100 ml. The capsule includes a coffee capsule, e.g. a Nespresso® capsule (including a Classic, Professional, Vertuo), Nescafe® Dolce Gusto capsule or other capsule. The container may be defined as a receptacle for end user consumption therefrom.
As used herein, the term “external device” or "external electronic device" or “peripheral device” may include electronic components external to the machine, e.g. those arranged at a same location as the machine or those remote from the machine, which communicate with the machine over a computer network. The external device may comprise a communication interface for communication with the machine and/or a server system. The external device may comprise devices including: a smartphone; a PDA; a video game controller; a tablet; a laptop; or other like device.
As used herein, the term “server system” may refer to electronic components external to the machine, e.g. those arranged at a remote location from the machine, which communicate with the machine over a computer network. The server system may comprise a communication interface for communication with the machine and/or the external device. The server system can include: a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.
As used herein, the term “system” or "beverage or foodstuff preparation system" may refer to the combination of any two of more of: the beverage or foodstuff preparation machine; the container; the server system, and; the peripheral device.
As used herein, the term "beverage" may refer to any substance capable of being processed to a potable substance, which may be chilled or hot. The beverage may be one or more of: a solid; a liquid; a gel; a paste. The beverage may include one or a combination of: tea; coffee; hot chocolate; milk; cordial; vitamin composition; herbal tea/infusion; infused/flavoured water, and; other substance. As used herein, the term "foodstuff" may refer to any substance capable of being processed to a nutriment for eating, which may be chilled or hot. The foodstuff may be one or more of: a solid; a liquid; a gel; a paste. The foodstuff may include: yoghurt; mousse; parfait; soup; ice cream; sorbet; custard; smoothies; other substance. It will be appreciated that there is a degree of overlap between the definitions of a beverage and foodstuff, e.g. a beverage can also be a foodstuff and thus a machine that is said to prepare a beverage or foodstuff does not preclude the preparation of both.
As used herein, the term "precursor material” may refer to any material capable of being processed to form part or all of the beverage or foodstuff. The precursor material can be one or more of a: powder; crystalline; liquid; gel; solid, and; other. Examples of a beverage forming precursor material include: ground coffee; milk powder; tea leaves; coco powder; vitamin composition; herbs, e.g. fo'r forming a herbal/infusion tea; a flavouring, and; other like material. Examples of a foodstuff forming precursor material include: dried vegetables or stock as anhydrous soup powder; powdered milk; flour based powders including custard; powdered yoghurt or ice-cream, and; other like material. A precursor material may also refer to any preprecursor material capable of being processed to a precursor material as defined above, i.e. any precursor material that can subsequently be processed to a beverage and/or foodstuff. In an example, the pre-precursor material includes coffee beans which can be ground and/or heated (e.g. roasted) to the precursor material.
As used herein, the term "fluid" (in respect of fluid supplied by a fluid conditioning system) may include one or more of: water; milk; other. As used herein, the term "conditioning" in respect of a fluid may refer to a change in a physical property thereof and can include one or more of the following: heating or cooling; agitation (including frothing via whipping to introduce bubbles and mixing to introduce turbulence); portioning to a single-serving amount suitable for use with a single serving container; pressurisation e.g. to a brewing pressure; carbonating; fliting/purifying, and; other conditioning process.
As used herein, the term "processing unit" may refer to an arrangement that can process precursor material to a beverage or foodstuff. It may refer to an arrangement that can process a pre-precursor material to a precursor material. The processing unit may have any suitable implementation, including a container processing unit. The processing unit may be controlled by electrical circuitry to perform a preparation process based on preparation information.
As used herein, the term "container processing unit" may refer to an arrangement that can process a container to derive an associated beverage or foodstuff from a precursor material in the container. The container processing unit may be arranged to process the precursor material by one of more of the following: dilution; heating; cooling; mixing; whisking; dissolution; soaking; steeping; extraction; conditioning; pressurisation; infusion, and: other processing step. The container processing unit may therefore implement a range of units depending on the processing step, which can include: an extraction unit (which may implement a pressurised and/or a thermal, e.g. heating or cooling, brewing process); a mixing unit (which mixes a beverage or foodstuff in a receptacle; a dispensing and dissolution unit (which extracts a portion of the precursor material from a repository, processes by dissolution and dispenses it into a receptacle), and: other like unit.
As used herein, the term "electrical circuitry" or "circuitry" or "control electrical circuitry" may refer to one or more hardware and/or software components, examples of which may include: one or more of an Application Specific Integrated Circuit (ASIC) or other programable logic; electronic/electrical componentry (which may include combinations of transistors, resistors, capacitors, inductors etc); one or more processors (e.g. circuitry structure of the processor); a non-transitory memory (e.g. implemented by one or more memory devices), that may store one or more software or firmware programs; a combinational logic circuit; interconnection of the aforesaid. The electrical circuitry may be located entirely at one component of the system, or distributed between a plurality of components of the system (e.g. a server system and/or external device) which are in communication with each other over a computer network via communication resources.
As used herein, the term "processor" or "processing resource" may refer to one or more units for processing, examples of which include an ASIC, microcontroller, FPGA, microprocessor, digital signal processor (DSP), state machine or other suitable component. A processor may be configured to execute a computer program, e.g. which may take the form of machine readable instructions, which may be stored on a non-transitory memory and/or programmable logic. The processor may have various arrangements corresponding to those discussed for the circuitry, e.g. on-board or distributed as part of the system. As used herein, any machine executable instructions, or computer readable media, may be configured to cause a disclosed method to be carried out, e.g. by the system or components thereof as disclosed herein, and may therefore be used synonymously with the term method, or each other.
As used herein, the term "computer readable medium/media" or "data storage" may include any medium capable of storing a computer program, and may take the form of any conventional non-transitory memory, for example one or more of: random access memory (RAM); a CD; a hard drive; a solid state drive; a memory card; a DVD. The memory may have various arrangements corresponding to those discussed for the circuitry. As used herein, the term "communication resources" or "communication interface" may refer to hardware and/or firmware for electronic information transfer. The communication resources/interface may be configured for wired communication (“wired communication resources/interface”) or wireless communication (“wireless communication resources/interface”). Wireless communication resources may include hardware to transmit and receive signals by radio and may include various protocol implementations e.g. the 802.1 1 standard described in the Institute of Electronics Engineers (IEEE) and Bluetooth™ from the Bluetooth Special Interest Group of Kirkland Wash. Wired communication resources may include; Universal Serial Bus (USB); High-Definition Multimedia Interface (HDMI) or other protocol implementations. The machine may include communication resources for wired or wireless communication with an external device and/or server system.
As used herein, the term "network" or "computer network" may refer to a system for electronic information transfer between a plurality of apparatuses/devices. The network may, for example, include one or more networks of any type, which may include: a Public Land Mobile Network (PLMN); a telephone network (e.g. a Public Switched Telephone Network (PSTN) and/or a wireless network); a local area network (LAN); a metropolitan area network (MAN); a wide area network (WAN); an Internet Protocol Multimedia Subsystem (IMS) network; a private network; the Internet; an intranet.
As used herein, the term "code" may refer to a storage medium that encodes preparation information. The code may be an optically readable code, e.g. a bar code. The code may be arranged as a bit code (e.g. a binary sequence of Os and 1 s encoded by the absence or presence of an element). The code may be formed of a plurality of units, which can be referred to as elements or markers. The elements may implement a finder portion and a data portion, wherein the finder portion encodes a predefined reserved string of bits that is identifiable when processing the code from the data portion, to enable location of the data portion, which encodes the preparation information. The code may be arranged as a one dimensional code, which is read by relative movement between the code and a code reader. The code reader may provide a bit stream signal or a high and low signal for processing by preparation information extraction. It will be understood that a code may therefore exclude a mere surface finish or branding on a container, which is not configured in any way for information storage.
As used herein the term “preparation information” may refer to one of more of: parameters as defined herein; a recipe as defined herein; an identifier, and; other information related to the operation of the machine. As used herein, the term “parameter” may refer to a variable that is used as an input for controlling (e.g. RPM) and/or or a property of the beverage/foodstuff or a precursor thereof that is controlled by the processing unit (e.g. a fluid target temperature or volume) during the preparation process. Depending on the implementation of the processing unit said parameter may vary. Examples include: volume of a particular component of the beverage and/or foodstuff; fluid temperature; fluid flow rate; operational parameters of the processing unit, e.g. RPM of an extraction unit based on centrifugation or closing force for a hydraulic brewing unit; an order of dispensing of components of the beverage and/or foodstuff; agitation (e.g. frothing degree); any of the aforesaid defined for one or more phases, wherein the preparation process is composed of a series of sequential, discrete phases. The parameter may have a value, which may be numerical and can vary in predetermined increments between predetermined limits, e.g. a temperature of the water may vary between 60 - 90 degrees in 5 degree increments. As used herein, the term “recipe” or “control data set” may refer to a combination of said parameters, e.g. as a full or partial set of inputs, that are used by the processing unit to prepare a particular beverage and/or food stuff.
As used herein the term “directly” or “direct” in respect of a value of a parameter encoded by the code, may refer to the parameter having a number of possible values that encode a magnitude of the associated parameter, with one of which being directly extractable from the code, rather than extractable along with a series of other parameters via an identifier and a look-up table. Alternatively put, it may refer to the encoding of a value that can vary independently of the other parameters of the recipe on code. For example, four bits may encode 1 - 16 magnitudes of water temperature with 1 being the lowest and 16 being the highest, these magnitudes may be scaled by a rule on the machine to provide an actual temperature used in the preparation process.
As used herein, the term "preparation process" may refer to a process to prepare a beverage or foodstuff from a precursor material or to prepare a pre-precursor material from precursor material. A preparation process may refer to the processes electrical circuitry executes to control the processing unit to process said precursor or pre-precursor material.
As used herein, the term "code reading process" may refer to the process of reading the code to extract the preparation information (which can include the identifier and/or parameters). The process may include one or more of the following steps: obtaining a digital image of the code or a code signal; extracting a sequence of bits from the code; identifying a finder portion of the code in the sequence; locating a data portion using the finder portion, and; extracting the preparation information from the data portion.
As used herein the term “liner” or “liner member” may refer to a layer of material that is capable of providing a barrier to oxygen and/or water. An example of a suitable liner material is provided in EP3284140 or WO2023061891 A1 or WO2021/14576.
[General system description]
Referring to figure 1 , the system 2 comprises a machine 4, a container 6, server system 8 and a peripheral device 10. The server system 8 is in communication with the machine 4 via a computer network 12. The peripheral device 10 is in communication with the machine 4 via the computer network 12.
In variant embodiments, which are not illustrated: the peripheral device and/or server system is omitted.
Although the computer network 12 is illustrated as the same between the machine 4, server system 8 and peripheral device 10, other configurations are possible, including: a different computer network for intercommunication between each device: the server system communicates with the machine via the peripheral device rather than directly. In a particular example: the peripheral device communicates with the machine via a wireless interface, e.g. with a Bluetooth™ protocol, and; the server system communicates with the machine via a via a wireless interface, e.g. with a IEE 802.11 standard, and also via the internet.
[Machine]
Referring to figure 2, the machine 4 comprises: a processing unit 14 for processing the precursor material; electrical circuitry 16, and; a code reading system 18.
The electrical circuitry 16 controls the code reading system 18 to read a code (not illustrated in figure 2) from the container 6 and determine preparation information therefrom. The electrical circuitry 16 uses the preparation information to control the processing unit 14 to execute a preparation process, in which the precursor material is process to a beverage or foodstuff or a precursor thereof. [Processing unit]
Referring to figures 2 and 3, in a first example of the processing unit 14, said unit comprises a container processing unit 20 and a fluid conditioning system 22.
The container processing unit 20 is arranged to process the container 6 to derive a beverage or foodstuff from precursor material (not illustrated) therein. The fluid conditioning system 22 conditions fluid supplied to the container processing unit 20. The electrical circuitry 16 uses the preparation information read from the container 6 to control the container processing unit 20 and the fluid conditioning system 22 to execute the preparation process.
[Fluid conditioning system]
Referring to figure 3, the fluid conditioning system 22 includes a reservoir 24; pump 26; heat exchanger 28, and; an outlet 30 for the conditioned fluid. The reservoir 24 contains fluid, typically sufficient for multiple preparation processes. The pump 26 displaces fluid from the reservoir 24, through the heat exchanger 26 and to the outlet 30 (which is connected to the container processing unit 20). The pump 26 can be implement as any suitable device to drive fluid, including: a reciprocating; a rotary pump; other suitable arrangement. The heat exchanger 28 is implemented to heat the fluid, and can include: an in-line, thermo block type heater; a heating element to heat the fluid directly in the reservoir; other suitable arrangement.
In variant embodiments, which are not illustrated: the pump is omitted, e.g. the fluid is fed by gravity to the container processing unit or is pressurised by a mains water supply; the reservoir is omitted, e.g. water is supplied by a mains water supply; the heat exchanger is arranged to cool the fluid, e.g. it may include a refrigeration-type cycle heat pump); the heat exchanger is omitted, e.g. a mains water supply supplies the water at the desired temperature; the fluid conditioning system includes a filtering/purification system, e.g. a UV light system, a degree of which that is applied to the fluid is controllable; a carbonation system that controls a degree to which the fluid is carbonated.
[Container processing unit]
The container processing unit 20 can be implemented with a range of configurations, as illustrated in examples 1 - 6 below:
1 - Referring to figures 4A and 4B, a first example of the container processing unit 20 is for processing of a container arranged as a capsule 6 (a suitable example of a capsule is provided in figure 8, which will be discussed) to prepare a beverage. The container processing unit 20 is configured as an extraction unit 32 to extract the beverage from the capsule 6. The extraction unit 32 includes a capsule holding portion 34 and a closing portion 36. The extraction unit 32 is movable to a capsule receiving position (figure 4A), in which capsule holding portion 34 and a closing portion 36 are arranged to receive a capsule 6. The extraction unit 32 is movable to a capsule extraction position (figure 4B), in which the capsule holding portion 34 and a closing portion 36 form a seal around a capsule 6, and the beverage can be extracted from the capsule 6. The extraction unit 32 can be actuator driven or manually movable between said positions.
The outlet 30 of the fluid conditioning system 22 is arranged as an injection head 38 to inject the conditioned fluid into the capsule 6 in the capsule extraction position, typically under high pressure. A beverage outlet 40 is arranged to capture the extracted beverage and convey it from the extraction unit 32.
The extraction unit 32 is arranged to prepare a beverage by the application of pressurised (e.g. at 10 - 20 Bar), heated (e.g. at 50 - 98 degrees C) fluid to the precursor material within the capsule 6. The pressure is increased over a predetermined amount of time until a pressure of a rupturing portion (not illustrated in figure 4A, 4B) of the capsule 6 is exceeded, which causes rupture of said portion and the beverage to be dispensed to the beverage outlet 40.
2- In variant embodiments, which are not illustrated, although the injection head and beverage outlet are illustrated as arranged respectively on the closing portion and capsule holding portion, they may be alternatively arranged, including: the injection head and beverage outlet are arranged respectively on the capsule holding portion and closing portion; or both on the same portion, e.g. on either the holding portion or closing portion. Moreover, in a second example extraction unit may include both parts arranged as a capsule holding portion, e.g. for capsules that are symmetrical about the flange, including a Nespresso® Professional capsule.
3- Referring to figure 5, in a third described example of the container processing unit 20, the extraction unit 32 is as described for the first example, however the extraction unit 32 operates at a lower fluidic pressure and by centrifugation. In particular, the extraction unit 32 includes a rotation mechanism 33 that includes a capsule holding portion 34 to hold the capsule 6 and a drive system 37 to rotate said capsule holder 34.
The outlet 30 of the fluid conditioning system 22 is arranged on the closing portion 36 as an injection head 38 to inject the conditioned fluid into a centre of the capsule 6 through a closing member of the capsule 6 as will be discussed. The rotation mechanism 33 rotates the capsule to effect transmission of the conditioned fluid radially outwards through precursor material in the capsule 6 and out through peripheral arranged puncture points (not illustrated) in the closing member. An example of a suitable processing unit is present in a Nespresso® Vertuo beverage preparation machine. The preparation of a beverage by using centrifugation and corresponding devices are, for example, disclosed in W02008/148601 , W02008/148650, WO2013/007776, WO 2013/007779 and WO 2013/007780, which are incorporated herein by reference. An example of a suitable capsule is a Nespresso® Vertuo capsule. A suitable example is provided in EP 2594171 A1.
4- In a fourth example, (which is not illustrated) the capsule processing unit operates by dissolution of a beverage precursor that is selected to dissolve under high pressure and temperature fluid. The arrangement is similar to the extraction unit of the first and second example, however the pressure is lower and therefore a sealed extraction unit is not required. In particular, fluid can be injected into a lid of the capsule and a rupturing portion which is located in a base of a storage portion of the capsule. An example of a suitable capsule is a Nespresso® Dolce Gusto capsule. Examples of suitable extraction units are disclosed in EP 1472156 A1 and in EP 1784344 A1.
5- In a fifth example, (which is not illustrated) the container processing unit is arranged as a mixing unit to prepare a beverage or foodstuff precursor that is stored in a container that is a receptacle, which is for end user consumption therefrom. The mixing unit comprises an agitator (e.g. planetary mixer; spiral mixer; vertical cut mixer) to mix and a heat exchanger to heat/cool the beverage or foodstuff precursor in the receptacle. A fluid supply system may also supply fluid to the receptacle. An example of such an arrangement is provided in WO 2014067987 A1 .
[Code reading system]
Referring to figures 4A and 4B, the code reading system 18 is arranged to read a code 44 arranged on a closing member of the container 6. The code reading system 18 is integrated with the extraction unit 32 of first example of the container processing unit 20. The code 44 is read with the extraction unit 32 in the capsule extraction position (as shown in figure 4B).
The code reading system 18 includes an image capturing unit 46 to capture a digital image of the code 44. Examples of a suitable image capturing unit 46 include a Sonix SN9S102; Snap Sensor S2 imager; an oversampled binary image sensor; other like system. The electrical circuitry 16 includes image processing circuitry (not illustrated) to identify the code in the digital image and extract preparation information. An example of the image processing circuitry is a Texas Instruments TMS320C5517 processor running a code processing program.
Referring to figure 5, for the second example of container processing unit 20 the code reading system 18 is alternatively arranged to read a code 44 from an underside of a flange portion of the container 6. The code 44 is read based on rotation of the code 44 relative a code reader 46 of the code reading system 18. The code 44 is read with the extraction unit 32 in the capsule extraction position (as shown in figure 5), with the rotation mechanism 33 rotating the container 6.
The code reading system 18 includes a code reader 46 to capture a code signal of the code 44. Examples of a suitable image code reader 46 include a photo diode or other electrical componentry that can distinguish between elements of the code (as will be discussed). The code reader may be operable in the infrared and/or visible wavebands. The code reader 46 includes a lighting unit (e.g. an infrared and/or visible light source), not illustrated, to illuminate to code for reading. In variant embodiments, which are not illustrated, the code reader can be implemented as the image capturing unit, as discussed above, or with another suitable reading system.
In variant embodiments, which are not illustrated, the code reading system is separate from the container processing unit including: it is arranged in a channel that the user places the container in and that conveys the container to the container processing unit; it is arranged to read a code on a receptacle, which is positioned to receive a beverage from an beverage outlet of a dispensing and dissolution unit. In further variant embodiments, which are not illustrated, the code reading system is arranged to read a code at a different location of the container, e.g. on a storage portion.
[Control electrical circuitry]
Referring to figure 6, the electrical circuitry 16 is implemented as control electrical circuitry 48 to control the processing unit 14 to execute a preparation process.
The electrical circuitry 16, 48 at least partially implements (e.g. in combination with hardware) an: input unit 50 to receive an input from a user confirming that the machine 4 is to execute a preparation process; a processor 52 to receive the input from the input unit 46 and to provide a control output to the processing unit 14, and; a feedback system 54 to provide feedback from the processing unit 14 during the preparation process, which may be used to control the preparation process. The input unit 50 is implemented as a user interface, which can include one or more of: buttons, e.g. a joystick button or press button; joystick; LEDs; graphic or character LDCs; graphical screen with touch sensing and/or screen edge buttons; other like device; a sensor to determine whether a container has been supplied to the machine by a user.
The feedback system 54 can implement one or more of the following or other feedback controlbased operations: a flow sensor to determine a flow rate/volume of the fluid to the outlet 30 (shown in figure 3) of the fluid supply system 22, which may be used to meter the correct amount of fluid to the container 6 and thus regulate the power to the pump 26; a temperature sensor to determine a temperature of the fluid to the outlet 30 of the fluid supply unit 22, which may be used to ensure the temperature of fluid to the container 6 is correct and thus regulate the power to the heat exchanger 28); a level sensor to determine a level of fluid in the reservoir 24 as being sufficient for a preparation process; a position sensor to determine a position of the extraction unit 32 (e.g. a capsule extraction position or a capsule receiving position).
It will be understood that the electrical circuitry 16 is suitably adapted for the other examples of the processing unit 14, e.g.: for the second example of the container processing system the feedback system may be used to control speed of rotation of the capsule.
[Container]
Referring to figure 7, a general example of a container 6, that is for use with the processing unit 14 arranged as an extraction unit, comprises the container 6 arranged as a capsule. The container includes: a body portion 60 having a storage portion 62 and a flange portion 64, and; a closing member 66 to close the storage portion 62.
The storage portion 62 includes a cavity for storage of the precursor material (not illustrated in figure 7). The closing member 66 closes the storage portion 62 and comprises a flexible membrane. The flange portion 60 presents as a flat surface for connecting the closing member 66 to the storage portion 58 to hermetically seal the precursor material. The container 6 has a diameter of 2 - 5 cm and an axial length of 2 - 4 cm.
The container 6 is arranged with the flange portion 64 positioned in a plane defined in a local longitudinal direction 100 and a lateral direction 102. The storage portion 62 extends in a depth direction 104 from the flange portion 64, the depth direction 104 being orthogonal to the longitudinal direction 100 and the lateral direction 102. The container 6 is fully axis symmetric about an axis of rotation 106 (e.g. circular in cross-section) which is aligned to the depth direction 104.
The container includes the code 44, which is arranged on a first surface of the flange portion 64, which faces the storage portion 62. The code 44 is arranged as an annular ring. The code 44 is typically formed by printing on to said surface.
In variant embodiments, some of which are illustrated in the following examples; the body of the container can have various shapes (including: hemispherical; curved; rectangular in section; frustoconical, and; other like shapes; the closing member may be arranged as a rigid member, rather than a membrane; the container may be for use with other processing units; the container is partially rotationally symmetric examples of which are illustrated in the following examples.
Where the container 6 is implemented for the second example of the container processing unit 20: the container 6 may be configured; to withstand rotation of maximum 7000 RPM, typically between 3500 et 6000 RPM, and/or; the container 6 may be configured to withstand a centripetal force of 500 N. Said loading may be applied to the storage portion 62 by liquid and/or the precursor material during processing by the container processing unit 20. As used herein the term “withstand” may be defined as not experiencing a failure mode under said condition(s). A failure mode may be defined as one or more of: the debonding of portions of the container, e.g. the closing member from the flange portion or the flange portion from the storage portion; material crack propagation or other material failure.
[Example 1 - container formed by drawing]
Referring to figures 8 - 25, in a first example, the container 6 may implement any features of the preceding general embodiment of figure 7 or another compatible embodiment disclosed herein, and may be implemented with any of the preceding embodiment machines 4. Referring to figure 8, the storage portion 62 is formed from a blank 68 of extensible paper-based sheet material. Multiple blanks 68 can be cut from the same sheet, as will be discussed. The storage portion 62 in blank 68 formation may be referring to as an undrawn or planar state. The blank 68 is circular in shape with a periphery 76.
Referring to figures 9 and 10, the blank 68 of figure 8 is shown in a drawn state, in which the hemispherical shaped storage portion 62 is formed by drawing. In the drawn state, the storage portion 62 includes wrinkling portions 70.
The storage potion 62 includes a cavity 72 having a base 74 and the periphery 76, which is defined by the periphery of the blank 68. The wrinkling portions 70 extend from said periphery 76 generally in the depth direction 104 and are arranged entirely around the periphery 76.
The wrinkling portions 70 are formed without cutting of the blank 68, as will be discussed. The wrinkling portions 70 are evenly distributed (including substantially evenly distributed) around the periphery 76. The wrinkling portions 70 extend substantially (e.g. 65 - 95%) the depth of the storage portion (which extends from the periphery 76 to the base 74.
The wrinkling portions 70 may be referred to as wrinkles, and are a product of the drawing process of the paper-based material, and are a result of buckling due to the compressive instability of the material.
The storage portion 62 is entirely formed by drawing without individual flaps or folding. Individual flaps, which are defined by cuts and folds may reduce strength of the storage portion. Hence drawing occurs directly from the blank 68 without an intermediate folding or cutting step.
The paper-based material for forming the storage portion has a thickness of less than 60 - 150 micron and a stretch at break in a machine direction of 1 .5 - 5 or 7%. The paper-based material is pressed to the drawn state by 500 to 1500 N.
In variant embodiments, which are not illustrated, the storage portion is alternately configured, for example: other non-hemispherical shapes may be implemented, including frustoconical or cubical; the storage portion may alternatively be formed by moulded wood-pulp or by bending flaps, as will be discussed for example 2.
Referring to figures 10 and 1 1 , the flange portion 64 includes connecting members 78 to connect to the wrinkling portions 70 to retain the drawn state, as will be discussed. The connecting members 78 are arranged as individual flaps which are circumferential disposed around the periphery 76 of the storage portion 62. The connecting members 78 extend from said periphery 76 generally in the depth direction 104.
There are 12 connecting members 78. The connecting members 78 extend to a depth of 50 - 80% of the total depth of the storage portion 62 (defined as the distance in the depth direction 104 from the periphery 76 to the base 74).
Referring to figures 11 and 12, the connecting members 78 have a leading edge 80 and trailing edge 82 with respect to a clockwise rotation about the axis 106. The leading edge 80 and trailing edge 82 are angled at angle a relative the depth direction 104, e.g. by 20 - 40 degrees. Such an angling may provide adequately sized exposed regions 84 between adjoining connecting members for adhesion to the liner member, as will be discussed.
Referring to figures 10 and 12, the connecting members 78 include cut-out portions 86 that define enclosed regions for adhesion to the liner member, as will be discussed. The cut-out portions 86 have the same shape as the connecting member 78 and extend contiguous their edges.
In variant embodiments, which are not illustrated, the connection portions may be alternatively implemented, for example: there are other numbers of flaps, e.g. 8 - 15; the connecting members are alternatively shaped, e.g. as rectangles with a space between; the connecting members are alternatively angel; the optional cut-out portions are alternatively shaped, e.g. as circular, square, triangular or a combination thereof, or as multiple cut-outs per connecting member.
Referring to figures 10 and 1 1 , the flange portion 64 has a first surface 88 and a second surface 90. The storage portion 62 includes an interior surface 92 and an outer surface 94. The flange portion 64 includes an extension portion 98, which projects outwardly from the storage portion 62 and is arranged in the plane defined by the longitudinal direction 100 and the lateral direction 102. The first surface 88 and a second surface 90 extend over both the flange portion 64 and the extension portion 98.
The connecting members 78 are adhesively bonded to the storage portion 62 by spot welding (not illustrated) over, for example, a heat activated lacquer applied to the first surface 88 surface of the flange portion 64, as will be discussed. This bonding retains the crimped portions 70 in the drawn state and positions the flange portion 64 relative the storage portion 62, for more comprehensive bonding with a liner member, as will be discussed. Referring to figures 10 and 11 , the container 6 comprises a liner member 96, which is arranged over an interior of the storage portion 62 (which is comprised of the interior surface 92 of the storage portion 62, and where overlapped, the second surface 90 of the connecting members 78 of the flange portion 64).
The liner member 96 is adhered to the interior of the storage portion 62 by thermoforming. In particular, it is adhered to the: interior surface 92; connecting members 78, and; the exposed regions 84, to connect the flange portion 64 to the storage portion 62. This bonding further retains the crimped portions 70 in the drawn state.
The adhesive(s) may be selected to be heat activated at above the temperature of the liquid supplied to the container during a preparation process, e.g. above 90 or 100 degrees.
In variant embodiments, which are not illustrated: the flange portion and storage portion are alternatively connected, for example: by just the liner member or just the spot welding of the lacquer or any of their associated variants; contact adhesive may be applied to the connecting member rather than the use of the heat activated lacquer; the liner may be alternatively adhered, e.g. by a contact adhesive rather than heat activated adhesive.
Referring to figures 10, 11 and 13, the container 6 comprises a separate stiffening ring 110 arranged connected to the flange portion 64 to stiffen the flange portion 64. In particular, the stiffening ring 110 stiffens proximal a periphery 112 of the extension portion 98 of the flange portion 64, as will be discussed.
The stiffening ring 110 is adhesively connected to the second surface 90 (which may be referred to as an upper surface) of the extension portion 98 of the flange portion 64. The stiffening ring 110 and second surface 88 of the extension portion 98 of the flange portion 64 thus define a cavity 114 for receiving the closing member 66, as will be discussed. The stiffening ring 110 is arrange slightly inset in a radial direction from the periphery 112 to define a lip 116 of the extension portion 98 proximal the periphery 112.
The liner member 96 is arranged to line the interior of the storage portion 62 (as discussed previously) and is arranged over the second (upper) surface 90 of the flange portion 64 portion. The liner member 96 extends from the second surface 88 distal the periphery 112 around the stiffening ring 110 and back to the second surge 88 at the periphery 112 and lip 116. The separate stiffening ring 110 is annular in shape and is formed of a solid strip of paper-based material, which is cut from a tube such that it has a rectangular section. The stiffening ring 110 has an outer diameter of 55 - 65 mm and a thickness of 1 .2 - 2.5 mm and a depth of 1 .2 - 2.5 mm.
The container has a machine-readable code 44 arranged on the first surface 88 (referred to as a lower surface) of the extension portion 98 of the flange portion 64.
Referring to figures 13, 14 and 16, the container 6 comprises the closing member 66, which is arranged to connect via the liner member 96 to the flange portion 64 to close the storage portion 62. In particular, the closing member 66 is arranged to extend up to and sit within the cavity 114 defined by the stiffening ring 110. The closing member 66 is bonded to the liner member 96, e.g. by a heat activated, ultrasonic welding or contact adhesive.
The paper-based material of the flange portion 64 has a thickness of less than 200 or 190 microns and/or a grams per square metre (GSM) of 80 -120.
The material of the stiffening ring 110 is a cardboard-based material. The fibres of the cardboard in the tube may be aligned in the circumferential direction. Such an arrangement may provide improved stiffness compared to a folded or curled ring.
In variant embodiments, which are not illustrated: the stiffening ring is formed integrally with the flange portion, e.g. by folding and/or rolling or by moulding; the stiffening ring is alternatively connected to the lower surface or to the periphery of the flange potion; the stiffening ring is alternatively arranged at the edge or the extension portion, e.g. such that there is no lip; the code is alternatively arranged e.g. on the upper surface or closing member; the stiffening ring is alternatively formed, e.g. by moulding rather than by cutting from a tube; the stiffening ring is alternatively shaped, e.g. with a circular or other cross-section; the liner member may not extend over the stiffening ring; the closing member may extend over the stiffening ring.
[Method of Formation - Example 1]
A method of forming a container 6 comprises the following steps, which are execute by a manufacturing line 120, with converter machines 122 - 136: 1 . Body portion formation:
Step 1 : referring to figure 16, from a web of sheet material 150 blanks 68 (figure 8) of the storage portion 62 are cut by a first converter machine 122. This step may be executed with the web of the sheet material 150 or sheets of the sheet material (not illustrated) with cutting in series and/or parallel.
Step 2: referring to figure 16, for the blanks 68 of step 1 , the storage portion 62 is formed by drawing by a second converting machine 124. Referring to figure 17 the second converting machine 124 comprises a former 152. Referring to figure 18, the blank 68 is pressed into the former 152 to draw the blank 68 into the form of the storage portion 62. This step may be executed with a web of the sheet material 150 with cutting in series and/or parallel.
2. Flange portion formation
Step 4: referring to figure 19, from a web of sheet material 156 blanks of the flange portion 64 are cut by a third converter machine 126. This step may be executed with the web 156 of the sheet material, or sheets of the sheet material (not illustrated) with cutting in series and/or parallel.
Step 5: referring to figure 19, for the blanks of step 4, the code 44 is formed (e.g. by flexo printing or otherwise applied) on the first surface 88 of the flange portion 64 by a fourth converting machine 128.
The lacquer of the first surface 88 of the connecting members 78 and/or the second surface 90 of the extension portions 98 (see step 6 and/or step 7) may also be printed (or otherwise applied) during this step, e.g. after formation of the code 44.
3. Stiffening ring formation
Step 6: referring to figure 20, from a tube 158 of cardboard material, stiffening rings 110 are cut by a fifth converting machine 130 with a reciprocating blade arrangement 160. The tube 158 may be axially displaced relative the blade arrangement 160 for cutting of subsequent stiffening rings 110.
4. Connection of flange portion and storage portion
Step 7: referring to figure 21 , the flange portion 64 and storage portion 62 are positioned in alignment with each other (e.g. with the connecting members 78 to extend into the cavity 72 of the storage portion so that first surface 88 (as shown in figure 10) of the connecting members 78 abuts the interior surface 92 of the storage portion 62. This step may be implemented with the second converting machine 124 of the step 2 or a dedicated converting machine (not illustrated). With the flange portion 64 and storage portion 62 positioned in alignment with each other, the first surface 88 of the connecting members 78 are connected to the interior surface 92 of the storage portion 62 by spot welding of the heat activated lacquer (not illustrated) of the connecting members 78. The storage portion 62 may be retained in the drawn state in during this step by a vacuum applied (not illustrated) to the exterior surface 94 of the storage portion 62.
Step 8: the stiffening ring 110 (formed by step 6) is connected to the second (upper) surface 90 of the extension portion 98 of the flange portion 62. This step may be implemented by the same converting machine as for step 2, or a dedicated converting machine (not illustrated). This step comprises spot welding of the lacquer of the second surface 90 of the extension portion 98 of the flange portion 62 proximal the stiffening ring 110.
Step 9: referring to figures 22 and 23, the liner member 96 is formed over the interior of the storage portion 62, the second surface 90 of the extension portion 98, and the stiffening ring 110 by a sixth converting machine 132. The liner member 96 is set in position by thermoforming (or other suitable process). The storage portion 62 may be retained in the drawn state in during this step by a vacuum applied (not illustrated) to the exterior surface 94 of the storage portion 62. This step may be executed with a web of liner material 96 (as illustrated) or with separate sheets of liner member (not illustrated) with the storage portion and flange portion assembly supplied in series and/or parallel. Subsequent to thermoforming, the liner member may by cut to size (not illustrated) to correspond to the periphery 112 of the flange portion 64.
5. Filling and sealing
Step 10: referring to figure 24, precursor material 162 is supplied to the cavity 72 of the storage portion 62 by a seventh converting machine 134. The precursor material 162 may be supplied as loose and optionally compacted in the storage portion 62 by a compactor (not illustrated) or may be supplied as a compacted unit (not illustrated). This step may be executed with the storage portion, flange portion, stiffening ring and liner assembly of step 9 supplied in series and/or parallel.
Step 11 : referring to figure 25, the closing member 66 is connected to the filled assembly of step 10 by an eighth converting machine 136. This comprises adhesively connecting (e.g. by welding) the closing member 66 in proximity of the edges of the cavity 114 defined by the liner member 96 and the stiffening ring 110 (as shown in figure 13). This step may be executed with a web of closing member material 66 (as illustrated) or with separate closing members (not illustrated) and with filled assemblies supplied in series and/or parallel.
[Example 2 - container formed by bending]
Referring to figures 26 - 29, in a second example, the container 6 may implement any features of the preceding general embodiment of figure 7 or another compatible embodiment disclosed herein, and may be implemented with any of the preceding embodiment machines 4. The storage portion 62 is formed from a blank 68 of paper-based material (figure 26) and in a hemispherical state (figure 29) comprises a hemispherical cavity 72. The blank 68 comprise flaps 170 that extend in a radial direction about the axis 106, and adjoin each other (e.g. they are entirely in contact with each other along their edges, as best seen in figure 29) in the hemispherical state. Referring to figures 28 and 29, the flange portion 64 includes connecting members 78 to retain the storage portion 62 (as discussed in the preceding embodiments).
The hemispherical shape is formed by bending of the flaps 170 without forming fold lines. By forming the hemispherical shape by bending without introducing fold lines, the hemispherical shape may be more accurate.
The second example implements the same flange portion 64, stiffening ring 110, and liner member 96 and their associated connection configuration as for the first example, including the discussed variants, hence for brevity, these parts are not additionally discussed.
The blank 68 is arranged with 12 identical flaps 170, each having a leading edge 172 and a trailing edge 174 defined in respect of a clockwise direction about the axis 106. The flaps 170 are separated from each other in the planar state as shown in figure 26. A large number of flaps, e.g. above 8, may enable better recreation of the hemispherical shape, e.g. for retro compatibility with existing machines that generally require a hemispherical container.
The blank 68 has a circular central portion 176 to form the base 74 of the cavity 72. The circular central portion 176 is delineated by vertices 178 at a proximal end of the flaps 170, wherein proximal and distal are defined relative the axis 106. The leading edge 172 and a trailing edge 174 extend from each vertex 178 to define V-shaped cut-out regions between the flaps 170. The circular central portion 176 may be used to facilitate correct placement of the blank 68 in a mold, e.g. with the axis 106 aligned to a centre of the mold. The flaps 170 at a distal end have generally parallel leading and trailing edges 172, 174. Selection of a radial distance of this region enables variable depth containers to be specified. The periphery of the flaps 170 is linear.
In the second example, the storage portion 62 is formed of a paper-based material or a compact board-based material with a thickness of 100 microns to 1 mm, and may be from 100 gsm to 1000 gsm.
As discussed for the first example, the connecting members 78 can be adhesively connected (e.g. by spot welding) to retain the flaps 170 in the hemispherical state, followed by the application of the liner member 98 to further adhere connecting members 78 and flaps 170.
Referring to figures 28 and 29, there are 12 connecting members 78 and 12 flaps 170. In this way, the connecting members 78 can be aligned with the exposed region 84 centrally between two flaps 170 to expose an edge 172,174 adjoining said two flaps 170 on the interior of the storage portion 62. With such an arrangement the edges 172,174 remain exposed around the entire periphery of the storage portion 62, and the liner member 98 can extend over the edges 172,174 to provide reinforcement to these regions.
In variant embodiments, which are not illustrated: there are other numbers of flaps, e.g. 8 - 15; the flaps may have other shapes; the connecting members can be aligned to conceal the edge of the flaps, or there may be different numbers of flaps to connection members.
[Method of Formation - Example 2]
A method of forming a container 6 comprises the steps as discussed for the first example, including the associated variants, which for brevity are not discussed. However, the second step is adapted due to the alternative formation of the storage portion 62:
Step 2: for the blanks 68 of figure 26 which are alternatively formed by step 1 , the storage portion 62 is formed by pressing by the second converting machine 124. The second converting machine 124 alternatively comprises the former 152 and is arranged to press the blank 68 into the former 152 to bend the flaps 170 into the hemispherical state of figure 29. The circular central portion 176 may be used to facilitate correct placement of the blank 68 in relative the former, as discussed previously. The circular central portion 176 may be pressed by the former to a flat or curved base. The pressing force may be less than 1 kN. Prior to forming of the storage portion by pressing, the blank 68 may be pre-creased/crushed to form crushed regions. Said crushing can be implemented with the same tool as for cutting (e.g. a press that both cuts and implements creases/crushing) or subsequent to cutting of the blank 68. The additional thickness of the paper-based material (e.g. compared to the first example, which is formed by drawing) may be implemented to enable the formation of the crushed regions, e.g. by creasing/crushing of the fibres. The crushed regions (not illustrated) may be arranged as one or more rings aligned concentrically about the axis 106 of the blank 68. The cruised regions may be formed on the inside (e.g. precursor material facing) or outside of the storage portion 62.
It will be appreciated that any of the disclosed methods (or corresponding apparatuses, programs, data carriers, etc.) may be carried out by either a host or client, depending on the specific implementation (i.e. the disclosed methods/apparatuses are a form of communication(s), and as such, may be carried out from either ‘point of view’, i.e. in corresponding to each other fashion).
As used in this specification, any formulation used of the style “at least one of A, B or C”, and the formulation “at least one of A, B and C” use a disjunctive “or” and a disjunctive “and” such that those formulations comprise any and all joint and several permutations of A, B, C, that is, A alone, B alone, C alone, A and B in any order, A and C in any order, B and C in any order and A, B, C in any order. There may be more or less than three features used in such formulations.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word ‘comprising’ does not exclude the presence of other elements or steps then those listed in a claim. Furthermore, the terms “a” or “an,” as used herein, are defined as one or more than one. Also, the use of introductory phrases such as “at least one” and “one or more” in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an." The same holds true for the use of definite articles. Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.
Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, example or claims prevent such a combination, the features of the foregoing embodiments and examples, and of the following claims may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of the example(s), embodiment(s), or dependency of the claim(s). Moreover, this also applies to the phrase “in one embodiment”, “according to an embodiment” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an’, ‘one’ or ‘some’ embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment.
As used herein, any machine executable instructions, or compute readable media, may carry out a disclosed method, and may therefore be used synonymously with the term method, or each other.
The foregoing description of one or more implementations provides illustration and description, but is not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of various implementations of the present disclosure.
LIST OF REFERENCES
60 body portion
62 Storage portion
68 Blank
70 Wrinkled portion (Example 1 )
170 Flaps (Example 2)
172 Leading edge (Example 2)
174 Trailing edge (Example 2)
176 Central portion (Example 2)
178 Vertices (Example 2)
72 Cavity
74 Base
76 Periphery
92 Interior surface
94 Exterior surface
64 Flange portion
78 Connecting members
80 Leading edge
82 Trailing edge
86 Cut-out portion 98 Extension portion
112 Periphery
116 Lip
84 Exposed region
88 First surface
90 Second surface
66 Closing member
96 Liner member
110 Stiffening ring
114 Cavity
158 Tube
100 Longitudinal direction
102 Lateral direction
104 Depth direction
106 Axis of rotation
120 Manufacturing line
122 First converting machine
124 Second converting machine
152 Former
126 Third converting machine
128 Fourth converting machine
130 Fifth converting machine
160 Blade arrangement
132 Sixth converting machine
134 Seventh converting machine
136 Eighth converting machine
150 Sheet material (storage portion)
156 Sheet material (flange portion)
162 Precursor material